automatic control panel mase at 92b i
Contents
1. LMO YANMAR2. 20 Parameters adjustable by the user option 21 essre A EE 21 erie Tee S 22 mase GENERATORS AT 92B FORE WORD AT92B and sets enable the control and the total running of a generating set with extremely easiness Certain functions which will be named as follows 1 OPTION parameters which can be adjusted by the user 2 SET UP parameters which can be adjusted by the installer enable modifications in the equipment functioning compared to standard version supply OPTION parameters can be modified by the user himself while SET UP parameters must be modified by skilled personnel who are provided with all necessary information and knowledge in this field We always suggest however that for further details and questions you consult skilled personnel NOTICE These sets have been manufactured to avoid radiofrequency which could jam domestic or industrial equipment SUGGESTIONS FOR THE INSTALLER Customers must receive this set supplied with the present service manual which also includes warranty conditions All operations concerning the instal lation of control panel should be carried out by skilled personnel in conformity with be performed when the control panel live take the necessary precautions Electric connection must be carried outin compliance with the present CEI regulations Particularly supply cables mu
3. 08 11 12 14 47 RED BLACK GREEN GREY BROWN WHITE 0 5 BLUE 1 5 BLUE 1 56 YELLOW PINK POSITIVE BATTERY NEGATIVE BATTERY ENGINE TEMPERATURE LOW OIL PRESSURE BATTERY CHARGER REGULATOR BATTERY CHARGER REGULATOR NEUTRAL GENERATOR 220V PHASE GENERATOR 220V START STOP DE EXCITATION BRIGGS amp STRATTON SUZUKI Ajddns 5 SJOSNOL dOLS LYVLS JOJOBUUOd JESUS LMO Ajddns surew SJOSNOL dOLS LYVWLS Aelixny JOJOBUUOD JESUay lt SILENT 5000B Robin Ajddns surew SJOSNOL dOLS LYVLS Aelixny JOJOBUUOd Ue
4. Function state alarm visualization by means of 15 led Diaphragm button strip with 7 mechanical effect buttons Voltage measure at Real Effective Value RMS All setups accessible from the frontal side without dip switch by software in permanent memory Setups protected by admittance key Intelligent modulation of tension and current control battery charger CONSTRUCTION FEATURES AT92B control panel leakage protection IP44 CARD DESCRIPTION AT92B LEGEND The following devices are placed on the frontal side of the card Led allarms alarms ON Led engine ON generator ON Led sf failure generator starting failure Led failures fault alarm signal 5 Led battery battery charger condition 6 TLG led generator remote control switch 7 TLR led main remote control switch 8 Led VOLT HERTZ V BATT HOUR METER selected measure signal 9 Measure buttons to select display visualization 1 2 3 4 10 Test button to select operating procedures 11 Aut button to select operating procedures 12 Man button to select operating procedures 13 Reset button to select operating procedures 14 3 figure display measures alarms etc visualizations 15 Led RESET MAN AUT TEST selected operating procedure signal START STOP buttons Start Stop of the generating set 16 mase GENERATORS AT 92B 1 Led allarms ON allarms When on
5. contact opens E04 GENERATOR VOLTAGE LACK It occurs when with engine running the generator voltage does not exceed the fixed threshold within a fixed time ERRORS ALARMS SUMMARY ERR DESCRIPTION A01 Temperature alarm 02 Oil pressure alarm A03 500 RPM failure alarm 04 Oil sensor alarm A05 Request for maintenance 06 Runaway speed alarm E01 Emergency stop E03 Remote stopping on E04 Generator voltage lack mase GENERATORS AT 92B MESSAGESTABLE Code Option Range Default 1 Mains voltage minimum STA START cycle of the threshold 160 230 VAC 190 VAC 9 9 2 Mains voltage maximum During the stopping of the generating threshold 253 345 VAC 253 VAC STO STOP hae set after the cooling time OP 3 Mains off delay 0 120 sec 5 sec AUTOMATIC TEST OP 4 Mains on delay 0 240 sec 10 sec E ST REMOTE STARTING 5 Generator voltage is acti minimum threshold 160 230 190 VAC EJP FUNCTION When the EJP start entry is active and the system is in automatic mode OP 6 Generator voltage maximum threshold 253 345 VAC 253 VAC scr When the SCR start entry is active OP 7 Generator off delay 1 180 sec 5 sec and the system is in automatic mode OP 8 Generator on delay 1 180 sec 20 sec OP 9 Cooling time 1 300 sec 30 sec PARAMETERS WHICH CAN BE ADJUSTED BY THE Gatien 2 arm ringin me sec
6. seconds the manual button to switch from the network contactor to the unit contactor and viceversa 13 Reset button to select operating procedures Press to immediately stop the generator or to reset any alarms 14 3 figure display measures alarms etc visualizat Communication display in addition to the display of the following measurements genset and mains Volt Hz battery Volt Hour counter alarm messages appear 15 Leds RESET MAN AUT TEST selected operating procedure signal They switch on to indicate the selected operating procedure 16 START STOP buttons Start Stop ofthe generating set Press to START button the generating set is on press to STOP button is stop only in manual operation By pushing it in the automatic mode motor will be stopped immediately and the display will show the following message E01 thus indicating that there is an emergency stop Warning If the STOP button is pressed in manual mode the motor cuts out after the cooling period 17 WIRING DIAGRAM AT92B 0000 00000000 0900000000 00 D 000 121109876543 21 LEGEND 1 Battery positive 2 Battery negative 3 Temperature 4 Oil 5 Remote stop exchange mains and GE function EJP SCR 6 Remote starting Start EJP SCR 7 Regulator yellow battery loading alternator type 8 Regul
7. GENERATORS AAU gt A AUTOMATIC CONTROL PANEL MASE AT 92B LIBRETTO USO E MANUTENZIONE GB USAGE AND MAINTENANCE MANUAL F MANUEL D INSTRUCTIONS ET D ENTRETIEN D HANDBUCH R BENUTZUNG UND WARTUNG E MANUAL DE USO Y MANTENIMIENTO REV 5 04 05 07 0 41235 mase GENERATORS 92B CONTENTS ee 15 Suggestions for the installer 15 ECTS ee See eR ee eee 15 Features of the electronic control 16 Mains iiss tse Prcadacniaotanacencoesissnsnsnsnsaczeaesasesiosooss 16 Construction features 16 Wiring diagram 17 Technical term definition 17 8 rererere 18 Operating procedures 19 19 19 19 19 Automatic leS lassen e 19 Connecting disconnecting 19 Remote 5 19 Remote Stop 20 EJP TONCUON 20 Working hours calculation 20 Periodic maintenance 20 Alarms and description codes
8. MEASURE DISPLAY The following measures can be selected on the dis play mains generator voltage Volt frequency of generator signal Hertz battery voltage V Batt generator working hours Hour Meter The displayed measure is also signalled by the light up of its respective LED TENS FREQ BATT HOUR To select another measure on the display press the measure button When you select voltage measure and the generator is OFF the display will show mains mase GENERATORS AT 92B voltage starting LED OFF but if the generator is ON the display will show generator voltage starting LED ON The displayed value of mains and generator voltage is precise at 1 volt the frequency at 0 1 Hz the battery voltage at 0 1 volt and working hour at one hour even if the instrument measure is calculated in minutes OPERATING PROCEDURES The card operates 4 different procedures which are RESET MANUAL AUTOMATIC TEST Each of these procedures is connected with a button and a signalling LED To select a procedure push the respective button It is also possible to change proce dure at any time Here follows a detailed description of each RESET When the card is in RESET the generator stops if it was working and it will not be possible to carry out any operations Selecting RESET procedure you will set to zero all displayed alarms on condition that the alarms are not still effective see alarms and failur
9. ator yellow battery loading alternator type 9 Alternator D 10 Free 11 Neutral generator 12 Phase generator 13 Battery positive 14 Starting 15 Battery positive 16 Stop excitation it is possible through a 17 set up to change the operation of this outlet for an electro magnet an accelerator and a spark plug pre heating 17 Stop de energizing it is possible through a 28 set up to change the operation of this outlet for a solenoid valve and air starter control or gasoline fed motors 18 Horn 19 Alternator D 20 Battery positive 21 Neutral mains 22 Phase mains 29 30 TLR coil NC contact 31 32 TLG coil NO contact 33 34 Generic alarm 35 Fuel optional 36 Free alarm 37 Free alarm 38 Free 39 Free 40 Free J9 N RST Load outlet J8 N RST Generating set inlet J7 N RST Network Inlet Warning It is of utmost importance lo install a fuse onto terminal 1 and a magnetothermal switch and or differential onto inlets J8 and J7 Only with optional cards installed mase GENERATORS AT 92B TECHNICAL TERM DEFINITION Reading this manual you will meet with terms largely described below Refer to the following definitions whenever these terms are mentioned in the manual SET UP It is the stage of arrangement of the card which can be made before or during the installation of the card itself All operating times and calculations which affect the system f
10. during setup when the genera tor voltage exceeds the starting threshold As an emergency signal working in parallel to one or the other signal a threshold has been fixed on the generator frequency The engine ON signal is shown by its LED ALARMS ON Oil pressure and high temperature alarms are con nected after a certain delay compared to the engine ON signal To stress that the alarm ON LED lights up During the stopping cycle the alarms are disconnected and simultaneously the fuel solenoid valve closes too ALARM OPERATING TIME When one or more alarm signals occur they immedi ately cause the generator remote control switch cutoff and accordingly the generator stopping and ringing alarm Becomes lower than the minimum fixed threshold and remains in that state for a while That cause the mains remote control switch cutoff in any case MAINS ON In the same way the mains ON signal occurs when for a certain time voltage exceeds the fixed threshold The remote control switch make will depend on the selected operating procedure GENERATOR ON Generator ON signal works as the mains ON signal described above The delay interval is independent On the contrary the generator is OFF when voltage becomes lower than the fixed threshold MAINS GENERATOR AND GENERATOR MAINS SWITCHING Between mains and generator remote control switches besides the mechanical interlock a delay time occurs to avoid their overlap
11. e function or STOP if you want to disconnect it Pushing RESET you restore the normal operating procedure while working on this function in fact the control panel maintains the previously selected proce dure Measure display goes back to voltage value TEST REMOTE STARTING When the card is in automatic procedure the genera tor can be started be means of the remote starting connecting terminal As in automatic test the execution of the starting cycle is preceded by 5 seconds siren signal and 3 seconds interval When the mains is back however the exchange does not take place till the engine has stopped connecting terminal cutoff failure emergency stop mase GENERATORS AT 92B REMOTE STOP The remote stop connecting terminal stops the genera tor at once in any operating procedures and forbids its starting The display will show the relative code E03 The connecting terminal cutoff will restore the control panel functioning automatically EJP FUNCTION EJP function can be arranged during set up When this function is ON the remote starting connecting terminal conform to EJP START and the stopping connecting terminal to EJP switching consent When the starting connecting terminal is ON a time delay occurs at the end of which the starting cycle is carried out Then when the switching consent signal arrives the exchange between mains and generator takes place Atthe switching consent cutoff the
12. e messages Also external controls are forbidden external start EJP function The battery charger however is still working and you can select and see any measures on the display MANUAL In MANUAL procedure the generator can be started or stopped by the respective START and STOP buttons The START button is only used for beginning the starting cycle which in any case will be carried out automatically by the card following the automatic starting procedure STOP button in the same way begins the stopping cycle which will follow the automatic proce dure cooling solenoid valve magnet The remote starting signal is forbidden Alarrns work as usual see ALARMS In manual procedure however the automatic ex change between the remote control switches does not take place the remote control switches work one by one If you select manual procedure whenmains re mote control switch is connected it will be energized or de energized with reference to the mains voltage but the generator remote control switch will never be energized the same remarks are valid if you select manual procedure when TLG is ON AUTOMATIC In AUTOMATIC procedure the generator starts when the mains voltage drops and its respective remote 19 control switch is off When the generator is running and its voltage reaches the fixed limits the generator remote control switch makes The generator goes on working till the mains is back After the mains
13. he generator stops at once A02 OIL PRESSURE ALARM It operates like the one mentioned above butit refers to the sensor for insufficient oil pressure A03 500 RPM FAILURE ALARM This alarm appears when during the generator running and with generator voltage on the alternator signal 500 rpm is missing The generator stops A04 GENERIC ALARM This alarm is connected when the engine running signal depends only on the generator voltage It occurs when with engine on and without the intervention of stopping devices the generator voltage is missing Also in this case the emergency stopping cycle takes place A05 REQUEST FOR MAINTENANCE This alarm occurs when the periodic maintenance interval set up during the first setting or the last maintenance has passed The control panel however goes on working normally A06 RUNAWAY SPEED ALARM This alarm occurs when frequency therefore the en gine revolution exceeds the value fixed by SETUP In this case the generator remote control switch opens and the generator stops immediately EO1 EMERGENCY STOP This message is displayed when the generator is stopped by the operator by pushing the STOP button in automatic or test procedures E03 REMOTE STOPPING ON It is displayed when the remote stopping connecting terminal is on It stops the generator at once and forbids the generator starting Unlike the other alarms itresets automatically without pushing RESET when the connecting terminal
14. is back the remote control switches exchange and the generator carries out the stopping cycle When the generator is running it can be stopped by means of the stop button or the external stop signal In automatic procedure both the external start con necting terminal and the automatic test are on too see further TEST In TEST procedure the generator stars and the engine runs as long as you use this procedure but the generator is loaded only when the mains drops In that case the new exchange between remote control switches takes place only when changing from it is possible to stop the generator at once by pushing the stop button AUTOMATIC TEST AUTOMATIC TEST is a periodic check which is car ried out by the control panel at fixed intervals intervals can be fixed during set up if the control panel is in automatic procedure and this very function had been previously set After starting the generotor runs for a fixed period at the end of which it stops Before starting the warning horn rings signalling the beginning of this procedure AUTOMATIC CONNECTION DISCONNECTION To connect or disconnect the automatic test function push MEASURE button and while keeping it pressed also push TEST button The display will show the following messages OFF if the test is disconnected the test is connected g stands for the number of interval days programmed during set Up At this stage push START if you want to connect th
15. itindicates that the generator is being chacked and that all of the alarm signals are active 2 Led engine ON generator on When on it indicates that the generator has started 3 Led st failure generator starting condition When on it indicates that desplite attempts to start the generator the generator has not started 4 Led failures fault alarm signal When on it indicates generator stop for anomaly read the alarm indentification message on the display 5 Led battery battery charger condition When on it indicates that the battery is ok 6 TLG led generator remote control switch When on it indicates that the panel has given closure consent to the group contactor 7 TLR led mains remote control switch When on it indicates that the panel has given closure consent to the mains contactor 8 Leds VOLT HERTZ HOUR METER selected measure signal They switch on to indicate the selected measure 9 Measure button to select display visualization Press to select the measurement 10 Test button to select operating procedures Press to perform the test 11 Aut button to select operating procedures Press for automatic functioning 12 Man button to select operating procedures Press for manual operation Warning if stop is pressed in manual the stoppage is notimmediate the cooling time must elapse before the stop press RESET to stop immediately Notice Ifin manual mode push for some
16. load returns on the mains and the generator carries out the stopping cycle at the starting connecting terminal cutoff EJP function is connected only in automatic proce dure Protections and alarms are on too WORKING HOUR CALCULATION After the engine starting the working minutes are counted The calculation expressed in hours can be shown on the display The calculation continues even in case of disconzero by the user Switching off the connecting terminal the stopping cycle is carried out While work ing the generator by this function ifthe mains drops the load moves to the generator PERIODIC MAINTENANCE INTERVAL By means of SET UP a periodic maintenance interval expressed in hours is set When the working minutes reach the fixed amount the display shows the code of maintenance request The control panel however goes on working normally Pushing RESET you set to zero the calculation and the message disappears ALARM AND DESCRIPTION CODES The display can show certain codes to signal emer gency or specific situations The message disappears only when those emergency conditions have disap peared too and the user has pressed RESET button Here follows the scheduled codes A01 TEMPERATURE ALARM This message appears when with the engine running and alarms on there is an intervention of the sensor 20 connected to the temperature connecting terminal In this case the generator remote control switch opens and t
17. se of the control panel or in any case a use thatis notin compliance with the manufacturer s instructions changes ofthe unit carried out without our previous approval D damages during transports E damages related to atmospheric discharges In the above mentioned cases assistance replace ment of parts and transport are to be changed to customers ALWAYS SPECIFY THE SERIAL NUMBER WHEN ENQUIRING ABOUT YOUR CONTROL PANEL OR ASKING FOR WAR RANTY SERVICE B mase GENERATORS AT 92B TECHNICAL FEATURES OF THE ELECTRONIC CONTROL BOARD Supply voltage 12Vcc or 24Vc Operating field 9V 15V 18 30V Stand by input 100 mA 100 mA Battery charger voltage 13 8 Vcc 27 6 Charging current 500 mA Mains voltage control 0 220V 10 380V on request Generator voltage control 0 220V 10 380V on request Max usable voltage 400V Insulating voltage 4 KVAC 1mm Max usable current AT92B 16A per 380 N 30A per 220V single ph Max voltage on connections 15Vdc V Battery 30Vdc V Battery 24V Max current 10mA START STOP ev STOP magn siren contact capacity 125Vac 30Vdc Outlet contact capacity for remote control switch coils 5A 250Vac 380V max MAIN FEATURES Controlbasedon 11 MhzIntel80c552 microprocessors 32Kbyte EPROM memory program 32Kbyte static RAM data memory 256 word EPROM inviolate data memory Measure visualization by means of 3 figure LED display
18. sec USER OPTION To reach the parameters which can be adjusted by the rill a test time aan user position in RESET then push RESET and 29 23 contemporary push MEASURE for 5 seconds OP 12 Automatic test duration 1 30 min 10 min The display will show the code ofthe first value to be set 1 At this stage using MEASURE button you OP 13 Engine start delay after EJP start 0 99 min 25 min can select the parameter that you want to modify By pushing START or STOP button you will see the OP 14 Commutation delay established value of the parameter on the display for 3 for EJP T 1wire 0 30 min 5 min seconds During that interval if you push again the START button you can increase the variable up to its max granted limit while by pushing the STOP button TROUBLESHOOTING you can decrease it up to its min limit If you do not push any button and let the 3 seconds pass you go back to option selection OP X By pushing RESET you can leave this procedure If you do not push any buttons for 30 seconds the control panel leaves this procedure automatically Here follows a table of the adjustable options with the minimum and maximum allowed values for each NOTICE Options number 13 and 14 are displayed only if EJP function has been activated during setup The values quoted under default are set during the card setup 21 1 Three dotted lines appear on the display screen both when the machine is
19. st be size and placed so that the cable does not attain to temperatures which are 50 over room temperature Itis necessary to check thatno cables have loosened at the respective terminals and to remove any dust or other materials which have fouled the control panel during installation The cleaning must be done by means of an exhausted avoiding in any case blowing dust off the control panel with air Connections to the terminal board must be done using acable of correct section respecting carefully the electric diagram Never fix the control panel near heating sources or places where incidental electric leakages could cause an explosion This control panel standard version has a IP44 structure for other uses ask for structures with adequate features To open the control panel front door use the proper tool supplied with the panel which should be placed so that only skilled personnel could reach it 15 Toprotectfrom electric shocks and any atmospheric discharges itis necessary to make a good grounding of all parts which can cause an earth return The connection must be done using the yellow green cable sized in compliance with CEI 164 8 ART 9 6 01 WARRANTY The control panel is fully guaranteed for one year after the date of purchase The warranty is not valid if the fault is due to A faults in the installation and or a use of the control panel not in compliance with the present technical and safety regulations improper u
20. switched on and during start up battery voltage is too low check that power cables are tightened in their clamps replace battery or recharge it 2 During start up the card is reset and switches off and then switches on again all leds battery voltage is too low check that power cables are tightened in their clamps replace battery or recharge it 3 Unit s remote switch does not switch on in automatic mode TLG LED is ON check fuse in versions with fuse use appropriate instrumentto check that reelis correct ifthe TLG led is off check that minimum and maximum voltage values codes P O5 P 06 have been set correctly on the basis of the value read on the unit voltage display Use the option function to adjust mase GENERATORS AT 92B 4 Network s remote switch does not switch on in automatic mode TLR LED is ON check fuse in versions with fuse use appropriate instrument check that reel is correct if the TLR led is off check that minimum and maximum voltage values codes P 01 P 02 have been set correctly on the basis of the value read on the unit voltage display Use the option function to adjust N B For versions with separate DRV minimum and maximum voltage relay check that the adjustments are correct in relation to the actual network voltage value When this Led s green light is on the calibration is correct 5 Voltage and frequencies recordings on the display are
21. unctioning can be set up and the parameters are stored on a permanent memory This function can be reached by skilled personnel only and is protected by admittance key OPTION Same procedure as in SET UP but referred to param eters which can be adjusted also by the final user of the card There is no admittance key STARTING CYCLE Generator starting procedure carried out through the following operations first the fuel solenoid valve is activated Then the control panel carries out some starting at tempts of adjustable duration of the generator alter nating with intervals of adjustable duration too Once the engine is ON the starting attempts stop immediately If the engine fails to start after the fixed number of attempts an acoustic alarm signal rings for 20 seconds lighting up the starting failure LED To restore press RESET button STOPPING CYCLE Generator stopping procedure The remote control switch opens and the engine continues to work for a certain time cooling at the end of which the fuel solenoid valve drops out and the stop magnet relay trips The magnet remains energized till the generator ON signal stops and for a further time interval previ ously fixed In case of emergency stop the above mentioned procedure takes place without considering the cooling time ENGINE ON The engine is ON when the 500 rpm signal which comes out of the alternator exceeds the fixed thresh old or if previously set
22. unstable card probably set at incorrect frequency Set up 01 has been incorrectly set in relation to frequency used Change setting by using set up only for specialised personnel following set up procedure 6 During start up the card reports that the motor is running even if the motor has not started up double motor running signal reaches the card for motors without battery charging alternator D and with monitoring by clamps 7 and 8 remove wire 9 from terminal block J5 of the card set motor running threshold according to type of measurement selected start set up and check setting of parameters set up 05 06 07 only for specialised personnel following procedure 7 Excessive motor speed alarm A06 message appears although the motor is running correctly the problem is caused by a very rapid signal peak on voltage wave of alternator voltage during start up contact alternator supplier in case you need filters override safety device by means of function 34 of set up only for specialised personnel following procedure 16 YELLOW POSITIVE BATTERY NEGATIVE BATTERY NEUTRAL GENERATOR 220V PHASE GENERATOR 220V START STOP EXCITATION POSITIVE BATTERY NEGATIVE BATTERY ENGINE TEMPERATURE LOW OIL PRESSURE BATTERY CHARGER REGULATOR BATTERY CHARGER REGULATOR NEUTRAL GENERATOR 220V PHASE GENERATOR 220V START STOP DE EXCITATION AUTOMATIC AIR STARTER 22
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