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POLYVALENT PANEL - MANUAL - MULTIFUNCTIONAL AUTOMATIC

QPE-C

User Manual (version 02/2010) This document is the exclusive property of Elcos S.r.l and it reserves all rights in this document and in the information contained therein. Elcos reserves the right to update and modify this document at any time and without any advance notice. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.


MANUAL CONTENTS: • • •

INSTALLATION USE MAINTENANCE

INDEX POLYVALENT PANEL............................................................................... - MANUAL ..............................................................................................1 - MULTIFUNCTIONAL AUTOMATIC .......................................................1 1.0 USER MANUAL ................................................................ .............................................................................................. ..............................................................10 ..............................10 1.1 INTRODUCTION ................................................................ ............................................................................................ ............................................................10 ............................10 1.2 AIM ................................................................ ................................................................................................ ................................................................................ ................................................11 ................11 1.3 OPERATING BASICS ................................................................ ................................................................................... ...................................................11 ...................11 1.3.1 1.3.2

HOW THE QPE-C PANEL WORKS WITH THE GENSET. .....................11 ADJUSTABLE OPERATING MODES ...................................................14

1.4 EXAMINATION OF “MC4 ON QPEQPE-C PANEL” PANEL” MODULE ................................17 ................................17 1.5 FUNCTIONAL FUNCTIONAL DESCRIPTION OF PANEL COMPONENTS COMPONENTS ..............................19 ..............................19 1.5.1 DESCRIPTION OF KEYED SELECTOR FUNCTION ............................19 1.5.2 DESCRIPTION OF SINGLE BUTTONS AND WARNING LIGHTS FUNCTIONS ..................................................................................................20 1.5.3 DESCRIPTION OF DIFFERENT MEASUREMENTS AND REPORTING PAGES...........................................................................................................23 1.6 COMMANDS AND FUNCTIONING IN THE THREE MODES ............................37 ............................37 1.6.1 SETUP OF OPERATING MODES.........................................................37 1.6.2 MODE 1 MANUAL...............................................................................38 1.6.3 MODE 2 AUTOMATIC .........................................................................39 1.6.4 MODE 3 MOD – BUS ...........................................................................40 1.7 SETUP LANGUAGE................................ LANGUAGE................................................................ ....................................................................................... .......................................................41 .......................41 1.8 OTHER FUNCTIONS ................................................................ ..................................................................................... .....................................................42 .....................42 1.8.1 ENERGENCY STOP .............................................................................42 1.8.2 BLOCKED GE ......................................................................................43 1.8.3 REMOTE TESTING ..............................................................................44 1.8.4 MASTER START ..................................................................................44 1.8.5 MAINTENANCE REQUEST ..................................................................45 1.8.6 TELEPROCESSING..............................................................................45 1.8.7 SCHEDULED START-UPS....................................................................45 1.8.8 PROGRAMMABLE RELAY GENSET CONDITIONS ..............................46 1.8.9 DIFFERENTIAL OR EARTH FAILURE PROTECTION ...........................46 1.9.10 ELECTRONIC OVERLOAD PROTECTION FROM (51) AND SHORTCIRCUITS (50)...............................................................................................47 1.9.11 REVERSE POWER PROTECTION (32) ................................................48 1.9.12 ALARMS HISTORY. ............................................................................49 1.9.13 FUEL PUMP COMMAND .....................................................................50


1.9

INTERPRETATION OF ALARMS AND CONTROLS ............................................... ............................................... 51

1.9.1 WHAT TO DO IN CASE OF GENSET FAILURE ............................................ 51 1.9.2 ALARMS AND STATES SUMMARY ............................................................. 21 1.9.3 ELECTRICAL MAINTENANCE ..................................................................... 59 1.9.4 MCCB RESET .............................................................................................. 59 1.9.5 MECHANICAL MAINTENANCE ................................................................... 60 1.9.6 PERIODIC CHECKS ..................................................................................... 60 2.0 INSTALLATION MANUAL ................................................................ ....................................................................................... ....................................................... 28 2.1 CONSTRUCTIVE DESCRIPTION OF QPE-C PANEL........................................ 28 2.1.1 EXTERNAL COMPOSITION ........................................................................ 28 2.1.2 INTERNAL COMPOSITION .......................................................................... 29 2.2 CONSTRUCTIVE DESCRIPTION OF MC4 CARD ..................................................... ..................................................... 29 2.2.1 REFERENCE RULES. ................................................................................... 29 2.2.2 CONSTRUCTIVE CHARACTERISTICS MC4 CARD. .................................... 30 2.2.3 TECHNICAL CHARACTERISTICS SUMMARY. ........................................... 31 2.3 ELECTRICAL CONNECTIONS BETWEEN MC4 MC4 MOTHERBOARD AND THE GENERATING SET. SET. ................................................................ ................................................................................................ ...................................................................... ...................................... 32 2.3.1 J1 CONNECTOR POWER SUPPLY SYSTEMS CC AND COMMAND RELAY.32 2.3.2 J2 CONNECTOR CAN-BUS ENGINE CONNECTION. .................................. 33 2.3.3 J3 CONNECTOR ENGINE PROTECTION DIGITAL INPUTS. ...................... 33 2.3.4 J4 CONNECTOR ANALOGICAL INPUTS TO MEASURE ENGINE PARAMETERS. ..................................................................................................... 35 2.3.5 J5 CONNECTOR TOROID CONNECTION DIFFERENTIAL PROTECTION... 37 2.3.6 J6 CONNECTOR AMMETER TRANSFORMERS CONNECTION. ................. 38 2.3.6 J7 CONNECTOR RELEASING COIL MAGNETOTERM CIRCUIT BREAKER.39 2.3.7 J8 CONNECTOR LINE GENERATOR INPUT. ............................................. 39 2.3.8 J9 CONNECTOR FUEL PUMP SUPPLY. ..................................................... 40 2.3.9 J10 CONNECTOR FLOATING OVERFLOW. ................................................ 40 2.4 ELECTRIC WIRING MC4 MOTHERBOARD WITH EXTERNAL USERS. USERS. ................... 41 2.4.1 J11 CONNECTOR DATA TRASMISSION IN MOD-BUS............................... 41 2.4.2 J12 CONNECTOR REMOTE CONTROLS. ................................................... 41 2.4.3 J13 CONNECTOR REMOTE SIGNALS. ....................................................... 41 2.4.4 J14 CONNECTOR PROGRAMMABLE REPORTING RELAY. ....................... 42 2.4.5 J15 CONNECTOR MANAGEMENT OF MAINS-GENSET REMOTE COMMUTATION. .................................................................................................. 42 2.4.6 J16 CONNECTOR BATTERY CHARGER CONNECTION............................. 44 2.4.5 J17 CONNECTOR MAINS PRESENCE SENSOR CONNECTION.. ............... 44 2.5 SETUP ................................................................ ................................................................................................ ................................................................................... ................................................... 46 2.5.1 SETUP MODE ACTIVATION ....................................................................... 46 2.5.2 CLOCK MENU............................................................................................. 46 2.5.2 DIFFERENTIAL MENU. ............................................................................... 47 2.5.4 TIMES MENU.............................................................................................. 48 2.5.5 THRESHOLDS MENU. ................................................................................ 48 2.5.6 SETTINGS MENU. ...................................................................................... 50 2.5.7 CALIBRATION MENU. ................................................................................ 52 2.5.8 MODEM MENU............................................................................................ 54 2.5.9 CAN-BUS MENU. ........................................................................................ 54 Nome file QPE-C ITA versione 01 10

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2.5.10 MOD-BUS MENU. ..............................................................................55 2.5.11 USB MENU. .......................................................................................55 2.5.12 CARD MENU......................................................................................55 2.6 TECHNICAL NOTES OF MC4 CARD ............................................................... ...............................................................57 ...............................57 2.6.1 ENGINE RUNNING DETECTION ..........................................................57 2.6.2 OPERATING WHEN THE MICROPRECESSOR IS BLOCKED ................57 2.6.2 FIRMWARE SOFTWARE DISPLAY........................................................57 2.7 ACCESSORIES COMBINABLE WITH WITH QPEQPE-C PANEL ...................................... ......................................59 ......59 2.7.1 MODEM FOR REMOTE MANAGEMENT OF GENERATING SET...........59 2.7.2 REMOTE DISPLAY. .............................................................................60 2.7.3 14 RELAY MODULE.............................................................................63 2.7.4 RADIO CHANNEL. ...............................................................................63 2.7.5 SOFTWARE FOR TELEPROCESSING. .................................................64 2.7.5 MOD-BUS PROTOCOL. ........................................................................64 2.8 ELECTRIC CONNECTION DIAGRAM ............................................................ ............................................................68 ............................68 2.8.1 ENGINE CONNECTOR.........................................................................68 2.8.2 ALTERNATOR CONNECTOR. ..............................................................68 2.8.3 FUEL TOPPING SYSTEM CONNECTOR.. ............................................69 2.8.4 WIRING DIAGRAM...............................................................................69 2.9 INSTALLATION................................ INSTALLATION................................................................ ............................................................................................ ............................................................70 ............................70 2.9.1 DEGREE OF PROTECTION ...................................................................70 2.9.2 GROUND CONNECTION (PE) ...............................................................70 2.9.3 POWER CONNECTIONS .......................................................................70 2.9.4 BATTERY CONNECTION.....................................................................71 2.9.5 SUMMARY OF CONTROL PROBES MOUNTED ON THE ENGINE .......71 2.9.8 DIELECTRIC STRENGTH TEST............................................................72 2.10 SERVICE PROCEDURES ................................................................ ............................................................................ ............................................73 ............73 2.10.1 FIRST START-UP PROCEDURE .........................................................73 2.10.2 PROCEDURE FOR REPLACING THE BATTERY .................................73 2.10.3 PROCEDURE FOR REPLACING MC4 CARD .......................................73 3.0 MAINTENANCE MANUAL ................................................................ .............................................................................. ..............................................74 ..............74 3.1 ROUTINE MAINTENANCE.......................................................................74 3.2 ELECTRICAL AND MECHANICAL MAINTENANCE. ................................74 3.3 TEST AND ALARMS SIMULATION ..........................................................74 3.3 ENGINE PROTECTIONS ..........................................................................74 3.4 GENERATOR PROTECTION ....................................................................74 3.5 51 OVERLOAD PROTECTION..................................................................74 3.6 TROUBLESHOOTING. .............................................................................75 The data presented herein could undergo modifications for technical improvements made to the project.

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1.0 USER MANUAL 1.1 INTRODUCTION Congratulations for choosing QPE-C panel (with MC4 electronic logic) for managing your genset. Later on, you will appreciate the great flexibility of use and high performance allowed by the high technology of the electronic module MC4. This is a microprocessor based electronic module that manages all types of gensets, both traditional ones and with CAN-BUS commands. It is set to communicate over MOD-BUS with various devices such as maingenset transfer switching cabinets with commutation, pc, remote touch-screen panels, alarm repeating modules etc. Through a GSM module (integrated on-demand) you can manage and totally control your genset from miles away. MC4 is equipped with fully digital instrumentation that allows you to monitor all the parameters of the engine, generator, and related accessories. The USER MANUAL aims to provide a clear and simple guide in order to consent a quick, complete and safe use of the genset.

1.2 AIM This manual provides all the necessary information regarding the use of the genset with QPE-C panel: 1. 2. 3. 4.

Knowing the operating basics of the panel; Interpreting the indications of the electronic panel; Setting the electronic card in the different service requirements; Making the minimum necessary checks to ensure the smooth functioning of the genset.

Any technical or adjustment elements are not discussed because they are managed by the manafacturer during creation of the machine.

1.3 OPERATING BASICS 1.3.1 HOW THE QPE-C PANEL WORKS WITH THE GENSET. The QPE-C panel can be matched with all the generators with power range from 10 to 2500 kva, with operating voltages from 220 to 460 volts, 50 or 60Hz, with traditional engines or with Can-bus control ones. In Fig. 1 is shown the standard components of the plant that is made of: a generating set GE, control panel QPE-C, a machine switch INT. (which varies according to the power of the genset).

Fig. 1

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The QPE-C panel monitors and detects all the parameters of both the engine and the generator. It has a three-position key that sets the type of plant’s operating mode. With key on position 0 the panel is switched off, the genset is off. With key on Manual the start-up is decided by the user by pressing the start button. With key on Automatic, depending on the operating mode, the start-up could be through external contact, lack of electricity from the relative mains, command in MOD-BUS, from the communication network via sms, etc.. During the functioning all the electrical and mechanical parameters of the genset are displayed and all the protections are enabled, including overload, short-circuit and earth fault if set. If an anomaly happens the INT switch opens through the opening coil and it disconnects the load, then after the cooling phase the engine stops. In combination with an ATS (Automatic Transfer Switch) with or without mains sensor, it becomes a complete system for the mains failure, (as per Figure 2). The QPE-C panel is able to autonomously manage even the commutation mains-genset. Fig.2

RETE Public mains GE Generating set

QPE-C CARICO

Command and control panel Preferential load

CR CG

Mains counter Genset counter

(generator + engine) 1.3.2 ADJUSTABLE OPERATING MODES The QPE-C panel, in order to cover all needs, can be set in three distinct operating modes: 1 Manual mode 2 Automatic mode 3 Mod-bus mode The setting of these three modes is done by inserting three micro-switches (dip 1-2-3) on the motherboard, see page 30. MANUAL MODE. In Manual mode, the panel can be used in two ways, depending on the position of the board key. With key on Manual, the genset start-up occurs exclusively by pressing the start button by the user. With key on Automatic, the start-up occurs through an external command (potential free contact) that if Active, it launches the automatic process of start-up and the possible management of inserting load. So, the consent of start-up can be given by external devices such as floats, pressure switches, thermostats, relay voltmeters etc.

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In Automatic mode, and with key on Automatic, the panel is able to operate as an emergency system to the mains. It fully manages both the start-up of the genset and the complete management of mains-genset commutation in the separated ATS. Suppose that we are in the situation represented in Figure 2, where the mains is within normal values: the CR counter is closed and the use is powered by the mains. The QPE-C monitors the mains and in case of any anomaly or the lowering or lack of a phase or because of asymmetry of the phases themselves, it acts as follows: 1. It commands the opening of CR mains counter; 2. It enables the start-up of the genset and once it has reached the right functioning level, it commands the closing of the CG counter, powering the use through the GE generator; N.B.: During the functioning, the engine and generator are monitored to determine if any abnormalities occur. If this is the case, these abnormalities would cause the immediate arrest of the genset with consequent storage and visualization onto the display, showing the cause of the alarm (e.g. low oil pressure, overload, etc.). 3. When the mains come back to normal values, after a set delay the QPE-C opens the CG genset counter and after one second, closes the CR counter. In this way it re-powers the use with the mains. 4. The genset keeps running for at least one minute to burn off the excessive heat and at the end of cooling time, it stops automatically. If the user has its own ATS with an independent management of commutation, then he can only use the mains sensor of QPE-C panel to handle only the start-up when the mains fail. MOD-BUS MODE. In this mode, if the key is on Manual position, the genset start-up occurs by pressing the start button. On the contrary, if the key is on Automatic position, the start input can be sent through a Mod-Bus message, which is sent by a management control unit or by an external plc.

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1.4 EXAMINATION OF “MC4 ON QPE-C PANEL” MODULE Functional description of panel controls.

5. ACK MUTE alarm Fuel pump manual command Engine pre-heater or glowplug

1. COMMAND KEY Automatic functioning. (AUT) Manual functioning. (MAN)

3. Graphic display for visualizing all the measurements, alarms and commands.

6. Button for activating the automatic weekly test and instantaneous test.

2. Buttons for manual command of running or arrest.

4. MODE reset buttons to restore functions or unlock alarm. In Setup mode, it confirms the set data.

7. Buttons to change the display view or to modify parameters in Setup.

1.5 FUNTIONAL DESCRIPTION OF PANEL COMPONENTS 1.5.1 DESCRIPTION OF KEYED SELECTOR FUNCTION

1. The keyed selector selects the operating mode. With key on AUT position, the genset starts automatically. According to the functional mode that is set, the command can be made via external potential free contact, via the mains failure, via a Mod-Bus signal, or through an sms etc. With key on automatic, the green led corresponding to the writing remains turned on with fixed light. Nome file QPE-C ITA versione 01 10

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2. With the keyed selector on ZERO, the genset is totally disabled, power consumptions on the power battery are excluded. If the key is turned to ZERO position while the genset is running, the panel will not switch off immediately, but it will first start the process of shutdown and when the engine cooling process is finished, the panel will shut down entirely. The timing of the shutdown procedure is displayed through an animated hourglass on the graphic display. 3. When the key is on MAN, the START and STOP buttons are enabled. Therefore, it is up to the user to decide the start-up of the genset. 1.5.2 DESCRIPTION OF SINGLE BUTTONS AND WARNING LIGHT FUNCTIONS. 1. SIREN MUTE BUTTON (T1) When it is pressed, this button silences the alarm buzzer, the corresponding red LED indicates the presence of a failure. The reset of the alarm occurs by pressing the reset button indicated here below. In Setup mode, pressing the button allows you to leave the various Setup menu.

2. FUEL PUMP ACTIVATION BUTTON (T2) If it is pressed with key on Manual, it activates the pump for refuelling the daily tank from an external tank, if it is pressed again, it switches it off. The pump stops automatically when it reaches the maximum level. The corresponding green LED lights up every time the pump starts running. With key on Automatic, the button is disabled because the activation of the fuel pump takes place automatically according to the level of the tank. In setup mode, the pressure of the button needs to increase the values of the parameters visualized on the display.

3 GLOWPLUGS OR ENGINE PRE-HEATER ACTIVATION BUTTON (T3) The warning light corresponding with this button has two distinct functions, depending on the type of setting. If the “glowplugs” function is enabled in the card, the light will turn on before the start-up, indicating the insertion of glowplugs for pre-scheduled time. If the “engine pre-heater” function is enabled on the card, the light turns on every time the resistance that keeps the engine water at the correct temperature is activated. The button is active only in manual mode and only in "glowplugs" mode. If pressed, it allows the reintegration of glowplugs. In Setup mode, the pressure of the button needs to decrease the values of the parameters visualized on the display. 4 RESET-ENTER BUTTON (T4) If pressed during normal functioning, it erases the alarms states and restores the functions. In setup mode, it confirms the selection or stores the data.

5 STOP BUTTON (T7) This button is always enabled both in manual and automatic. It stops the machine when pressed. The red LED corresponding with this button indicates that the shutdown phase is in progress.

6 START BUTTON (T8)

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This button in enabled only when the change-over switch is on MAN position. The control is manual, it is therefore necessary to hold the start button until the start-up is completed. The green LED corresponding with this button indicates that the start-up command is in progress.

7 GENSET TEST BUTTON (T9) The button in active only if the key is on Automatic and it enables two different functions: “Instantaneous automatic test” is obtained by pressing the button for more than 3 seconds. The genset starts, the machine runs freely for the scheduled time and then it stops automatically. The corresponding green led flashes, indicating that it has activated the function. “Programmed automatic test” is activated by quickly pressing the button. This function allows the inner timer to activate, in order to test the genset at pre-scheduled times and dates. If this function is activated, the corresponding green LED remains turned on with fixed light. The setup test scheduling is carried out in Setup menu described later, see page 47.

8 DISPLAY MODE BUTTONS (T5-T6)

These buttons allow you to navigate around the display pages. In setup mode, they allow you to access the different menus.

1.5.3 DESCRIPTION OF DIFFERENT MEASUREMENTS AND REPORTING PAGES During the ignition phase, for a few seconds, the screen displays the company logo and the version of the relay card software. Then the first page display appears

Page 1 13

14

15

16

1

2

12

3 11

4 5

10 00

9

8

7

6

The first page shows the user the main functioning indications of the genset. In detail, these are as follows: Nome file QPE-C ITA versione 01 10

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1. Key state display, possible indications AUT. (key on automatic), MAN (key on manual), MSTR (forced start-up with key on off, Master start function). 2. Voltage supplied by the generator, the parameter changes sequentially according to the phases indicated by point 12. 3. Current supplied by the machine on phase X. 4. Operating frequency. 5. Engine alarm display, in case of multiple alarms they are displayed alternately. 6. Page number 7. Generator status, possible combinations, G-ALRM (genset in alarm), G-off (genset turned off), G-on (genset running), G-stop (genset shutting down), G-strt (genset starting up). 8. Indication of operating mode MOD1 (manual operating), MOD2 (automatic operating) MOD3 (mod-bus operating). 9. Time Display 10. Date display 11. Display numbers of alarms occurring simultaneously. 12. Sequential display of voltage measurements. 13. This icon indicates the presence of a modem, of a GSM signal and, if flashing, the presence of sending and receiving an SMS. 14. Presence of scheduled events of genset start-up on a pre-set timetable. 15. Animated icon to display timing in progress. By pressing the down arrow underneath the display screen, you will display the following pages.

Page 2 In detail, the indications are as follows: 1. Engine cooling water temperature. 2. Level of engine lubrication oil pressure 3. Amount of fuel in the tank expressed in percentage 4. Battery voltage 5. Available space for an additional programmable analog measure of engine. If one of the measures is not present, it means that it is not planned in the preparation of the machine. In engines equipped with CAN-bus communication, the values of water temperature and oil pressure are communicated by the engine electrical box.

Page 3 In detail, the indications are as follows: 1. Concatenated voltage phase L1-L2 2. Concatenated voltage phase L2-L3 3. Concatenated voltage phase L3-L1 In case of running in single-phase, the following page will not be displayed.

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Page 4 In detail, the indications are as follows: 1. neutral-phase L1-N Voltage 2. neutral-phase L1-N Voltage 3. neutral-phase L1-N Voltage In case of running in single-phase, only the first measure will appear.

Page 5 In detail, the measures are as follows: 1. Current supplied by the machine on phase L1 2. Current supplied by the machine on phase L2 3. Current supplied by the machine on phase L3 In case of running in single-phase, only the first measure will appear.

Page 6 In detail, it is displayed as follows: 1. Instantaneous active produced power 2. Instantaneous apparent produced power 3. Instantaneous reactive power 4. Power factor, the value is displayed only with machine operating at load.

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Page 7 In detail, it is displayed as follows: 1. Total power produced by the machine throughout its lifetime (not resettable). 2. Partial power produced with resettable option by the user (see page 50) This is for the calculation of operating costs for rent. 3. Power produced after each start-up of the machine, it automatically resets at shutdown of the panel

Page 8 In detail, it is displayed as follows: 1. Total hours of running produced by the machine. 2. Partial hours of running resettable by the user (see page 50) for rented time. 3. Working time of the machine from last start-up made. 4. Countdown for the remaining hours until maintenance. Once it reaches "0" hours, the count restarts indicating the hours of running that go past the deadline. At the end of the maintenance hours of the machine, a beep and a warning icon with the "required maintenance� writing are displayed. 5. Start-up counter. The number of successful start-ups are stored, whether performed both in manual and automatic

Page 9 In detail, it is displayed as follows: 1. Date, day/month/year. 2. Day of week 3. Time The watch is equipped with a backup battery, so even disconnecting the battery of the genset, the date will not be lost

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Page 10 In detail, it is displayed as follows: Current wasted during the running of genset. Setting up of the alert threshold. If the wasted current exceeds the set value, the device for releasing the load intervenes. Setting the delay of intervention of the differential protection. This display page will appear only if the function of differential protection is enabled, and only with generators that have delta-star neutral connected to the earth. With the machine running the following writing will appear “TEST: press RESET/ENTER for 5 seconds�, which enables the possibility of testing the differential protection device.

Page 11 Display of input/output states summary table This page appears only if it is enabled in the Setup menu (see page 47). The following instructions are very useful for technicians to display any problems related to the malfunctions of the connected sensors. Into IN column the states of inputs are indicated. Into OUT column, the states of the output relays are displayed.

The table shows the details of input states.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Input Dinamo P.oil Temp. RisFuel Liv.H2O H2O-Oil Aux1 Aux2 Rete Blocco Test Start StartM P.A.E. Emerg.R Sic.Carb

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Description Report of the operating state of battery charger dynamo Report of oil pressure sensor conditions. Report of high temperature water sensor Report of the fuel reserve float Report of the low water level float in the radiator Report of the presence of water in the fuel Report of auxiliary input 1 active Report of auxiliary input 2 active Report of referenced mains in tolerance Report of external operating lock active Report of start-up testing enabled Report of external start enabled Report of external master start enabled Report of emergency alert button on board enabled Report of remote emergency alert button enabled Report of overflow float enabled

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The table shows the details of output states.

1 2 3 4 5 6 7 8

Output Start

Description Report of starter motor enabled

Stop E.M. E.V. Candel. Rete Gruppo Pompa R.Prog

Report of electromagnet stop enabled Report of fuel solenoid activated Report of pre-heater glowplugs enabled Report of contactor mains output command’s conditions Report of contactor genset’s output command’s conditions Report of fuel pump conditions Report of programmable relay’s activation

Page 12 This page is available only in combination with engines equipped with CAN-BUS electrical box and depending on the engine type, the following measures may be available: 1.Instantaneous fuel consumption 2.Oil pressure. 3.Engine speed. 4.Coolant liquid level in percentage. 5.Oil level in percentage. 6. Intercooler air temperature

Page 13 This page displays the alarms transmitted via CAN-BUS from the engine electrical box. In case of failure, the alarm codes are displayed to identify the type of failure. This system constitutes a diagnostics on the entire electrical system of the machine, even if the engine stopped, the efficiency of sensors and wiring is checked. To interpret the code you should check the corresponding engine’s manual (N.B.: each model, even if it is from the same manufacturer has its own manual to consult). The engine manual lists the type of alarm and the remedy to be made to the machine. For ex.: I own a genset with engine Volvo TAD1242GE and the display shows CAN 184 writing. By consulting the manual, this anomaly code corresponds to "fault on the oil temperature sensor”, so the connections of the sensor or the sensor itself have to be checked

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Page 14 This page appears after switching on the panel only with card set to operate in mode 2. It displays the status of the genset-mains commutation and the three mains voltages. The ON-OFF writings on top of the mains and genset symbols indicate the actual presence of mains or genset voltage within the limits. The CR and CG contacts symbols indicate the status of contacts for the management of remote commutation. The display shows the three mains voltages. Even if in only one phase the voltage goes out of minimum and maximum voltage set bounds, the genset starts up automatically anyway.

Page 15 This page appears automatically only in mode 2, and only when the genset is running. It displays the status of commutation and shows the genset voltage. The ON-OFF writings on top of the mains and genset symbols indicate the actual presence of mains or genset voltage within the limits. The CR and CG contacts symbols indicate the status of contacts for the management of remote commutation

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1.6 COMMANDS AND FUNCTIONING IN THE THREE MODES 1.6.1 SETUP OF OPERATING MODES The QPE-C panel can be set in three distinct operating modes: 1 Manual mode 2 Automatic mode 3 Mod-bus mode The setting of these three modes is made through the insertion of 3 micro-switches (dip 1-2-3) on the motherboard, see page 30. .

1 Manual Mode

2 Automatic Mode

3 Mod-bus Mode

The insertion of these dips has to be done with key in OFF position.

1.6.2 MODE 1 MANUAL With key in OFF position, the electrical circuits are no longer powered and the genset is not powered. (It is used for maintenance stages). With key in MAN position the genset manual controls are enabled through the START and STOP buttons. Once the genset is started-up, wait for it to reach the operating speed before closing the switch to power the load. When it is shutting down, as first operation the load has to be disconnected by opening the switch and after approximately one minute the genset has to be stopped. While running, the generator and motor are continuously monitored and any possible abnormality is immediately displayed on the screen (for example: fuel reserve, water level, overload, minimum voltage, etc.) and the relative arrest cycle is activated; if it is enabled also the instantaneous opening of the switch. With key in AUT position, the start-up is determined by an external command that starts the automated process of ignition. Once the engine has reached its full operating speed, then the consent to the closing of the load is given. While running, the generator and motor are continuously monitored, any abnormality is immediately displayed on the screen and the relative cycle arrest is activated, as well as the disabling of load and the subsequent cooling of the engine. The external enabled controls are as follows: 1. Available potential free contact for thermostats, pressure switches, floats, timers, selectors, etc. connected to the terminals 44-45 of motherboard J12 connector. 2. SMS command if inside the card the modem is mounted. 3. Start-up at scheduled intervals by a programmer watch integrated in the card.

1.6.3 MODE 2 AUTOMATIC Nome file QPE-C ITA versione 01 10

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The automatic mode comes as an application of the genset in case of public mains failure, so the panel is asked to manage both the automatic start-up of the genset whenever the public mains fails, and the mainsgenset commutation through two potential free contacts that drive some power change-over switches (remote ATS). With key in OFF position, the electrical circuits are no longer powered and the genset is not powered. (It is used for maintenance stages). The management of the mains line closing remains guaranteed even if the battery is disconnected.

WARNING! The management of the mains line closing is always guaranteed and always takes priority. No matter in which position the key has been put, or with the panel disconnected from the battery, the management contact mains-line remains closed.

With key in MAN position, the genset manual controls are enabled. It is possible to start it up through the START and STOP buttons, but the load will remain powered by the public mains. Therefore the maintainer can try the machine without creating power gaps on the usage powered by the mains. While the genset is running, in case there is a mains failure, the load commutation on the genset will start immediately. With key in AUT position, the start-up of genset is done automatically when the referenced mains-line goes beyond the limits of minimum and maximum set voltage, (the measure is carried out on each single phase). After the genset has started and the voltage and frequency have stabilized, the panel commands the insertion of the load. While running, the generator and engine are continuously monitored, any abnormality is immediately displayed on the screen and the relative cycle arrest is activated, as well as the disabling of the load and the subsequent cooling of the engine. When the mains come back after a programmable delay, the load is re-commutated on the mains and after the expected cooling time the genset stops automatically.

1.6.4 MODE 3 MOD – BUS Prologue The MOD-BUS is an industrial communication protocol that allows the connection of multiple devices (slave) to a concentrator device (master) which, in turn, allows you to view and drive all the connected devices. The connection is on port RS485, the standard communication format is RTU (binary), and via a two-wired cable you can make a teleprocessing up to 1Km away. With key in OFF position, the electrical circuits and the genset are no longer powered. (It is used for maintenance stages). With the key in MAN position, the operating is identical to the manual mode 1. With key in AUT position, the start-up is determined by an external command sent over the MOD-BUS line, which initiates the automatic process of ignition. With the engine at full operating speed, the consent to close the load is given via a return message over the MOD –BUS line. This mode allows the direct interfacing of QPE-C panel with external PLCs, computers, or with other types of devices that use the MOD-BUS as a communication system. The MOD-BUS connection, via a two-wired shielded cable, allows to bring the start-up commands to a remote distance and the acquisition of all the alarms and measures of the genset.

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1.7 SETUP LANGUAGE The MC4 control card provides the setup of 5 default languages through micro-switches placed on the DIP1 motherboard. In this way all the descriptive and warning messages that appear on the display will be easily understood by all users.

Italian

English

French

Spanish

Programmable

The setup of micro-switches can be made at any time, both with the card switched off and switched on.

N.B. The translation of the programming menus is available only in Italian and English.

1.8 OTHER FUNCTIONS The MC4 is set up for special functions listed below: 1.8.1 EMERGENCY STOP The activation of the emergency button is displayed on the screen with the following words:

“ EMERGENCY STOP ACTIVATED” The emergency stop is made via a mushroom-shaped button called PAE with rotating unlocking system. It is normally mounted on the canopy in an easily accessible position. In all the operating modes, the pressure of the PAE button causes an immediate engine shutdown and if set, the immediate opening of the machine switch. The activation of emergency in mode 2 does not cause the opening of the closing mains command, therefore the public mains will continue to power the load. The activation of the emergency will stop the genset, therefore in order to restore the normal operating mode unlock the PAE emergency button by turning it and afterwards resetting the MC4 card through the RESET button. The MC4 card provides a connection to a second emergency button that the user can mount on the most appropriate place, for example onto the electric cabin entrance so that in case of fire, firemen can inhibit the functioning of the genset. In order not to confuse the two commands, the insertion of the remote emergency button is displayed with the following different wording: “ REMOTE EMERGENCY ACTIVATED”

1.8.2 LOCKED GENSET The activation of the lock control is displayed on the screen with the following message: “ REMOTE LOCK ” The lock function is mainly used when the genset works at times or conditions set by an external control, such as floats or programmer watches. For example in a town where the emergency is not required at night, you can inhibit the genset through a watch. During the lock time, if the mains fail the genset does not intervene. By opening the lock contact everything starts to function normally again. The report of lock status is shown on display at page 1. Nome file QPE-C ITA versione 01 10

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1.8.3 REMOTE TESTING The activation of remote testing command is displayed on the screen with the following message “START COMMAND FROM EXTERNAL TEST” The test function allows the start-up of the genset through an external contact when you are in mode 2 and key is on Automatic. Enabling this function, the genset starts and remains running without powering the load. If you enable the "full-load test" function, the test is performed by commutating the load from mains to the genset. 1.8.4 MASTER START This function allows you to start the genset with the card key in off position. By closing a contact to the 52-53 terminals, the card will turn on and the genset start-up process will begin. Once it is started, the command for closing the load will be activated. This function limits the batteries consumption in those applications placed where there is no public mains and therefore where you can not plug in the battery charger. For example, a generator that powers an irrigation pump driven by a float, if the level in a tank drops, then the float activates the genset that, in turn, powers the pump. Once it has reached the maximum level, the float deactivates itself and both the genset and its card turn off completely, preserving battery power. The activation of this function is displayed N.B. This function is available only in mode 1.

at

page

1

Icon

Ref

1

MSTR

1.8.5 MAINTENANCE REQUEST The activation of maintenance request signal is displayed on the screen with the following message: “MAINTENANCE REQUEST” The MC4 has a hour-counter for requesting maintenance, oil change, filters etc. Its activation does not determines any alteration to the operating system, but it shows the signal on the display. At page 8 of the screen, the remaining hours to maintenance are highlighted in detail. When the required maintenance time has been reached, then the hours of running that go past the request are indicated. To reset the writing you need to set in settings a second maintenance service interval (see timing menu parameter 12). 1.8.6 TELEPROCESSING The genset can be remotely managed via a "remote" communication (PC or modem or GSM) and it can intervene automatically. See the following descriptions at page 64. 1.8.7 SCHEDULED START-UPS It is possible to schedule the start-up and the shutdown of the genset at predetermined times, for each day of the week 8 events are possible. If a scheduled event is set, the following symbol will appear on the display at page 1. The schedule of single start-ups can be set in “clock” menu, parameter 3. 1.8.8 PROGRAMMABLE RELAY GENSET CONDITIONS There is a programmable changeover relay for reporting some of the most important states of the genset, i.e.: • Cumulative Alarm • Running Genset • Low Fuel • Overload • Presence of Mains • Activated Emergency Nome file QPE-C ITA versione 01 10

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• Start-up failure The programming of this relay can be set in "Settings" menu, parameter 15. 1.8.9

DIFFERENTIAL OR EARTH FAILURE PROTECTION

The MC4 card verifies the current wasted through to the ground. Its action activates the opening coil of the machine switch and stops the genset after cooling time. During the functioning, if 80% of set current is exceeded, the following message will appear "exceeded 1 differential threshold ". The advance warning activates the siren in order to alert the operator with notice. Page. 10 of the display indicates the leakaged current, the programmed current and the set delay of intervention. The differential is equipped with a test, when the machine is running the message “TEST: Press the RESET / ENTER for 5 seconds" will appear at page 10 of the display. It is then possible to test the opening device. Technical characteristics: • Sensitive to sinusoidal waves, divided sinusoidal, button, button with continuous component up to 6mA. • Operating Frequency 47 - 63 Hz • Intervention Current I∆n programmable from 0.03 to 5 A. • Programmable Action Time from 0.1 to 5 seconds. • Instant Action Time within 60 milliseconds. • Negative Security (NA) on opening coil at current launch. • Toroid to use 500 / 1 turns optimized on Revalco • Auxiliary supply range + / - 20% • CEI EN 60947-2 CEI 64-8 Referenced rules

WARNING! The differential protection of the generating set is not to be intended as a "circuit breaker" protection because the settings have been made to reconcile the operational safety but also the continuity of service (standard setting 300mA rit. 3 secs). The installer must therefore ensure coordination in the selectivity of all the differential protections, so that end-users can work safely.

1.9.10 ELECTRONIC OVERLOAD (51) AND SHORT-CIRCUITS (50) PROTECTION The generators are provided with power expressed in KVA as the actual limit of genset capacity is given by the amount of Amperes allowed on the generator windings. It is thus provided an electronic protection to prevent any damage to the alternator. OVERLOAD (51): Whenever the nominal current of the genset is exceeded, after a set time, the genset contactor will open (and if set, the machine switch will open simultaneously). Then we will receive the alarm report for overload and the shutdown of machine after engine cooling time.

ACTION CURVE Ts

Tp = Set overload delay (15 – 255”)

L

I1 = Genset rated current (10 – 3000 A) I3 = l1 x 3 Short circuit current (Off – 16320 A) 1” Fixed delay

Tp

I 1 0

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SHORT-CIRCUIT (50): It intervenes immediately when the load current exceeds the value set for a time of 1". The shutdown occurs in the same way as overload.

1.9.11 REVERSE POWER PROTECTION (32) Using the QPE-C/MC4 with gensets that are predisposed to work in parallel, the protection against REVERSE POWER can be activated. This protection starts working when the generator absorbs current instead of supplying it. The detection of reverse power is based on a math calculation on cosφ, so only when the cosφ is L - or C – then we have reverse current in the generator.

COSFì COSFì

POS

C+

L+

ACTIVE POWER

NEG

L-

C-

REVERSE POWER

1.9.12 ALARMS HISTORY Premendo contemporaneamente I tasti “candelette” T3 ed “Enter” T4 per 3 secondi si attiva lo storico degli allarmi dove è possibile vedere gli ultimi diciotto eventi di allarme. Quando si verifica un allarme tutte le misure e le videate vengono “congelate” e memorizzate, e sono pertanto consultabili. Quando si entra nello storico compare la seguente videata:

- ALARMS HISTORY ______________________________ 1. Minimum battery voltage 2. High water temperature 3. Start-up failed 4. Forced STOP 5. Low fuel 6. L1 Minimum voltage 7. Presence of water in fuel tank 8. Low oil pressure ______________________________________

Holding the buttons down simultaneously "glowplugs" T3 and "Enter" T4 for 3 seconds, activates the alarm history, where you can see the last eighteen alarm events. When an alarm occurs, all the measures and the views become "frozen" and stored, and are therefore available to be accessible. When you enter the alarm history, the following screen will appear: By pressing the arrow keys you can highlight the alarm you want to check, then press "Enter", and afterwards all the screens of the display with the parameters when the alarm occurred will be shown. You will be able to determine the conditions of genset when the alarm went off: if the genset was running, how much load it was working with, the date and exact time when it happened and so on. The message "HIST.ALRM N ° X" at each page will indicate that the card is under View History condition. To exit the Alarms history, hold the "ACK" button down for 5 seconds, then you will go back to the alarms list. To go back to normal operation, hold the button "ASK" down for 5 seconds again. Warning, when an alarm goes off it is not possible to enter the Alarms History. You need to first remove the causes of anomaly and then reset the alarm.

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1.9.13 FUEL PUMP COMMAND The QPE-C panel is programmed to control the fuel pump to automatically refill the tank daily. Through the fuel level sensor, you can operate the pump for maintaining the level of the tank within programmable thresholds.

1.9.14 PROGRAMMING THE CARD THROUGH USB PORT Through a USB Port it is possible to program the setting parameters by directly tranferring the setting file on MC4 card. It is also possible to save the card settings from the card to the USB, to configure a second one in an identical way. (See setup menu).

1.9

INTERPRETATION OF ALARMS AND CONTROLS

WARNING! It is strictly forbidden to perform any action to parts under voltage.

1.9.1

1.9.1 WHAT TO DO IN CASE OF GENSET FAILURE

When there is an alarm condition, it is displayed on display at page 1. For any failure, press the ACK button once to silence the siren, then check the cause of arrest and press the RESET button to reset all functions. The causes and intervention are different according to the type of fault:

1.

LACK OF FUEL If this alarm goes off, you must restore the level of fuel within the set time (default is 5 minutes). Otherwise the genset shuts down automatically to prevent the emptying of fuel filters.

2.

FUEL RESERVE If this alarm gets activated it indicates the pre-alarm that anticipates the lack of fuel (default is set to 5%).

3.

DYNAMO FAILURE It indicates a malfunction of the battery charger dynamo. It requires the intervention of a technician. If enabled, it causes the automatic shutdown of the engine.

4.

LOW OIL PRESSURE It indicates a malfunctioning of the engine lubrication system. Check the oil level and refill it if necessary. If the problem persists, please require the intervention of a technician. This alarm causes the immediate shutdown of the engine.

5.

HIGH ENGINE TEMPERATURE It indicates that engine coolant temperature is too high. Check level and refill it if necessary. If the problem persists, please check the cleanliness of radiator and the possible presence of foreign bodies that restrict the passage of air to the inlet valves or to the radiator itself. The high temperature of the engine can also be caused by a prolonged overload of the engine, if it is so please reduce the load applied. If the problem re-occurs, it is necessary to require the intervention of a technician. This alarm causes the automatic shutdown and the cooling of the engine.

6.

LOW LEVEL RADIATOR WATER It indicates that there is no coolant liquid in the engine. Stop the engine as soon as possible and let the machine cool down. Reset the level as indicated by the Nome file QPE-C ITA versione 01 10

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service manual of the engine. This alarm generates only a warning (alert) but the genset keeps operating normally.

7.

PRESENCE OF WATER IN THE FUEL It indicates the presence of water in the fuel. Stop the machine and clean both the filters and the tank for operating under these conditions could severely damage the injection system. This alarm provokes the shutdown of the machine only if programmed.

8.

MINIMUM BATTERY VOLTAGE It indicates that the battery is flat. Please ensure the charging or replacement.

9.

MAXIMUM BATTERY VOLTAGE It indicates that the battery charging alternator (dynamo) is charging too much and you risk damaging both the battery and the electrical equipment of the machine. It requires the intervention of a technician. This alarm causes the automatic shutdown of the genset only if programmed.

10.

HIGH WATER TEMPERATURE It indicates the pre-alarm that anticipates the high engine temperature alarm (signal from analogical sensor) programmable threshold. The warning does not cause the arrest of the genset.

11.

INSUFFICIENT OIL PRESSURE It indicates the pre-alarm that anticipates the low oil pressure alarm (signal from analogical sensor) programmable threshold.

12.

MINIMUM WATER TEMPERATURE It indicates that the engine temperature is very low and therefore you must verify the efficiency of the engine pre-heater, if present. It is possible to start the engine even if this alarm goes off, but it is recommended to run the machine freely or lightly loaded until the engine temperature rises of a few tens of degrees. The threshold is programmable (default is 0 째).

13.

OIL SENSOR FAILURE It indicates that the oil pressure switch has not re-closed when the engine stopped. This sensor is crucial for the proper functioning of the machine, so you can not start the engine with this anomaly. Please request the intervention of a technician to replace the oil sensor or to restore the electrical wiring.

14.

START-UP FAILURE It indicates that after the programmed attempts to start, the genset has not started successfully. Please check the fuel supply circuit by manually purging it. If the problem comes back, please require the intervention of a technician.

15.

STOP FAILURE It indicates that the engine has not stopped despite the stop signal has been sent by the panel. Please, verify the correct functioning of fuel solenoid or of arrest electromagnet. With engines that have can-bus control, it indicates a missed communication with the engine control box. In this case, in order to stop the engine, please act on the stop button mounted on the engine. (For ex. Volvo engines Tad series). To further verify, please request the intervention of a technician.

16.

CAN-BUS DAMAGED It indicates the presence of one or more alarms sent by the engine control box. To display the list of warnings go to page 13 of the display. The identification numbers will be given and through the engine manual you can track the cause of the problem. This anomaly, based on the gravity of the situation, may provoke the immediate shutdown of the engine.

17.

L1-2-3 PHASE OVERLOAD It indicates that one of the outgoing phases from the generator is supplying a current bigger than the maximum allowed. Please test the applied load and if possible, better distribute the load. This alarm causes the arrest and cooling of the machine. Nome file QPE-C ITA versione 01 10

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18.

OUTPUT SHORTCIRCUIT It indicates that there is a fault on the output line. Please check the electrical connections between the genset and the powered plant. This alarm causes the opening of machine’s switch and the immediate arrest of the machine.

19.

L1-2-3 PHASE VOLTAGE TOO HIGH It indicates that due to a serious load imbalance between the three phases, one of the three provided voltages is too high. Better balance the applied load on all three phases. If the problem persists, request the intervention of a technician.

20.

GENERATOR VOLTAGE TOO LOW It indicates that the output voltage from the generator is lower than the minimum allowed threshold. Please, verify that the engine runs correctly at 50 Hz and that the load applied to the machine is not excessive. To solve this problem, please require the intervention of a technician.

21.

FREQUENCY / RPM TOO HIGH It indicates that the engine is running at a speed faster than the allowed one. In this case you run the risk of damaging both the machine and the electrical equipment connected. The activation of this alarm causes the immediate shutdown of the machine. To solve this problem, require the intervention of a technician.

22.

FREQUENCY / RPM TOO LOW It indicates that the engine does not reach the proper number of rpm. Please check the fuel power system and if the problem occurs with load, it may be caused by an excessive power demand, thus reduce the load applied. If the problem persists, request the intervention of a technician.

23.

POWER RETURN It indicates that the generator has absorbed energy instead of supplying it. Verify if it has made a wrong connection in parallel to a line already in voltage powered by the mains or by another genset. This alarm can also be generated by particular loads that under certain conditions act as generators (ex. hoists, lifts, etc.). The activation of this alarm causes the opening of the switch and the arrest of the genset.

24.

DIFFERENTIAL PROTECTION INTERVENTION It indicates that there is an earth dispersion fault in the generator or in the load applied. At page 10 of the display the calibration values of the differential and the set delay of intervention are shown. In this page, you can also in real time display the current dispersed in order to estimate the threshold for action that has to be set (See differential setting menu). The intervention of this protection causes the immediate opening of the machine switch and the arrest of engine after the cooling phase.

25.

DIFFERENTIAL PROTECTION THRESHOLD 1 EXCEEDED It indicates the pre-warning that anticipates the differential protection alarm. It is triggered when the 80% of set current as threshold for release is exceeded. This alarm activates the buzzer alarm that can alert the user in advance.

1.9.2

ALARMS AND STATES SUMMARY

In the table are all the alarms and operating states summarized with their relative function: N°

1 2 3 4 5

DESCRIPTION

PROGR. ACUST. IMMED. FUNCTION ALL. STOP

ENGINE PROTECTIONS No Fuel Fuel reserve (analogical prealarm) Dynamo anomaly Low oil pressure High engine temperature Nome file QPE-C ITA versione 01 10

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DELAY. EXCLUD OTHERS STOP ABLE

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6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 26 27 28 29 30

31 32 33 34

Low radiator water level Presence of water in fuel tank Minimum battery voltage Maximum battery voltage High water temperature (analogical prealarm) Insufficient Oil Pressure (Analogical prealarm) Minimum water temperature Oil sensor damaged Start-up failure Stop failure Can-Bus anomaly Maintenance request Aux1 Programmable Input Aux2 Programmable Input

GENERATOR PROTECTIONS L1-L2-L3 Overload Short circuit L1-L2-L3 phase voltage too high Generator voltage too low Frequency /Rpm too high Frequency /Rpm too low Frequency /Rpm too high Frequency /Rpm too low Power return Differential Protection Intervention Differential Protection Threshold Exceeded

1

STATES & CONTROLS Emergency Button Activated Remote Emergency Activated Remote Lock Start-up control from external test

* * * *

* * * * *

*

*

*

* * *

* * * * * * * *

* * * * * * * * * * *

* * * * * * * * * * *

* * *

* * *

* * * *

*

*

*

* *

* *

* *

*

* *

*

* * * * *

* * * * * * * *

*

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*

*

1.9.3 ELECTRICAL MAINTENANCE Any interventions must be carried out by specialized staff. If you need to access the equipment inside the panel, please follow these steps: 1. Turn the programming switch OFF. 2. Check the total arrest of the genset. 3. Divide up the mains line that powers the panel, by opening the general switch on the mains. 4. Open the panel and proceed to determine any possible anomalies of: • fuses; • Automatic switches; Once you have completed the maintenance, please repeat the operation in reverse order to restore original state. 1.9.4 MCCB RESET Some alarms can determine the opening of genset circuit breaker (lever in central position, TRIP). The latter must be restored by firmly pressing the lever down to position OFF and then to position ON Nome file QPE-C ITA versione 01 10

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1.9.5 MECHANICAL MAINTENANCE In case of failure to start because of an anomaly to the fuel circuit and in emergency conditions, here are some tips. Resetting of the fuel circuit procedure 1. Set the change-over switch to (MAN), quickly press the START button without starting the genset: in this way it activates the 15/54 which powers the solenoid valve of fuel interception. 2. After filling up with fuel, please activate the hand pump located on the engine, until the restoration of the circuit shown by hardening of the pump force. 3. Execute the manual start-up command (we recommend a limit of start-ups to within the 10� and interrupt with pauses of 15" to allow for a good recovery of the battery). 1.9.6 PERIODIC CHECKS To maintain the genset efficiently, it is necessary to make regular checks in addition to those that are already planned by the engine manufacturer and the installer: 1. 2.

3. 4.

Check the electrolyte level of batteries every 15 days after installation and require the intervention of a technician if there is an excessive consumption. After the initial period, check every 30-60 days. In gensets with engine pre-heater, check if the engine is warm at every check. Otherwise require technical intervention. (WARNING! A cold engine at low temperatures may have difficulty starting-up or powering once it is running) If the genset rarely intervenes in case of mains failure, please perform an automatic test monthly for at least 2'. If new electric machines are added to the plant powered by the genset, please ask for a technical check to verify that the commutation CG / CR / Mains/ Genset is appropriate to the new load.

SUMMARY:  Periodically check the electrolyte level on transparent batteries.  Tap the engine to check if it is hot (if equipped with pre-heater).  Perform periodic manual or automatic tests.

2.0 INSTALLATION MANUAL 2.1 CONSTRUCTIVE DESCRIPTION OF QPE-C PANEL The entire construction meets the following stringent European standards: ANS Low Voltage Electrical Panels Directive regarding EMC Electromagnetic Compatibility

EN 60439-1 89/336/CEE

The panel is implemented in a 15-20/10 steel sheet closet, carefully treated and painted with silicon black epoxy powder. Standard protection degree IP 44, if mounted on base-frame generators. If mounted into canopy, it reaches the protection degree IP55. 2.1.1 EXTERNAL COMPOSITION The control panel is made up of: 1. MC4 Electronic card "Display Module" visible from the glass window. 2. Connectors for connection to the genset (Engine conn., alternator, pump refill). 3. Mushroom-shaped button for emergency stop (mounted on the canopy); Nome file QPE-C ITA versione 01 10

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4. Plate indicating operational rules.

2.1.2 INTERNAL COMPOSITION 1. Cablaggio con codifica fili a colori posto entro canale in PVC; 2. 1 Fusibile 10 x 38 con portafusibili bipolare del tipo sezionabile per scaldiglia; 3. Targa di identificazione, calibro fusibili e morsettiera di connessione.

1. MC4 Card, “power module�. 2. Wiring with color-coded wires placed within the channel in PVC; 3. 1 Fuses 10 x 38 with bipolar fuse box, divisible type for pre-heater; 4. Battery charger cb1 12/24 Vdc 2.5 A (if provided); 5. Rpms regulator if provided in the engine set up; 6. Terminals for auxiliary inputs to 220 volts to power pre-heaters; 7. Name plate, calibre fuses and terminal box of connection.

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2.2 CONSTRUCTIVE DESCRIPTION OF MC4 CARD 2.2.1 REFERENCE RULES. The construction of MC4 electronic card meets the following stringent European standards: For the design of the card, the following regulation has been taken

CEI EN 60664-1

It has been tested for electromagnetic compatibility

EN 61000-4-4 Burst EN 61000-4-5 Surge EN 61000-4-6 RF Indotta

Each card is 100% tested and accompanied by test certificate, declaration of conformity and CE marking in compliance with safety standards 626. 2.2.2 CONSTRUCTIVE CHARACTERISTICS MC4 CARD. The motherboard is the connection point of all electrical connections, it is equipped with removable terminal boxes that can make easier the quick replacement of the card. Each connector has a step and a different number of poles to avoid errors in inserting. The terminal boxes placed at the top of the motherboard are intended for connection to the genset and to all the equipment mounted on the machine, the lower terminal box is intended for the outside connections of genset that the user may need, for example automatic transfer switch commands, mains line incoming, start controls etc. The motherboard is equipped with integrated fuses to protect the different circuits. Nome file QPE-C ITA versione 01 10

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To protect the power supply system, it has been provided a lamellar automotive type fuse 30 A, four 5 x 20 type of fuses that protect respectively the input to genset, fuel pump and release coil. The used components are range-extended with operating temperature from -40 ° C / +85 ° C, it has been used tantalum condensers to ensure a long-life and a high accuracy. The picture below shows the layout of the main elements.

2.2.3 TECHNICAL CHARACTERISTICS SUMMARY

Panel protection degree: Frontal transparent panel Mains voltage input l1-l2-l3- In insulation Genset voltage input l1-l2-l3- In insulation Genset ac voltage : Frequency : Genset current Cc Voltage Absorbed max current : Absorbed min current : Reverse Polarity Protection Operating temperature Relative humidity Vibration Resistance Pollution degree Portata relè avv./arr. Start/Stop relay capacity Portata relè candelette Glowplugs relay capacity Portata rele’ alimentazione E.V. ed E.M. EV and EM power relay capacity Nome file QPE-C ITA versione 01 10

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IP 44 – IP55 on soundproofed machine LEXAN with UV filter => 4KV => 2,5KV 0 / 600V ac 50 / 60Hz 15 to 3000 / 5 A 12V or 24V +/- 30% 0,5 A at 12v 0,3 A at 24 v 0,001 A with key in off position Included from -20 to +70° C 90% non-condensing 40 mm/sec 1 30 A 30V cc. 30 A 30V cc. 30 A 30V cc.

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Pump relay capacity Opening coil relay capacity Commutation and alarm relay capacity 1° started-up engine detection via Hz gener. 2° started-up engine detection via Ac Gener. Battery protection, functions Genset protections, functions Overload and short-circuit protections Direct voltage detection on the genset Direct voltage detection on the mains Genset voltage detection via tv…/100v Mains voltage detection via tv…/100v Relay contacts Insulation Voltage

7 A 270 Volt max 400 W inductive 3 A 270 Volt 5 A 270 Volt From 5 to 25 Hz adjustable (default 18) 200 v Ac ritardato 2” < V 27 and >V 59 27 - 59 – 81- 47 - 32 50 – 51 80 / 500V ca. Threefase 80 / 500V ca. Threefase 500 ÷ 9.000 / 100V 500 ÷ 9.000 / 100V 1000 Vac

MC4 Module Regulations Compliance

EN 60255/6/21 EN 61810-1 EN60947-2 (All.B) EN 61000-4/2-3-4-6-8-11

NB: Please note that these specifications may vary for technical improvements without any notice

Protections Summary (*) FUNCTIONS 27 Minimum voltage 59 Maximum voltage 60 Dissymmetry of voltages 81 Protection for minimum and maximum frequency 47 Sequence of phases 50 Instantaneous current or short circuit 51 Maximum current with programmable delay 87G Ground fault differential protection 32 Reverse Power

2.3 ELECTRICAL CONNECTIONS BETWEEN MC4 MOTHERBOARD AND THE GENERATING SET Here below, we will describe the functions of each single connector and terminal and also the connection modes. 2.3.1 J1 CONNECTOR POWER SUPPLY SYSTEMS C.C AND COMMAND RELAY The J1 connector is a 6 terminals connector step 7.5 and the connections are as follows: Terminals 1-2 battery powered. The power comes from the genset batteries and it is a voltage that can vary according to the genset setup. The supply voltage can be indifferently either 12 or 24 V, but it is tolerated a variation from 9 to 40v. The normal operating is guaranteed even when you have voltage drops to 5v that last 1 sec., phase that occurs when you insert the starter motor.

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Terminal 3 Start control of starter motor (positive output). This terminal is connected with the starter motor, device that can absorb even 30A but only for a few seconds. The starter motor with key on manual gets activated every time you press “START”. With key on Automatic, the starter motor is managed by micro, with specific times and modes. Following the start input, the insertion of the solenoid (terminal 5) gets activated first and after a time adjustable via setup (start-up delay), the starter motor gets activated for a time that can be programmed (start-up duration). If it detects that the genset is running, the starter motor switches itself off immediately, if the genset does not start there is a break (start-up pause) and a subsequent attempt to start. The number of start-ups is programmable from 1 to 4 (number of start-up attempts). Every time you activate the starter motor, the green led next to the “START” button turns on. Terminal 4 Electromagnet stop control (positive output). This terminal is connected to a closing electromagnet that pulls the engine stop lever (only for old designed engines). With key on manual, this output gets activated every time you press the stop button. Even when you turn the key in 0 position, it gets activate for a programmable time (e.m. activation time) before the final shutdown of the card. Each time you activate the output, the red led next to the “STOP” button on Display module turns on. Terminal 5 Solenoid stop (positive output). This terminal is connected to the fuel solenoid which is always powered when the engine is running. If you use this terminal to power a can-bus type electrical box, please program the output as "electrical box supply" from the "Settings" menu parameter 25. In this way, the terminal will go on voltage immediately when turning the key on automatic or manual. Terminal 6 Engine pre-heating glowplugs supply (positive output). In case of engines equipped with preheating glowplugs, it is programmable for a set time (preheating duration). If this time is set to 0, the output is not activated. If the time is set to x seconds, it gets activated in different ways depending on how you turn the key. With key turned to manual, as soon as the key is turned, the output for the set time is activated (the activation is monitored by the corresponding led next to the pre-heater button). Then if you press the preheater button, the output gets reactivated, but only while the button is held down. With key on automatic, the output gets activated only after the start input and the starter motor command will be delayed until the time (duration of preheating) will be completed. Please see the diagram below.

START-UP COMMAND GLOWPLUGS PREHEATING. 6 START-UP

6

The contactor controls the pre-heating system. PROGRAMMING “Settings” menu parameter 13 set “pre-heater” "Thresholds" menu set min/max temp. parameters 19-20

-B

There is the possibility of guiding an engine pre-heating system through resistances supplied at 230V, by programming the sixth output properly (setup menu, parameter 13 pre-heater). Nome file QPE-C ITA versione 01 10

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In this case, the sixth terminal can activate a contactor in continuous current to automatically turn off the pre-heater when the genset is running or it goes above the maximum set temperature (max). It automatically activates the pre-heater when the engine temperature goes below the minimum value (min) (this function is active only when the temperature transducer is connected to terminal 19).

2.3.2 J2 CONNECTOR CAN-BUS ENGINE CONNECTION J2 connector, 3-poles step 0,5, is the connector for the Can-bus communication with the engine. Terminal 7 can high, Terminal 8 can Low Terminal 9 cable shielding. If you activate the Can-bus communication (Can-bus menu) you will get, according to the engine types, either only alarms related data, or alarms and also start-up commands, stop commands, change rpm 1500/1800. The managed engines are Volvo EDC3 - Volvo EDC4 - Iveco - Deutz - MTU - J1939 standard. The Volvo EDC3 type engines have a complete protocol where you can start and stop the engine, get the genset running signal, get all the alarm signals, get water temperature, oil pressure, oil temperature, working hours, engine rpm, instant fuel consumption etc.. In addition to the on-board diagnostics. The Volvo EDC4 type engines, Iveco, Deutz, MTU have instead only the acquisition of the alarms, engine size and of the on-board diagnostics, while the start-up and stop are managed traditionally. 2.3.3 J3 CONNECTOR ENGINE PROTECTION DIGITAL INPUTS J3 connector of digital inputs towards the genset has 9 poles step 0.5. The input signals are always referred to ground. Terminal 10 Dynamo Input. This input provides an output to excite the battery charger alternator. It has a 3W load circuit that is automatically set according to the voltage supply to 12V or 24 V. This alarm input is active only when the engine is running, and it is delayed, so if while the genset is running it closes to ground due to the dynamo failure, the alarm goes off after 30 seconds. When the anomaly occurs, the alarm buzzer gets activated and on the first page of display it shows "Dynamo failureâ&#x20AC;?. In setup you can decide whether this alarm must also stop the genset, see "Settings" menu parameter 9. In setup, you can completely exclude this alarm, see "Settings" menu parameter 8. Terminal 11 Oil pressure bulb input. This connection is crucial because it is an important alarm and it is also an input to determine the on-off state of the engine. This terminal must be connected an oil pressure-switch that, when the engine is not running (so the oil pressure is 0 Bar), is directly connected to ground (logic state 1). As soon as the engine starts running, the lubrication circuit goes in pressure and the pressure-switch will open (logic state 0). Considering the importance of this sensor, this connection is continuously monitored even when the engine is stopped, i.e. the reclosing of the contact occurs 2 minutes after the engine stops. If this does not happen the alarm "oil sensor faultâ&#x20AC;? intervenes. Following the start-up of genset, this contact gets enabled as an alarm after a delay. (activation alarms delay). If it recloses, the alarm goes off immediately and stops the genset straight away. On the display the "low oil pressure alarmâ&#x20AC;? is shown.

IMPORTANT: The status of this contact is also needed to give the approval to activate the starter motor. If the contact is closed the starter motor will be activated regularly, if the contact is open (so the genset is running) any attempt to gear the starter motor will be stopped. The functions and alarms connected to the oil bulb can be disabled via the "Settings" menu parameter 7 "oil input exclusion". Terminal 12 High temperature water bulb input. This terminal is connected to a thermostat that closes to ground when the engine water temperature reaches a critical level. The closing of this contact causes an alarm with two modes of arrest, an immediate one or with cooling stage, both programmable in the "Settings" menu parameter 11. If the alarm occurs, the following indication " high temp. engine alarm" appears on the display, with the immediate release of the load (opening of the contacts at terminals 60-61) and the shutdown of the engine, after the cooling phase (if set). This alarm is active even on manual. If the sensor of engine high temperature has a Normally Closed contact, you can reverse the operating logic, see "Settings" menu parameter 10.

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Terminal 13 Low fuel input. This terminal is connected to a floating which closes to ground when the tank is short on fuel. This alarm is active also when the genset is stationary and it gives alarms with or without causing the arrest depending on how it is programmed, see “Time” menu parameter 14. If the signal is active, the acoustic alarm gets always activated as well as the “Low fuel” reporting message on the display, but it causes the shutdown of the machine after a time programmable from 0 to 300 secs. If set above 300 seconds, the alarm goes to OFF and the shutdown is therefore excluded. Terminal 14 Low water level input. This terminal is connected to a sensor mounted on the radiator that goes to ground when the level decreases. If the signal is active, the acoustic alarm gets activated as well as the “Low level radiator water” reporting message on the display, the engine shutdown is not planned. It is possible to reverse the state of the input contact from Normally Open to Normally Closed. See "Settings" menu parameter 12. Terminal 15 Presence of water in fuel input. This terminal is connected to a sensor that goes to ground when it detects the presence of water in the fuel filter. If the signal is active, the acoustic alarm gets activated as well as and “Presence of water in fuel” reporting message on the display. The shutdown of the genset occurs only if set, see "Settings" menu parameter 16. Terminal 16 Available input 1. Different alarm sensors can be connected to this input, always referred to ground. The message that appears on the display in case of alarm can be set in setup, see “Settings” menu parameter 17 (default text aux.1). This input can be set in 4 different ways: - Reporting on display only - Reporting and buzzer alarm - Signalling buzzer alarm and shutdown - Signalling buzzer alarm and shutdown after cooling. See settings menu parameter 18. Terminal 17 Available input 2. Same mode as the previous one (see Settings menu parameters 19-20) Terminal 18 Emergency button Input. Normally closed to ground, if opened it causes the immediate shutdown of the engine and the “Emergency Button Activated” reporting message on the display.

IMPORTANT: each alarm described above remains active even if the input re-opens (therefore stored). To restore the normal operating it is necessary to reset everything by pressing the Reset button.

2.3.4 J4 CONNECTOR ANALOGICAL INPUTS TO MEASURE ENGINE PARAMETERS J4 Connector analogical inputs, 5 poles step 0.5. The inputs are always referred to ground, in this case the reference ground is separated from the supply ground (terminal 23). This is to avoid any errors regarding analogical readings when the card absorbs current. The connection of sensors to the analogical inputs automatically enables the view of measurements on the display. In the following pictures two of the most commonly used sensors are shown.

.

VDO pressure transmitter plus alarm contact 0-8 bar

11

Termistore (variable resistance) + thermostat (NO contact) VDO for tool and warning light

20

2 – Batt OP ET

OM

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19

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Terminal 19 Water temperature input. This input is connected to a temperature sensor, via the “Settings” menu parameter 5. Five different models can be set: 1. Resistive temperature sensor standard Veglia/Vigil 120 C° 2. Resistive temperature sensor standard VDO 120 C° 3. Resistive temperature sensor standard VDO 150 C° 4. Adjustable 0-10v temperature sensor (linear course) 5. PT100 temperature sensor The transition from resistive sensor to 0-10v is automatic and does not need any particular connection. In Setup you can calibrate the measures in order to compensate the lack of precision of the automotive sensors. This input determines the view of the temperature on the screen. Three functions are associated to this input: 1. “high water temperature alarm" if a set threshold in Setup is exceeded (threshold menu parameter 10), it causes a prewarning that appears on the display and with audible buzzer. 2. “minimum engine temperature" if the detected temperature drops below a set threshold (threshold menu parameter 18), the pre-alarm goes off and it appears on the display and with audible buzzer. 3. The detected temperature is used in “heater” function to activate a contactor that powers a water pre-heating resistance system (see terminal 6 function). In Setup you can set the thresholds for activation and disconnection of the pre-heater (see thresholds menu parameters 19-20).

ENGINE TEMPERATURE

°C 150

PRE-ALARM

50

PREHEAT.OFF

40

PREHEAT.ON

20

MINIMUM TEMP

If no sensors are connected to this input, then the line of temperature is not visualized and all the functions associated with it are disabled. The pre-alarms can be excluded/disabled by bringing the activation thresholds to OFF in the thresholds menu.

Terminal 20 Oil pressure input. A pressure sensor is connected to this input, via the “settings” menu parameter 6. Three different models can be set:

OIL PRESSURE BAR MOTORE 10

1. resistive pressure sensor Veglia 0-10 bar. 2. resistive pressure sensor VDO 0-10 bar. 3. Adjustable pressure sensor 0-10v (linear course). The transition from resistive sensor to 0-10v is automatic and does O,5 MINIMUM PRESSURE not need any particular connection. In Setup you can calibrate the measures and the “0 bar” in order to compensate the lack of precision of the automotive sensors. This input determines the view of oil pressure on the screen. A “low oil pressure” pre-alarm with programmable threshold is associated to this input (see thresholds menu parameter 11). The pre-alarm can be excluded by bringing the activation thresholds to OFF in the thresholds menu.

CAUTION: DO NOT CALIBRATE THE 0 VALUE WHILE THE ENGINE IS RUNNING. To align the reading of zero, go to the "calibration" menu parameter 3 when the engine is stopped (pressure to 0) and then calibrate it by pressing the button "enter".

Terminal 21 Fuel level input. A resistive linear sensor is connected to this terminal. It goes from 0 hom (full tank) to 300 hom (empty tank). This input determines the display on the screen of fuel level in percentage (%.) The following 3 functions are associated to this input: Nome file QPE-C ITA versione 01 10

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1. “Low fuel” pre-alarm that activates the reporting on the display and it activate the buzzer when the level goes under/drops below the set threshold (see thresholds menu parameters 14). 2. Activation of the fuel pump connected to the terminals 36-37 when the level goes under a set threshold (thresholds menu parameter 12). 3. Stop fuel pump, when the level exceeds the maximum set threshold (thresholds menu parameter 13).

FUEL LEVEL

% 80

The pre-alarm can be excluded by bringing the activation threshold of thresholds menu to OFF. The stop of fuel pump is also guaranteed by an “overflow” safety floating connected to the terminals 39-40.

OFF FUEL PUMP

40

ON FUEL PUMP

10

FUEL RESERVE

Before setting the level, it is necessary to calibrate it (operation that takes place in the factory). The procedure that must be follow is as below: 1. Bring the floating rod to the minimum level. 2. Enter the Setup, calibration menu, parameter 1 3. Press "enter" to store the position 0%. 4. Bring the floating rod to the maximum level. 5. Move to Setup menu, parameter 2. 6. Press "enter" to store the level 100%. During the level installation, you must consider the actual excursion of the floating rod in both directions upper and lower. Therefore, place the floating as indicated here below:

Place the level transducer outside the tank, simulate the functioning and adapt to the tank.

Place the variable resistance on the rod, in a central position compared to the level excursion.

Max

RECOVERY INTO TANK

100% 80% OFF PUMP

R 40% ON PUMP

Min

10% ALARM 0%

Terminal 22 Analogical input available for pressure, temperature and levels measurements. It can be used exclusively in 0-10v mode and it is possible to add in Setup the setting of unit of measurement, the values that correspond to different thresholds voltage and the text that has to appear before the measurement. The taken measurement appears in the last line of page 2. To enable this measure, go into Setup menu “settings” parameter 14. Once the input is activated, the following submenu will appear: 1. M22 text (maximum 10 characters) 2. M22 unit of measurement (bar, C°, %) 3. M22 decimals (1-2 decimals) 4. M22 points setting (ten points corresponding to 0-10 volt) Set all the parameters by confirming them with Enter button. Nome file QPE-C ITA versione 01 10

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Terminal 23 common mass of the tools that is equal to the minus battery. If the panel is more than 5 meters from the genset, the mass must be taken directly to the common of sensor to avoid errors in reading. This is because the overall measured resistance is influenced by the current on the minus battery. If the sensor goes to ground directly on the genset frame, please connect this terminal to the bolt closest to the sensor. 2.3.5 J5 CONNECTOR TOROID CONNECTION DIFFERENTIAL PROTECTION J5 2-poles connector step 0,5 connections to the toroid for detecting the leakage current (differential), mounted on demand. All the generating sets produced by Elcos to the European market have rigorously connected the neutral delta-star to ground (TNC or TNS system). This connection is made inside the terminal compartment of the generator. This configuration is always performed even if the machine does not have the differential protection. On demand, for specific applications or specific markets, the implementation of the neutral isolated from the ground can be required. Through the toroidal transformer placed on the delta star-ground bridge, the MC4 constantly monitors that the outgoing currents do not return to the ground connection (i.e. neutral delta star). When the detected ld current exceeds the set value, which means that a part of current is scattered to the ground, after a possible delay, it disables the load through the opening of the machine switch. The picture A represents the ground fault protection 87G, commonly used on our gensets (homopolar type protection) because apart from carrying out the protection against direct contacts, it also detects any possible leakages to the ground from windings of the generator itself. During the commissioning, the isolation between the N neutral and ground PE at the switch downstream should be verified, as their join interferes with the differential protection.

Pic. A

BA

The toroid to be used must have a turns ratio of 500 /1, the card is optimized with a Revalco TOR1D. If the leakage current set threshold is exceeded (after the differential delay time), the “differential protection intervention” alarm gets activated. It causes the view on the display and the release of the magnetoterm circuit breaker by a opening coil connected to the J7 terminals 30-31. It is also expected a pre-alarm, if you exceed 80% of the set threshold, the message "exceeding 1 differential protection threshold” appears on the display with consequent activation of the alarm siren.

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2.3.6 J6 CONNECTOR AMMETER TRANSFORMERS CONNECTION 4-poles connector step 0,5, connections for ammeter transformers (CT) to detect the supplied current. The common terminal 29 must be connected to the terminals S2 of the ammeter transformers, the grounding of the common terminal is not required because it is already made internally the card. The transformers measures are used to determine the views of current on the three phases, of the three powers, of the produced kwh and of exceeding of overload (51) and short circuit (50) thresholds. The connection is very important, it is necessary to strictly respect the input direction P1 of CT and S1 and S2 connections.

Connections: CT1 PHASE X-L1 CT2 PHASE Y-L2 CT3 PHASE Z-L3 Common

Term. 26 Term. 27 Term. 28 Term.29

The CT used to guarantee protection against overload and short circuit, must have a minimum power of => 4VA. If the CTs also power other equipments, the power should be increased according to the power that those equipments require, plus the losses of the wirings. Consumptions table in VA per wiring meter. SECTION mmq

1,5

2,5

4

6

CONSUMPTION

0,685 VA

0,41 VA

0,254 VA

0,169 VA

VA The three current measures with CT ... / 5A are in 0,5 class up to 1000 A, in class 1 from 1000 to 2000 A and in class 1,5 from 2 to 3000A. The ammeter circuits consist of three 0,1â&#x201E;Ś 5W resistors, with a dissipation of 2,5 W at maximum current of 5 A. They can work with a constant overload of 20% 6 A and they accept 15 A for 3" or 20 A for 2â&#x20AC;? for protection against short circuit. In Setup (settings menu parameter 2) you can set the transformation ratio of the different TA with the following scales: 60/5-100/5-150/5-200/5-300/5-400/5-600/5-800/5-1000/5-1500/5-2000/5-2500/5-3000/5. In Setup, it is possible to calibrate the 0 and the measurement of the ammeter readings (calibration menu to reset parameters 6-7-8 to calibrate parameters 15-16-17). The card has been optimized to work with Revalco ammeter transformers, TAR or TAM series. In case of single-phase system, the connection of the sole CT1 FASE X between terminals 29-26 is required. Nome file QPE-C ITA versione 01 10

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WARNING For Function 50 - short circuit protection, TA measurements are provided in order to supply the nominal current times 3 (5x3= 15A), in a linear way without going into saturation.

2.3.6 J7 CONNECTOR RELEASING COIL MAGNETOTERM CIRCUIT BREAKER 2 poles connector 0,75 step to power the releasing coil (BA) at 230V of magneto-thermic circuit breaker. The output is taken off of the F2 fuse downstream and guided by a 6A relay. Terminals 30-31 phase and neutral respectively. The releasing coil of the circuit breaker is always driven in the following cases: 1. Exceeded the overload threshold for a time longer than the set delay. 2. Exceeded the short circuit threshold. 3. Exceeded the differential protection threshold. 4. The emergency button has been pushed. 5. Engine failure alarm (if programmed). The setup of the coil activation from engine failure alarm is activated in the "Settings" menu parameter 22. 2.3.7 J8 CONNECTOR LINE GENERATOR INPUT 4-poles connector 0,75 step, connections with the three phases and neutral of the generator. The voltmetric measures are made in real effective value (RMS) and have an accuracy of 1% with a drift of + / - 5.5 V with temperature from -20 to +70 ° C. The generator sensor is sensitive to the minimum and maximum voltage on each phase and to the sequence of three phases. It can work in a field of 100 to 500V directly connected and via the TV from 600 to 9.000/100V The three phase sensor is built with three 500K OHM high voltage insulation resistor dividers, that can resist to any over-voltages up to 3KV for 1". It is sensitive to the minimum and maximum voltage on single phase and to the asymmetry of the displacement angle of the three phases. All the values are adjustable, its main features are shown here below:

Three phase and single phase 27 – 59 – 60 – 81 – 47(*) 100 – 500 V ca with direct connection 600 – 9000/100V 180-390 (27) 280-499 (59) => 5 KV per 1s 50-60 Hz 41-58 HZ (81) 50-74 HZ (81)

Generator control Functions Operating Voltages Operatine voltages throgh TV Minimum adjustable voltage

Maximum adjustable voltage Isolation voltage on L1 – L2 – L3 – L4 Work frequency

Minimum frequency Maximum frequency

The three-phase sensor can be set to work with three-phase systems with neutral, three-phase systems without neutral or single phase ones (see settings menu parameter 1). If set on single phase, the check is activated only on the connections X (32) and N (35). To avoid any measurement errors, please connect the terminals Y (33) and Z (34) to neutral.

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Generator connections GEN.

GEN.

MC4

X Y Z N

X=32 Y=33 Z=34 N=35

MC4

X Y Z N

X=32 Y=33 Z=34 N=35

R THREE-PHASE WITH NEUTRAL TO GROUND CONNECTION TNC O TNS GEN.

X Y Z

THREE PHASE WITH GROUND-ISOLATED NEUTRAL CONNECTION IT GEN.

MC4

X=32 Y=33 Z=34 N=35

MC4

X

X=32

N

THREE-PHASE WITHOUT NEUTRAL CONNECTION

Y-Z-N

SINGLE CONNECTION

PHASE

The thresholds for minimum and maximum voltage and frequency can be set in the "threshold" menu parameters 2-3-5-6. If the voltages measures are not precise, you can calibrate them in the "CALIBRATIONS" menu parameters 9-10-11-12-13-14. 2.3.8 J9 CONNECTOR FUEL PUMP SUPPLY. Three poles connector 0,75 step, line 230 volt of fuel pump supply, driven by a 10A relay that takes the voltage from the generator input line. The output is protected by a 4 A (F5) fuse. Terminals 36-37-38 neutral, phase and ground respectively. This output is activated: With key on manual, when you press the "Fuel Pump" (T2) button. With key on automatic when the fuel level in the tank varies. The automatic function is linked to the presence of the fuel level sensor (see settings menu paragraph 2.3.4). The fuel pump operation is monitored by a led placed next to the "Fuel Pump" T2 button. The pump is powered by the generator line, so it can work only with the genset is running. You can directly control pumps at 230volt max 350 Watts. For higher powers or three phase pumps, the use of a re-launch contactor is required. The QPE-C panel provides a wiring predisposition for single phase pumps. 2.3.9 J10 CONNECTOR FLOATING OVERFLOW. 2 poles connector 0,5 step, Terminals 39-40 connection to the safety floating potential free contact normally closed. This floating gets activated as overflow safety in case of failure of the working floating. The opening of this contact stops the fuel pump in both manual and automatic modes. With key on automatic, it causes the “Tank overflow alarm”.

2.4 ELECTRIC WIRING MC4 MOTHERBOARD WITH EXTERNAL USERS The connection that are in the bottom of the MC4 card are made for the end user and control transfer switches, alarm warnings and remote controls. Later on, there are listed the functions of each connection. 2.4.1 J11 CONNECTOR DATA TRASMISSION IN MOD-BUS. 3 poles connector 0,5 step, RS 485 serial port for data transmission in mod-bus mode. Terminal 41 - 42 - 43 Connection A - B and shielding respectively. Through this connection you can remotely control all the measurements and alarms, the start-up and stop from distance and the switching commands. To interpret all data, it is necessary to consult the list of records indicated in paragraph Teleprocessing page 64. This connection is then used to: 1. Connect a monitor to display all parameters at a certain distance. Nome file QPE-C ITA versione 01 10

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2. Connect programmable relays in order to be able to activate some relays only for specific alarms. 3. Connect a PC with special interface RS485-USB. 4. Connect other devices remotely. The connection is optically isolated, so that you can make secure and stable connections even at 500 meters. A micro-switch dip2 allows the activation of 120 ohm end line resistance. 2.4.2 J12 CONNECTOR REMOTE CONTROLS. 4-poles connector 0.5 step, connection to external controls start, locked and test. In detail, the connections have the following functions: Terminal 44 common for different inputs connected to ground (- battery). Terminal 45 start control, it is active only with key on automatic and operation mode 1. If closed to ground, it causes the start-up of the genset and if opened it controls the shutdown after the cooling time. If enabled , the display will show the "remote start command” message. The start-up command can be given by thermostats, floatings, pressure switches, remote controls etc.. Terminal 46 lock control. When closed to ground, it prevents any automatic start-up in all modes. If enabled, the display will show the "remotely locked” message. The start-up command can be given by thermostats, floatings, pressure switches, remote controls etc.. By opening the contact, the card re-takes to manage the generator normally. By closing the contact while genset is running, you get the immediate arrest of the genset. Terminal 47 test command only active in mode 2. Used to test the machine even with mains. If closed to ground, it causes the start-up of the genset and if reopened it stops it. In Setup you have the load test option with commutation genset-mains (setting menu parameter 28). Summary table of command functions in different modes: Command

Start Locked Test

Mode n°1 Aut Man * * *

Mode n°2 Mode n°3 Aut Man Aut Man * *

*

*

*

2.4.3 J13 CONNECTOR REMOTE SIGNALS. 7 poles connector 0,5 step, connections for external controls and signals. Terminal 48-49 external emergency button, normally closet contact. If opened, it causes the immediate arrest and stops all the automatic features. If active, the display will show the “External emergency button” message. If it is not present, it has to be short-circuited. It can be taken up to 20meters distance with a common twisted pair, for longer distances we recommend to use a shielded cable. Terminal 50-51 direct supply 12v to an output buzzer protected by an auto-resetting thermal fuse 500mA. The buzzer gets activated in an identical way to the one mounted on the card. Terminal 52-53 MASTER START start-up contact, enabled also with key in off. If the contact gets closed, it is like we are closing simultaneously the key to automatic and the start command. If opened, the stop command, the opening of the load and the engine cooling are given. See applications paragraph 1.8.4. Terminal 54 Key in automatic reporting. If the key is in automatic position, a voltage of +12 V is present. The output is protected by an auto-resetting thermal fuse 500 mA. 2.4.4 J14 CONNECTOR PROGRAMMABLE REPORTING RELAY. Relay output with changeover programmable contact for the following warnings: 1. cumulative alarm 2. genset running 3. low fuel Nome file QPE-C ITA versione 01 10

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4. 5. 6. 7.

overload presence of mains emergency enabled start-up failure

Setup: â&#x20AC;&#x153;settingsâ&#x20AC;? menu parameter 15.

2.4.5 J15 CONNECTOR MANAGEMENT OF MAINS-GENSET REMOTE COMMUTATION. 6-poles connector 0,75 step, connections for the management of mains-genset commutation. The MC4 card, in mode 2 with key on automatic, includes the management of the genset start-up when the mains voltage fail and the relative monitoring of consents to the line commutation from the mains to the genset, i.e. the monitoring of ATS panel (automatic transfer switch). These contacts can guide power contactors, motorized change-over or motorized switches. The connections to be made are as follow: Commutation with power contactors.

The two power contactors (CR-CG) must have both electrical and mechanical interlocks (BM) to prevent genset-mains parallels which would cause irreparable damages to the generator. Commutation with motorized change-over.

The motorized change-over (CM) will switch the load on the mains line (1) or on the genset line (2). Make sure that the supply to the change-over (supply) is taken from an always available source, such batteries 12/24 v or 230volt line from UPS. This will give us the guarantee of operation even without the mains. Nome file QPE-C ITA versione 01 10

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Commutation with motorized switches.

in questo modo avremo la garanzia di manovra anche in assenza rete. Two motorized switches (IR-IG) carry out the mains-genset commutation. In order to avoid that dangerous manual operations will be done which would cause a mains-genset parallel, it is necessary to interpose a mechanical lock between the two switches. A further guarantee of safety is given by the electrical interlock that prevents the closing of a switch if the other did not open. Make sure that the supply to the switches (supply) is taken from an always available source, such batteries 12/24 v or 230volt line from UPS. This will give us the guarantee of operation even without the mains.

N.B.The motorized switches have activating times that in some cases last a few seconds (time that it is necessary for the springs to be loaded by the M engine), therefore, to avoid any problems, please set the MC4 card commutation time to a bigger value than the time spent to load the spring (Setup time menu parameter 10). In Setup you can change some time associated with the commutation: 1. Genset contactor closing delay (after detecting the genset is running) see “time” menu parameter 11. 2. Commutation delay when the mains come back, see “time” menu parameter 9.

WARNING! The management of closing the mains line is always guaranteed and it always takes priority. No matter in which position you put the key or if you disconnect the panel from the battery, the mains line management contact (terminals 58 60) remains always closed.

2.4.6 J16 CONNECTION.

CONNECTOR

BATTERY

CHARGER

5-pin 0.75 step connector for connecting the external battery charger. The QPE-C panel according to the setup of the panel itself has an internal battery charger (CB1) dual voltage automatic 12/24 2,5 A. Nome file QPE-C ITA versione 01 10

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The battery charger is protected against reverses polarity, overload and short circuit. Two leds indicate the operating status: • LED POWER ON if active, it indicates that the device is powered correctly. • LED CHARGE with fixed light, it indicates that the charging is in progress. If off, it means that the charging is finished. If the light is flashing, it means the activation of maintaining charge. The connections are: Terminal 64-65 battery voltage 12 to 24 vdc respectively + and – directly connected to terminals 1 and 2. Terminal 66-67 220v supply, taken for the mains line (J17 conn.) Terminal 68 ground connection. IMPORTANT The battery charger has to be set (operation performer at the factory) to the battery voltage to 12 or 24 volt, the change must be done with battery disconnected from the mains. Move the fuse and the bridge accessible in the front part, where it is reported the battery voltage. 2.4.5 J17 CONNECTOR MAINS PRESENCE SENSOR CONNECTION 5-pin connector 10 step, input to detect the mains line voltage, three-phase input plus neutral, the allowed voltage range is from 0 / 500 volts 50/60 Hz. The system automatically configures itself to the same one chosen for detecting the generator, i.e.: 1. Three-phase with neutral 2. Three-phase without neutral 3. Single-phase In setup, you can set the minimum and maximum voltage thresholds beyond which the generator shall start, see "thresholds menu” parameters 7-8. In case of power failure of even one phase, the generator will start automatically. The input also includes the insertion of voltage transformers in order to use the genset even in medium voltage, see "settings menu" parameter 4.

THREE-PHASE WITH NEUTRAL

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2.5 SETUP 2.5.1 SETUP MODE ACTIVATION The setup of the card allows you to customize the control, measurement and protection functions of any type of generating set. Once you entered the setup, recurrent messages on the display will guide you through the possibilities of setting. Setup is enabled in two ways: 1 By inserting the DIP1 switch 4. 2 By simultaneously pressing ”ACK” and “ENTER” keys for 8 seconds. Once you entered the setup, you have 11 menus that appear on two screens.

- SETUP MENU ______________________________

- SETUP MENU ______________________________ 10. USB MENU 11. CARD MENU

1. CLOCK MENU 2. DIFFERENTIAL MENU 3. TIME MENU 4. THRESHOLDS MENU 5. SETTINGS MENU 6. CALIBRATION MENU 7. MODEM MENU 8. CAN-BUS MENU 9. MOD-BUS MENU ______________________________________

______________________________________

To move through the setup menu you can use the “ARROW UP” and “ARROW DOWN” keys under the screen to navigate from a menu to another one, the "ENTER" key to confirm the parameter that has to change, the "ACK " key to return to the previous function and the "ARROW + "and "ARROW -" to increase and decrease the parameter values. In details, all the menus are as follows: 2.5.2 CLOCK MENU Enabling the clock menu you can access three submenus that allow you to adjust the clock, the date, the weekly test setting and the programmed start-ups. - 01 CLOCK MENU ______________________________ 1. DATE/TIME ADJUSTMENT 2. WEEKLY TEST OPTION 3. PROGRAMMED START-UPS

______________________________________

The table here below shows the variables and values associated with them. Nome file QPE-C ITA versione 01 10

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PARAMETER 1.

2.

3.

Date/time adjustment. Enabling the first option it will be displayed in full screen the date in full, the day of the week and the current time. Through the arrow keys under the screen, you move the cursor under the parameter you need to change and with the + and – keys you can modify the value and confirm everything by pressing the "ENTER" key. Weekly test option Weekly test setting. Enabling the second option it will be displayed in full screen the OFF state/day of the week, the starting time, the duration of the test and the frequency of the test. Through the arrow keys under the display, you position the cursor under the parameter that needs to be changed and with the + and – keys you can modify the parameter, then confirm it by pressing the “ENTER” key. The weekly test will be performed only with key on automatic and only if it is confirmed by the “TEST” button on the panel. The weekly test will be performed on the week after it has been activated. Programmed start-ups It allows you to set scheduled days of the week and times, the generator start and stop. Through the arrow keys under the display, you position the cursor under the parameter that needs to be changed and with the + and – keys you can add the startup and the stop time. The modified value has to be confirmed by pressing the “ENTER” key. A clock icon at page 1 of the display will indicate that a programmed start-up has been scheduled.

FIELD

DEFAULT

1 test every: 1 week 2 weeks 3 weeks 4 weeks

disabled

Test duration From 1 to 60 minutes

8 events of start-up and stop for each day of the week.

disabled

2.5.2 DIFFERENTIAL MENU The differential menu allows the setting of the alert threshold for intervention of ground leakage protection. The table here below shows the variables and values associated with them.

1.

2.

PARAMETER

VALUE

FIELD

DEFAULT

Intervention threshold Setting of the maximum limit of ground leakage current. When exceeded, it causes the release of the machine switch and the arrest of the generator. Intervention threshold Setting of the alarm delay when exceeding the set threshold.

mA

OFF 20-5000

300

Sec.

0-30

3

2.5.4 TIMES MENU The times menu allows the setting of all timings managed by the MC4 card. The table here below shows the variables and values associated with them.

1. 2.

PARAMETER

VALUE

FIELD

DEFAULT

Start-up delay It makes the genset insensitive to the micro-breaks. Engine cooling time It allows the engine to cool down by letting it spin freely after an automatic intervention.

Sec.

0-240

0

Sec.

0-120

60

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3.

4. 5.

6. 7. 8.

9. 10.

11.

12.

13.

14.

15.

Solenoid activation duration In engines equipped with stop solenoid, it determines for how long it remains activated. Starter duration It is the maximum time that the starter remains operating. Start-up pause It is the interval between a start-up attempt and the following one. Pre-heating duration It is the duration of glow plugs pre-heating before starting. Alarms activation delay It is the time to exclude alarms at the start-up of the machine. Overload intervention delay It is the intervention delay when exceeding the overload threshold. Mains return delay It is the delay Commutation Pause It is the pause that exists between the mains-genset commutation command. Inserting genset delay It is the delay that enables the taking of load after detecting that the genset is running. Maintenance Request Interval It is the interval that activates the signal for the maintenance request. Siren sound duration Duration of the siren activation, if brought to 0 it turns off. Over 120 seconds it is always ON. Low fuel alarm + shutdown delay It is the delay that causes the shutdown of the machine after the low fuel signal. If brought to 0 sec. (OFF), the engine does not stop when it goes in fuel reserve. Duration of genset running check It is the duration of the start-up phase check.

Sec.

0-60

0

Sec.

1-10

5

Sec.

0-15

3

Sec.

0-30

0

Sec.

5-30

5

Sec.

15-240

30

Sec.

15-240

30

Sec.

0-30

1

Sec.

1-240

5

Hours

0-40000

1000

Sec.

0-120-on

30

Sec.

Off-300

300

Sec.

1-30

5

2.5.5 THRESHOLDS MENU. The thresholds menu allows you to access the intervention thresholds of various alarms. The table here below shows the variables and values associated with them.

1.

2.

3.

4.

PARAMETER

VALUE

FIELD

DEFAULT

Max. generator voltage It is the maximum threshold voltage that if exceeded causes the alarm. By exceeding the value of 499 volts the alarm goes to OFF (disabled). Min. generator voltage It is the minimum threshold voltage that if exceeded causes the alarm. By setting the value under 180 volts the alarm goes to OFF (disabled). Minimum generator current It determines the maximum threshold of current supplied by the generator, beyond which the alarm intervenes, after suitable delay, and the engine gets stopped after the cooling time. By setting the value beyond 2999 A, it goes to OFF (disabled). Short circuit current It is the max power supplied by the generator beyond which intervenes the instant alarm of the machine, usually set at 3 times the rated current of the machine. If you set the value over

Volt

280-499 OFF

440

Volt

OFF 180-390

360

Amp.

1-2999 OFF

-

Amp.

1-8999 OFF

-

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5.

6.

7.

8.

9.

10.

11.

12. 13. 14. 15.

8999 A then the alarm goes to OFF (disabled). Maximum generator frequency It intervenes after 3 seconds and determines the immediate arrest for overspeed. If the value is set over than 74 Hz, the alarm goes to OFF (disabled). Minimum generator frequency If after the detection of engine running, the frequency falls below the set threshold the machine activates the alarm. If the value is set below 41 Hz, the alarm goes to OFF (disabled). If the engine started after the detection rate falls below the threshold Set the machine goes into alarm. If the value IS SET below 41 Hz the alarm port to OFF (disabled). Maximum mains voltage It is the threshold beyond which the genset starts and powers the load. Minimum mains voltage It is the threshold below which the genset starts and powers the load. Soglia di allarme potenza max di energia Maximum reverse power This is the threshold of the alarm of maximum consumption power when operating in parallel with other gensets. Maximum H2O temperature Threshold of pre-alarm from analog probe signal. If the value is set beyond 129 °C, the alarm goes to OFF (disabled). Minimum oil pressure Pre-alarm threshold from analog probe signal. If the value is set below 0.6 bar, the alarm goes to OFF (disabled). Fuel pump level ON Enabling threshold from fuel pump analog signal Fuel pump level OFF Disabling threshold from fuel pump analog signal Low fuel level Pre-alarm threshold from analog signal for low fuel Engine ON frequency threshold Frequency threshold beyond which the engine is considered started, it determines the release of the starter motor.

Hz

50-74 OFF

55

Hz

OFF 41-58

45

Volt

250-500

450

Volt

180-390

350

Watt

OFF 1009999

OFF

°C

60-129 OFF

OFF

Bar

OFF 0,6-3

OFF

%

5-30

10

%

40-95

80

%

3-20

5

Hz

5-25

18

16.

Minimum battery voltage Alarm/pre-alarm threshold for battery flat, it automatically varies in two different ranges depending on the setting of the power supply voltage.

Volt

12>9/12 24>17/24

9 17

17.

Maximum battery voltage Alarm/pre-alarm threshold for high battery voltage, it automatically varies in two different ranges depending on the setting of the power supply voltage. Minimum H2O temperature Threshold of pre-alarm from analog signal for minimum engine water temperature. If the value is set below -4 °C, the alarm goes to OFF (disabled). Maximum pre-heating temperature If active, the pre-heating mode is the threshold that deactivates the pre-heating device. The temperature is detected by external analog probe, terminal 19. Minimum pre-heating temperature If active, the pre-heating mode is the threshold that activates the pre-heating device. The temperature is detected by external analog probe, terminal 19. MAX number of start-ups Start-ups attempts that have been made.

Volt

12>15/20 24>25/35

20 35

°C

OFF -4-10

0

°C

30-90

40

°C

0-40

30

1-4

3

18.

19.

20.

21.

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2.5.6 SETTINGS MENU. The Settings menu provides access to several sets of operation. The table here below shows the variables and values associated with them. PARAMETER System type Supplying system 1-PH (single-phase), 3-PH (three phase without neutral) PH 3-N + (three phase with neutral) TA ratio Transformation ratio current transformers x/5 A

VALUE -

FIELD 1-PH 3-PH 3-PH+N

DEFAULT 3-PH+N

-

-

TV genset ratio Transformation ratio voltmeter transformers linear setting from 100 to 10,000 volts. TV mains ratio Transformation ratio voltmeter transformers linear setting from 100 to 10,000 volts. Temperature sensor type Selection analog input temperature probe terminal 19.

Volt

60/100/150/ 200/300/400/ 600/800/1000 1500/2000/ 2500/3000 10000/100

Volt

10000/100

100/100

-

Vdo120

6.

Pressure sensor type Selection analog input pressure probe terminal 20.

-

7.

Oil inlet exclusion Disabling oil pressure switch and function and related alarms. Dynamo input exclusion Disabling dynamo alarm. Stop when dynamo alarm occurs Enabling engine shutdown when dynamo alarm occurs.

-

Veglia Vdo120 Vdo 150 0;10 volt PT100 Veglia Vdo 0;10 volt ON (excluded) OFF (active)

1.

2.

3.

4.

5.

8. 9.

10.

11.

12. 13.

14.

15.

16.

Vdo

ON

-

ON (excluded) OFF (active) ON - OFF

OFF

High temperature input logic. Selection of the type of high temperature alarm sensor terminal 12 Immediate stop for high temperature. Enabling the arrest without engine cooling time when high temperature alarm occurs.

-

N.O.-N.C.

N.O.

-

ON- OFF

OFF

H2O low level input logic Selection of the type of the radiator water level sensor Pre-heating mode Selection of the engine pre-heating system, glow plugs during start-up or pre-heater 230volt for engine water. Input 22 enabling If enabled, it activates a submenu that allows you to configure the analog input in different modes, see menu here below. Out relays setup Setting the type of remote reporting from terminals 5556-57

-

N.O.-N.C.

N.O.

-

Pre-heater Glowplugs

Glowplugs

-

ON-OFF See submenus

OFF

-

Failure to start. Emergency. Presence of mains. Overload. Low fuel. Genset running. Cumulative alarm. ON - OFF

Cumulative Alarm

-

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ON

OFF


Enabling engine shutdown when detecting water in the fuel. Text Input 1 Available Activation of menu for entering text via a virtual keyboard on the display which can be activated with the arrow keys. To confirm the entry press ENTER, to save the written text press ACK twice, when asked to confirm press ENTER on OK. Through the TEST button, you choose the lowercase or uppercase font. Mode Input 1 Available It sets the type of action if the input 1 available is active.

-

-

-

-

reporting

Text Input 2 Available Activation of menu for entering text via a virtual keyboard on the display which can be activated with the arrow keys. To confirm the entry press ENTER, to save the written text press ACK twice, when asked to confirm press ENTER on OK. Through the TEST button, you choose the lowercase or uppercase font. Mode Input 2 Available It sets the type of action if the input 2 available is active.

-

Repor.+alarm+stop Repor.+alarm+cool. Repor.+alarm Reporting -

Battery nominal voltage It sets the battery voltage to which the alarm thresholds refer to, setting errors do not cause damages to the card. Circuit breaker releasing It sets the releasing mode of the circuit breaker mounted on board. Home page logo Enabling of the logo on the home page Page input / output Enabling the view of page 11 for monitoring the card input and output.

Volt

25.

26.

17.

18.

19.

20.

21.

22.

23. 24.

27.

28.

-

-

Repor+alarm+stop Repor.+alarm+cool. Repor+alarm Reporting 12-24

reporting

12

-

With each alarm Overload only

Overload only

-

ON - OFF

ON

-

ON - OFF

ON

Output terminal M5 It sets the type of function connected to terminal No. 5

-

Solenoid

Values rotation page. 1 Enabling the rotation display of volts on the three phases of page 1. Stop for V batt out of bounds Enabling engine shutdown when the battery voltage is out of bounds. Load test Enabling the load switching on the genset during the automatic test (both instant testing and test with timer)

-

Solenoid Electrical Box Can-bus engine supply ON - OFF

ON

-

ON - OFF

OFF

-

ON - OFF

OFF

Submenu M22

1.

2.

ENABLING INPUT M22 SUBMENU TEXT M22 Activation of the menu for entering text via a virtual keyboard on the display which can be activated with the arrow keys. To confirm the entry press ENTER, to save the written text press ACK twice, when asked to confirm press ENTER on OK. M22 unit of measurement Nome file QPE-C ITA versione 01 10

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VALUE -

FIELD -

DEFAULT -

-

%

-

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It selects the unit of measurement displayed on the side of the read value. 3. 4.

M22 decimal points It selects the decimal point position in the displayed data. M22 setting points It sets the 0-10Volt input, entry of the corresponding values.

째C Bar -

0-3

-

10 points

-

2.5.7 CALIBRATION MENU. The calibration menu allows you to calibrate the various made measures by the MC4 card in order to ensure high accuracy in readings. The table here below shows the variables and values associated with them. Some parameters are calibrated automatically by aligning themselves to the connected sensor, in other cases, the calibration must be done manually. The manual calibration is made by entering the parameter to be calibrated and pressing the ENTER key. There will then be displayed on the display 3 all the data, the read value (read), the calibration factor (default is 1) and the calibrated value, so the value normally displayed will be given by: Displayed value (calibrated) = read value (read) x coefficient (default is 1) PARAMETER 1.

2.

Calib. 0 fuel level Calibration of 0%. Enter the parameter, set the floating to the minimum level and press ENTER to store the position to 0. In this case the calibration is done automatically. Calib. Full fuel level Calibration of 100%. Enter the parameter, set the floating at the highest level and press ENTER to store the position to 100%. The calibration is done automatically.

CALIBR. TYPE AUTOMATIC

FIELD -

AUTOMATIC

-

3:

Calib. 0 oil pressure Calibration of 0 bar. Enter the parameter, with the engine stopped, press ENTER to store the position to 0. In this case the calibration is done automatically.

AUTOMATIC

-

4.

Calib. Oil pressure measure Change the calibration coefficient until the calibrated value matches the actual value. Calib. H2O temperature measure Change the calibration coefficient until the calibrated value matches the actual value. Calib. 0 current L1 Calibration of 0 A. Enter the parameter, with the engine stopped, press ENTER to store the position to 0. In this case the calibration is done automatically. Calib. 0 current L2 Calibration of 0 A. Enter the parameter, with the engine stopped, press ENTER to store the position to 0. In this case the calibration is done automatically. Calib. 0 current L3 Calibration of 0 A. Enter the parameter, with the engine stopped, press ENTER to store the position to 0. In this case the calibration is done automatically. Calib. Voltage L1-N Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Voltage L2-N Change the calibration coefficient until the calibrated value matches the

MANUAL

0,51,5

MANUAL

0,51,5

AUTOMATIC

-

AUTOMATIC

-

AUTOMATIC

-

MANUAL

0,51,5

MANUAL

0,51,5

5.

6.

7.

8.

9.

10.

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11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23

24

value measured with a precision instrument. Calib. Voltage L3-N Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Voltage L1-L2 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Function enabled only when the calibration is disabled from L1-N Calib. Voltage L2-L3 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Function enabled only when the calibration is disabled from L2-N Calib. Voltage L3-L1 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Function enabled only when the calibration is disabled from L3-N Calib. Current L1 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Current L2 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Current L3 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument.. Calib. Battery voltage Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Differential Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument.. Calib. Mains voltage L1 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Mains voltage L2 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Calib. Mains voltage L3 Change the calibration coefficient until the calibrated value matches the value measured with a precision instrument. Produced kw reset Entering the parameter, the kWh produced will be displayed (total, partial, single start-up). By pressing the ENTER key for 2 seconds, partial and single start-up ones will be deleted. The total ones reset is possible only at the factory. Operatine hours reset Entering the parameter, the worked hours will be displayed (total, partial, single start-up). By pressing the ENTER key for 2 seconds, partial and the single start-up ones will be deleted. The total ones reset is possible only at the factory.

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

MANUAL

0,51,5

-

-

-

-

2.5.8 MODEM MENU. The modem menu allows you to set passwords and telephone numbers for sending SMS alarms.

1.

2.

DESCRIPTION Genset ID It is the identification number that appears on the received SMS in order to identify which genset has an alarm. If set to 0, it disables the modem. SMS 1 By using the arrow keys and ENTER, you can dial the phone number by moving a cursor on a virtual keyboard. Dial the number with international prefix for example +3934775******. Once you dialled the number, press ACK twice, confirm the Nome file QPE-C ITA versione 01 10

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3. 4. 5. 6.

7.

number (by pressing ENTER), confirm the enabling (by pressing ENTER). If you want to disable the number without deleting it, confirm CANCEL in the enabling menu. SMS 2 Same as above SMS 3 Same as above SMS 4 Same as above Password It sets the password that authorizes the controls via SMS, the input mode is the same as the one of numbers. Enable feedback It enables the sending of feedback SMS as a confirmation of start and stop of genset.

Maximum 16 digits Maximum 16 digits Maximum 16 digits Maximum 5 digits Default 1234 ON-OFF

2.5.9 CAN-BUS MENU. The menu allows you to enable the CAN-BUS communication between the card and the engine and also allows you to select the various types of engine control units.

1.

2.

DESCRIPTION Can Bus It allows the enabling of communication with the various engine control units. In Volvo EDC3 engines, the start and stop controls are also sent.

Engine frequency In designed engines, it allows to adjust the exchange frequency rate.

FIELD OFF VOLVO EDC3 VOLVO EDC4 IVECO DEUTZ MTU J1939 1500 - 50Hz 1800 - 60Hz

2.5.10 MOD-BUS MENU. The menu allows you to enable and set the MOD-BUS communication between card and additional remote units such as plc, remote panels, pc etc.. The communication standard RTU (binary) standard format 8-N-1 (i.e. 8bit data, no parity and 2 stop bits).

1.

2.

3.

DESCRIPTION Genset ID It allows you to give an address identifier to recognize the device in a system with multiple MOD-BUS devices. If set to 0, the communication is disabled. Baud rate Data transfer speed.

Stop bit It sets the stop bit.

FIELD 1-31

DEFAULT

4800 9600 14400 19200 38400 1-2

9600

1

2.5.11 USB MENU. The menu allows you to access the saving or loading functions of the configuration parameters of the card, for example alarms thresholds for minimum and maximum voltage, the type of TA, etc. This makes it possible to create specific configuration files for each machine and load them quickly and accurately. Moving into the USB menu is like working in "My Computer" in Windows, to activate the function you must have a USB key and insert it into USB1 port located on the motherboard, by pressing the ENTER key the MC4 card connects to the key and displays the menu shown in the table below: Nome file QPE-C ITA versione 01 10

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1.

2.

DESCRIPTION Loading parameters The loading parameters updates all the setup menus, except for the clock menu, calibrations and the modem menu. To load the file, enter the "directoryâ&#x20AC;? containing the configuration files (using the arrow keys and ENTER to confirm), choose the setup file related to the genset that must be started and press ENTER to confirm. If the file is correct, within a few seconds, all the parameters are gradually updated. If the writing ERR.4 comes out, it means that the chosen file is incompatible. Saving parameters The saving creates a copy of the parameter settings. Entering the saving, it will be prompted to create a file or a directory (folder containing multiple files). In both cases, you must create the file name via a virtual keyboard by using the arrow keys and ENTER and TEST. Once you made the writing, press ACK twice and confirm with ENTER. The file or the directory should be made up of a maximum of 8 characters and TXT extension i.e. ge100kva.txt.

NOTES

The MC4 card can recognize USB keys up to 8GB, higher capacity keys cannot be recognized. If the USB key contains a high number of files, this could create errors in reading. We therefore recommend to use keys dedicated only to configuration files for the MC4 card.

2.5.12 CARD MENU. The card menu allows you to make specific hardware settings and set the initial default values. The table here below shows the variables and values associated.

1.

2.

3.

NOTES 1. Display contrast 2. Backlighting Mode 3. Buzzer for pressing keys

DESCRIPTION Menu parameters HW It sets the hardware parameters of the card.

Dip-switches status It shows the location of the Dip 1 switches to make functional checks when the motherboard is not accessible. Reserved menu

Da 0 -1000 0-10 min. ON-OFF

1 Default parameters progr. If confirmed with the ENTER key, it brings back the parameters of the different menus to the factory standard values. 2 Default parameters HW If confirmed with the ENTER key, it brings back the parameters of the calibration menu to the factory default values. 3 Default parameters test If confirmed with the ENTER button, it resets the settings of the weekly tests.

4 Default parameters start-ups If confirmed with the ENTER button, it resets the settings of the scheduled start-ups.

5 Default parameters of alarms history If confirmed with the ENTER button, it resets the settings of the alarms history. 4.

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It allows you to set the genset operating lock after the set time. To unlock it, a password with 6 digits is required. When you activate the lock, it will appears on the display the "lock password" writing and you cannot start the genset anymore.

2. Enabling lock

ON-OFF

3. Operating range.

1-150 days

The loading of a default of a single data can be made by pressing simultaneously the arrow keys up / down for 5 seconds.

2.6 TECHNICAL NOTES OF MC4 CARD 2.6.1 ENGINE RUNNING DETECTION

Genset Voltage

It does not require any external signal. The check take place on the generator frequency. In the start-up stage, once reached 540 rpm corresponding to 18Hz programmable, we have the first signal that the engine has started. A second check free from the microprocessor is made by detecting the output voltage from the generator, when exceeded 200 volts the starter motor is disabled. If the oil bulb has not been disabled, you have a third check, i.e. it is checked that the oil bulb is closed (0 bar oil pressure, engine off) before entering the starter motor. If the check gives negative result, then the start-up gets blocked.

51 52

=

>

18 Hz

Start Kran ckk

O Off 0 20 Hz

10

Once reached the set frequency: - 9Hz for 3000 rpm - 18Hz for 1500 rpm The control gets interrupted.

Setup. Thresholds menu parameter 15 Engine frequency thresholds ON. 2.6.2 OPERATING WHEN THE MICROPRECESSOR IS BLOCKED The MC4 card was designed to ensure the card manual start-up even in case of total failure of the microprocessor. The start control with key in manual position is free from the microprocessor and acts directly on the starter relay, so we can start the machine and turn it off by turning the key to off. If the engine is totally controlled by CAN-BUS (for ex. Volvo engines) the start-up with blocked microprocessor is not doable. WARNING when the machine has started with blocked microprocessor, all protections and alarms are disabled, so the user takes full liability for generator failure or any damages caused to the powered users.

2.6.2 FIRMWARE SOFTWARE DISPLAY. MC4 card has two identical microprocessors, one for the display card (which manages keys functions) and one for the motherboard (which deals with all the measures and protections). Both microprocessors are periodically updated to improve the card performances. The software version installed on the motherboard is shown when powering up the first screen page. The display of the card display version only happens when you turn on the card by pressing the reset button on the motherboard (the button is located in the central part of the motherboard, and it is accessible only by removing the cover/lid). The table here below shows the firmware versions and the associated changes.

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MOTHERBOARD ENTERED CHANGES DESCRPTION FIRMWARE VERSION

1.

1.0

No changes.

FIRMWARE CARD DISPLAY VERSION

1.00

ENTERED CHANGES DESCRPTION

No changes.

2.

3.

4.

5.

6.

7.

8.

9.

2.7 ACCESSORIES COMBINABLE WITH QPE-C PANEL 2.7.1 MODEM FOR REMOTE MANAGEMENT OF GENERATING SET. The modem can send SMS with specified the type of alarm to 4 mobile numbers, then through a password you can start and stop the genset from a remote distance by sending an SMS. The sent message is in the selected language and it is preceded by the genset number (genset id modem menu). For example: Genset 1 "lack of fuel" The MC4 modem card is specifically designed to fit within the display card. The assembly of the modem card is realized as follows: 1. 2. 3. 4. 5. 6. 7. 8.

Turn the card key to “0” position Remove the battery fuse F1 Remove the pre-cut sheet at the rear right side of the display card. Insert the modem card, taking care to properly align the connector. Fasten the modem to the sump with screws. Connect the antenna. Insert a SIM with disabled PIN. Replace the fuse F1 back.

Once the mechanical assembly has been made, you must activate the modem using the appropriate menu (see page 54), by bringing the parameter 1 of the modem menu to a value other than 0 (if left to 0 the modem is disabled). In the modem menu you can enter and search all the phone numbers and change the password for the Nome file QPE-C ITA versione 01 10

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remote control. You can also insert numbers and passwords by sending SMS’ as described below. When you turn on the panel on page 1 of the display, the symbol of an antenna will be shown, and after a minute above this symbol will appear the marks that indicate the quantity of the received signal. If not, check the GSM coverage area or verify that the inserted SIM has the PIN disabled. Receiving and sending an SMS is indicated by the animation of notches above the antenna. The controls and configurations that can be sent via SMS are the following: Changing the password. The default password is 1234, to change this number you must send an SMS to the SIM number enabled in the modem and composed as follows: PWD3426#1234 The PWD writing indicates the control, 3426 the new password, 1234 the password that authorized the control. The control letters may be recognized both if written in uppercase or lowercase. Recovery reset. In case the user loses or forgets the password, it has been programmed a system reset which restore the modem back to the basic state by sending an SMS, for example: RESET#1234 The reset password is obviously always the same and is not modified by the user. Phone numbers insertion. To save the phone number where messages of alarm and status will be sent, you must send an sms with the following command: NUM1+3934724356487#1234 The NUM writing indicates the command, the following number 1 indicates that this is the first phone number included in the list, +3934724356487 is the phone number to be inserted, #1243 is the current password (if it has not been previously modified). 4 numbers are allowed. Deleting a phone number. To delete a phone number you have to send the following command NUM1#1234 where the number 1 that follows the NUM command indicates which out of 4 numbers has to be deleted. Start-up control To start the genset remotely, send the command followed by the password, START#1234 When the genset is running, if enabled in the modem menu, an SMS will be received indicating “genset running” of course this message will be sent to all numbers on the list. The remote start control is active only with key in automatic, and only if the card was configured with operating mode 1. Stop control To stop the genset remotely, send the command followed by the password, STOP#1234 When it is stopped, if enabled, the message “genset stopped” will be sent. The stop control is active only if the genset was started manually on site. Block of SMS’ If you want to block the sending of SMS’, then send the command followed by the password SMSOFF#1234 To reactivate them send the message SMSON#1234 It is also possible to partially exclude the block of SMS’ by sending the command SMSOFF13#1234 which disables only the numbers in 1st and 3rd position. To reactivate them, then message SMSON13#1234 must be sent. Numbers list If you want to see the list of numbers stored in the modem, send the command followed by the password LIST#1234 Nome file QPE-C ITA versione 01 10

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You will receive a text message reporting the 4 numbers stored and their related activation status, i.e. ( E= enable, D = disable) IMPORTANT It takes three minutes before the modem becomes operational after the card has been turned on. All the alarms in this period are automatically ignored. If the modem fails to send the SMS, the â&#x20AC;&#x153;sending message failedâ&#x20AC;? will appear. Please check the coverage of GSM signal and the remaining credit. O.Q.MD-QPE-C ordering code

2.7.2 REMOTE DISPLAY.

Introduction The remote display is designed to provide the user with a remote interface of the generating set. Indeed, through this panel, you can see all the parameters and the alarms of the generating set. You can also start and stop the machine. Connections The connections required to operate the synoptic panel are two: the power supply and the connection to receive data. The panel must be powered with 24V dc voltage took from an external power supply (not provided). The connection for receiving data works through shielded twisted pair that connects the display (master device) to terminals 41-42-43 of MC4 card. The maximum allowed distance is 500m.

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Operation When starting the panel, a screen with Elcos logo will appear. Press the button "enter" to access the screen that provides access to the three main sections of the panel: measures section, alarms section and controls section.

In the Measures section, through the up-down commands, you can scroll the pages that contain measures information of the generating set. In details: fuel level, running hours, battery voltage, engine oil pressure, engine temperature, generator frequency, generator linked voltages and phase voltage, phase currents, generated power (active, reactive and apparent), total powered current, ground leakage, power factor.

In the Alarms section, through the up-down commands, you can scroll the pages that allow you to detect the state of the genset, the status of alarms and the activation of a protection. In case of active alarms, whatever the displayed screen panel is, the display will flash with red background. At this stage, you can access the alarms section (see above) and determine what the cause of the alarm was.

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In the Controls section, you can start, stop and reset the alarms of the genset.

O.Q.PR-QPE-C ordering code.

2.7.3 14 RELAY MODULE. It is available on demand an additional module that offers 14 potential free contacts reporting as many alarms and operating states of the generating set. The module communicates by MOD-BUS to the QPE-C panel, and therefore can be mounted both inside the panel or elsewhere up to a 500 meters distance.

The 14 relay module is designed for mounting on DIN rail and it is powered at 24 Vdc. O.Q.14-QPE-C ordering code.

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2.7.4 RADIO CHANNEL. It is available on demand a radio control 433 MHz 2 channels for remotely starting and stopping of the genset. The range of the transmitter varies depending on the interposed obstacles and it goes from a minimum of 100 to a maximum of 200 meters.

The supply includes a two-channel radio control (Start-Stop), a receiver module mounted inside the QPE-C panel and an antenna mounted on the machine. O.Q.RX6-QPE-C ordering code.

2.7.5 SOFTWARE FOR TELEPROCESSING. By installing a specific software provided by Elcos, it is possible to remotely monitor all parameters on one single screen of the pc. It is also possible to start and stop the genset, performing in this way a remote test of the machine.

The connection between PC and QPE-C panel is made by MOD-BUS protocol on an RS485 connection. Since the PC does not have this communication port, you must insert a USB-RS485 converter (not provided). O.Q.TG-QPE-C ordering code.

2.7.5 MOD-BUS PROTOCOL. Available on the MC4 card at terminals 41-42. (41 = A, 42 = B 43 = shield cable) Nome file QPE-C ITA versione 01 10

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Prologue. The MOD-BUS is an industrial communication protocol that allows different devices (slave) to communicate to a concentrator device (master), which in turn allows you to view and drive all the connected devices. The connection is on port RS485, the standard communication format is RTU (binary) and through a twowired cable you can make a remote teleprocessing up to 1 Km. The transmission type is the most widely used standard, i.e. 8,N,1 format or 8bit data, with no parity control and 1 stop bit. By enabling the setup MOD-BUS menu, you can set the ID address of the peripheral device from 1 to 32 (with ID to 0 the RS485 communication port is disabled). The transmission speed can be set to: 4800-9600-14400-19200-38400, and stop bits can be increased from 1 to 2. Message format. To communicate between two devices, the message must be contained in a “wrapper” that is transmitted by a communication port to the other one. The MOD-BUS defines that this "wrapper" includes: • • • •

The address of the device with which the master has determined the transaction The function code to be executed The data to be exchanged The error check composed according to the CRC16 algorithm

The address Each of the slave devices within a mod-bus system must have an address that uniquely identifies it, in our case it can be set from 1 to 32.

The function code The second character of the message identifies the function to be performed in the message sent by the master, which the slave responds with the same code to indicate that the function was executed. Standard functions are: FUNCTION DESCRIPTION 01 Read Coil Status 02 Read Input Status 03 Read Holding Register 04 Read input Register 05 Force single Coil The tables here below set out the list of useable registers.

INPUT Status 02 Register Nr.

DESCRIPTION

TYPE

FIELD

10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 10013 10014 10015 10016 10017

Genset running in Test mode Aux 2 Aux 1 Low H2o level Low fuel High water temperature Low oil pressure Dynamo Master start Presence of water in fuel Start-up in progress Key on automatic Start-up failed Overspeed Emergency on board External start active Stop command

State Alarm Alarm Alarm Alarm Alarm Alarm Alarm State Alarm State State Alarm Alarm Alarm State State

0= off-1= Test on 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= start on 0= off-1= alarm 0= off-1= crank 0= Man.1= Aut. 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= start on 0= off-1= arresto

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10018 10019 10020 10021 10022 10023 10024 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10041

Fuel pump inserted Engine running Glowplugs Maximum frequency alarm Minimum frequency alarm Maximum voltage alarm Minimum voltage alarm Water temperature analog alarm Fuel reserve analog alarm Overload analog alarm Short circuit analog alarm Min. oil pressare analog alarm Max. battery volt analog alarm Min. battery volt analog alarm Min. temperature analog alarm State of commutation on genset State of commutation on mains Signalling cumulative alarm Differential intervention alarm Failure to stop alarm Maintenance request alarm Failure to send sms alarm Can-bus failure Remote emergency

10042 10043 10044 10045

Forced stop alarm Reverse power alarm Weekly test enabled Oil sensor failure

State State State Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm State State Alarm Alarm Alarm Alarm Alarm Alarm Alarm

0= off-1= pump on 0= off-1=genset-on 0= off-1=glowplugs-on 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1=cg-on 0= off-1=cr-on 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm 0= off-1= alarm

Alarm Alarm State Alarm

0= off-1= alarm 0= off-1= alarm 0= off-1=test on 0= off-1= alarm

INPUT Register 04 Register Nr.

DESCRIPTION

FIELD

UNIT

30001 30002 30003 30004 30005 30006 30007 30008 30009 30010 30011 30012 30013 30014 30015 30016 30017 30018 30019 30020 30021

Triangle voltage phase X-Y Triangle voltage phase X-Z Triangle voltage phase Y-Z Triangle voltage phase X-NEUTRAL Triangle voltage phase Y-NEUTRAL Triangle voltage phase Z-NEUTRAL Current phase X Current phase Y Current phase Z Reactive power Apparent power Active power Generator frequency Cosfi – power factor Total produced power (low) Total produced power (high) Analog input terminal 22 Fuel level Engine water temperature Oil pressure Battery voltage

0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-100 0-100 0-65000 0-65000 0-9999 0-100 -20-200 0-100 0-9999

Volt Volt Volt Volt Volt Volt Ampere Ampere Ampere Kvar Kva Kw Hz 100=1 Kwh Kwh %-Bar-C° % C° Tenths of Bar Hundredths of volt

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30022 30023 30024 30025 30026

Total running hours Nr. of performed start-ups Differential current Hours to maintenance Instantaneous consumption (with canbus on) Air pressure (with can-bus on) Engine speed (with can-bus on) Engine water level (with can-bus on) Engine oil level (with can-bus on) Cooler temperature (with can-bus on) Spn alarm can 1 (with can-bus on) Spn alarm can 1 (with can-bus on) Spn alarm can 1 (with can-bus on) Spn alarm can 1 (with can-bus on) Mains voltage phase-phase R-S Mains voltage phase-phase R-T Mains voltage phase-phase T-S

30027 30028 30029 30030 30031 30032 30033 30034 30035 30036 30037 30038

0-40000 0-65000 20-5000 0-40000 0-999

Hours Unit mA Hours L/h

0-9999 0-3000 0-100 0-100 0-999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999 0-9999

mBar Rpm % % C째 Unit Unit Unit Unit Volt Volt Volt

FORCE single coil Register Nr. 50001 50002 50003 50004

FIELD 0-1 0-1 0-1 0-1

DESCRIPTION Start control Stop control Reset control Test control

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2.8 ELECTRIC CONNECTION DIAGRAM

2.8.1 ENGINE CONNECTOR 21 pin female connector to connect the wiring coming from the engine.

2.8.2 ALTERNATOR CONNECTOR. 16 pin male connector to connect the wiring coming from the alternator.

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2.8.3 FUEL TOPPING SYSTEM CONNECTOR 16 pin female connector to connect the wiring coming from the fuel pump and from the related safety sensors.

2.8.4 WIRING DIAGRAM.

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2.9 INSTALLATION 2.9.1 DEGREE OF PROTECTION The panel has a degree of protection (IP) suitable to the environment in which it will be installed: IP 42 when mounted on base version generators or separated from the genset. IP 55 when mounted on soundproofed canopy. 2.9.2 GROUND CONNECTION (PE)

WARNING !!

To ensure system reliability, it is essential that all plant components are connected to ground. PANEL

DAILY FUEL TANK EXTERNAL FUEL TANK

Qpe-c

GENERATING SET

GROUND

OTHER COMPONENTS

2.9.3 POWER CONNECTIONS To facilitate the installation, we provide wiring diagrams and tables for dimensioning of line conductors and auxiliaries. Please note that all equipments and lines should be short-circuit and overload protected according to standards. Also, for security reasons all preventive measures against accidental direct contact must be taken (see CEI 64-8/4). Therefore, on the first section of incoming mains cable, it must be placed an automatic circuit breaker of adequate value (and selectivity), on the using line a differential switch.

EN 60439-1

TABLE A1

AMPERE Ith

NUMBER OF CONDUCTORS

MINIMUM SECTION IN mmq

MAXIMUM SECTION IN mmq

25A 40A 60A 90A 110A 125A 160A 200A 260A 350A 400A 500A 630A 800A 1000A 1250A 1600A 2000A

1 1 1 1 1 1 1 1 1 1 1 2 2 2 3 4 5 6

2,5 6 10 16 25 35 50 70 95 150 185 95 120 240 240 240 240 240

6 10 16 25 35 50 70 95 120 185 240 120 150 300 300 300 300 300

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For more information please call your usual installer or refer to our technical department.

2.9.4 BATTERY CONNECTION

MC4

For transport safety reasons, the machines are delivered with the battery disconnected, the installer will then have the duty to connect it. The genset battery powers the QPE-C panel, if the tightenings of the cables on the starter motor or on the battery are not perfect, they can cause operating malfunctions. Faulty connections masses have frequently created problems to the alarms and measures functioning.

1

2

4 mm

+

It is important to carefully tighten the battery terminals.

BATT.

2.9.5 SUMMARY OF CONTROL PROBES MOUNTED ON THE ENGINE The probes measure the operating engine state. From their efficiency comes the guarantee of the integrity of the engine itself. There are two types: Contact ones for controlling states of alarms, such as low oil pressure, high engine temperature, low fuel level, etc..; Variable resistance ones depending on the measure, to control the measuring instruments such as thermometers, pressure gauges, levels, etc.. With engines controlled via CAN-BUS, the acquisition of alarms and measures come directly from the engine control unit. There are still the sensors, but not directly connected to the QPE-C panel.

PROBE

TYPE

OIL PRESSURE SWITCH WATER THERMOSTAT OIL THERMOSTAT OIL PRESSURE TRANSDUCER TEMPERATURE TRANSDUCER LEVEL TRANSDUCER

BRAND VALUE OHM

NC CONTACT

ZERO OHM

NO CONTACT NO CONTACT VARIABLE RESISTENCE VARIABLE RESISTENCE

VDO VDO VDO VEGLIA VDO VEGLIA

0÷180 HOM

RESISTENCE

ELCOS

0 ÷ 300 HOM

0÷660 HOM

T

NORMALLY OPEN

WATER AIR

Adjustable pre-alarm threshold Adjustable pre-alarm threshold Alarms threshold, prealarm, adjustable pump managment

VARIABLE RESISTENCE PROBES

PRESSURE SWITCH

P

ENGINE

0,5 Bar

0 HOM INFINITE 93°C tipical 0 HOM INFINITE 120°C tipical

CONTACT PROBES THERMOSTAT

ACTIVATION THRESHOLD

TRANSDUCTOR

NORMALLY CLOSED

P = PRESSURE T = TEMPERATURE L = LEVEL

?

ENGINE MASS

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2.9.8 DIELECTRIC STRENGTH TEST The panels must be tested for dielectric strength, they must be prepared taking into consideration that the only point of connection with the electronic logic is determined by the three-phased sensor of the generator, which is connected to a divider made up of 3 resistors 500K ohms for high voltage, for phase and connected to ground. Therefore, these inputs R - S - T - N shall be disconnected and only afterwards disconnect the J17 connector.

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2.10 SERVICE PROCEDURES 2.10.1 FIRST START-UP PROCEDURE Before proceeding with the functional testing: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Turn the setup key to MAN. Check the lighting of the display, if off then the battery may be disconnected. WARNING! Connect the terminals and tighten them properly. Press the start-up button until engine starts. Wait for 20/30” to let the oil flow, or the time needed for a minimum preheating of the engine and then plug the generating set switch in to power the load. Check the rotating direction of engines in use (reverse two phases if contrary to normal). Carry out simulations of alarm on probes to check the efficiency of wirings, if the switch is equipped with open control, it will open at each alarm. After each stop, reset and restart. Control the shutdown manually at the end of testing. If the panel shall operate automatically, then turn the key to AUT. And check the proper operation in the chosen 1,2,3 mode.

2.10.2 PROCEDURE FOR REPLACING THE BATTERY • •

Turn the setup key to zero; Replace the battery and check the program operation.

WARNING! All operations to connections while the genset is running and the cables are loose must be absolutely avoided, because the battery charger generators in case of battery disconnection while the genset is running deliver a voltage between 40 and 80 volts (destructive to electronics). 2.10.3 PROCEDURE FOR REPLACING MC4 CARD The MC4 card is programmed differently depending on the type of application and the machine on which is mounted. If the card was required and the serial number of the machine was previously specified, then it is will be delivered already programmed properly. If not, you must require the setup file that can be uploaded using a standard USB key. (See setup menu, USB section.) If you have the card, proceed as follows:      

Turn the key to 0 position. Disconnect all connectors from the card. Replace the MC4 card. Copy the SW1 setup placed on the replaced MC4. Reconnect all connectors back in the right order. Run an operating test. WARNING! It is absolutely forbidden to make any intervention to parts under voltage.

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3.0 MAINTENANCE MANUAL 3.1 ROUTINE MAINTENANCE The panel is designed to operate without needed maintenance, however, the following parts should be checked: TIME Every 30 to 60 days Every30 days Every 30 days Every 30 days Every 6 months

CHECKS TO BE MADE Battery electrolyte level Water, oil, fuel level Engine pre-heater temperature (if present) Automatic genset test Battery efficiency

 3.2 ELECTRICAL AND MECHANICAL MAINTENANCE. To do maintenance to the GENERATOR and the ENGINE, please refer to the respective manual, the following indications cover the electrical control parts and genset control. WARNING! The panel is supplied by the mains and the genset. Before accessing for maintenance disconnect the mains and shut down the genset by turning the key to ZERO

3.3 TEST AND ALARMS SIMULATION Operation tests of the various automatic functions. The undervoltage protections, minimum frequency, low oil pressure and dynamo are active when the genset is running and after the set intervention of the generator delay which enables the given load. Therefore, all simulations must be made after that time. 3.3 ENGINE PROTECTIONS On the engine, disconnect the wire from the respective sensing probe and connect it to about 3" to ground. The acoustic alarm will go off, then the genset will stop and this alarm will be reported. 3.4 GENERATOR PROTECTION Manually adjust the throttle lever or actuator, which causes a variation in speed in + or -, there is consequently a change in frequency Hz on the display. Act until the security threshold intervenes with activation of alarm and then stop. Minimum and maximum voltage. Manually adjust the VOLT on trimmer, placed on the electronic voltage regulator inside the generator. Operate first in one direction (+ or -) and then in the other one varying the output voltage until the protections get activated. After that, restore the voltage to the nominal value (test to be carried out rigorously with no load). 3.5 51 OVERLOAD PROTECTION Assuming that the load is not enough to exceed the maximum powered current, you should change the calibration of the overload to the load available current lower value. (see thresholds menu, parameters 3 and 4). When the genset is working in automatic mode, close the switch and insert the load. When passing the set current, after a delay, we will have the opening of the genset switch with its flashing led, the alarm and after cooling phase, the engine will shutdown.

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3.6 TROUBLESHOOTING All the panels are marked with a serial number indicated on the panel name plate. In some applications, the number to be considered is the genset serial number. The serial number are associated with all technical data and construction data of the panel, so you must refer to it for all requests for service or spare parts. However, it is important to detect and provide the following information:

• •

It starts and then stops

• •

TROUBLESHOOTING

It does not stop

Failure to start alarm

• •

The generator does not supply

Short and quick start-ups

• •

It gives immediately alarms

It attempts to start

• • •

Display off

It does not start

1. battery voltage (12 or 24V); 2. mains voltage (230 or 400V); 3. genset power (KVA); 4. frequency (50-60 Hz); 5. reports on MC4 module when detecting a failure.

PROBABLE CAUSE

REMEDY

Battery flat Battery flat Battery polarity reversed Battery connections slow or oxidized Battery fuse cut off The pinon gears does not get in the crown wheel

Connection to the oil pressare switch is missing

When starting up, there is overspeed When it gives immediate alarm for low fuel Immediate alarm for over voltage Low oil pressure High engine temperature Faulty switch The generator does not supply voltage

• • • • •

• • •

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Faulty shutdown system •

Lack of fuel or air in pipino

The supply system sucks air in

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Data Rev. 10/01/2010

LINGUA ITA

Battery charger fuse Charge the battery Check and reverse the wires Clean, tighten and lubricate the battery terminals Replace the fuse Replace the pinon or the whole starter Connect and check the ground connection of the pressure switch. Calibrate the electronic speed regulator. Fill up with fuel or disconnect the level Replace the voltage regulator. Replace the pressare switch. Replace the thermostat. Replace the switch Ask for assistance Clean from residuals, lubricate or replace Fill up the tank or purge the system "see engine manual" Check tightness of the pipes or the possible activation of tear valve

PAGINA Pagina 72 di 72

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