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OPERATING INSTRUCTIONS AC3

MRM PRPRPRPROOOOCCCCOOOOMMMM®®®® Pvt Ltd

ISO-9001-2008 certified organization Plot No. : 20-21, Industrial Estate,

Sector - 59, Phase-II, Faridabad (Haryana)

Ph.: 0129-4700400(10 Lines)

Email: [email protected]

Web: www.mrmprocom.com

AC3 Automatic Controller: 3 Phase

Cat_AC3-12-09-Ver1.0. /17

Index

1.0 Introduction

2.0 Protection, Supervision Salient features

3.0 Measurement & Display

4.0 Annunciations

5.0 Contacts

6.0 Timers

7.0 Switches Description

8.0 Setting Procedure

9.0 Annunciations Description

10.0 Lamp Test

11.0 Operating Mode

11.1 Auto Mode

11.2 Manual Mode

11.3 Off Mode

11.4 Test Mode

11.5 Semi Auto Mode

12.0 Programming mode

12.1 Parameter Mode

12.2 Programming Solenoid Mode

13.0 Faults

13.1 Internal Faults

13.2 External Faults

13.3 Fault Reset

14.0 Communication

15.0 Load Management

16.0 Model Selection

17.0 Terminal description

18.0 Specifications


Cat_AC3-12-09-Ver1.0. /17

1.0 Introduction

• 16 Bit RISC, state of art,

microcontroller based System.

True RMS measurement of all

measured parameters with 1% accuracy

of measured value (Not full scale)

• Backlit LCD Display for easy reading

and parameter settings. No need to

consult the manual while programming

the unit. • All the inputs, such as Mains, Generator

and Battery voltages are fully isolated,

providing the freedom to design a

totally isolated system. This avoids and

prevents malfunctioning/ burning of the

unit.

• Fully operational up to 4V. Can

withstand a voltage dip up to 0V for

1sec.

• 23 window annunciation

• All system parameters are user

programmable

• Suitable for all types of engines

including the one requiring choke.

• Easy selection of modes by a simple

press of a switch

• All outputs are through potential free

contacts for system stability and

reliability

• All contacts are protected by Snubber to

strengthen the EMI/EMC capabilities of

the unit.

• Housed in 92X192mm Din Standard

housing.

2.0 Protection, Supervision Salient features

• Mains 3 phase monitoring for

under/over voltage, under/over

frequency, Overload Phase Sequence

and Phase voltages unbalance.

• Generators 3 phase monitoring and

protection for under/over voltage,

under/over frequency, over load, and

over speeding.

• DC Battery Voltage supervision (Under

& Over voltage)

• 8 digital input for system protection

• DG Fail to Start supervision

• Fuel, HWT and LLOP measurements

and value display.

• DG fail to Stop supervision

• User programmable engine warm up

time, before the load is switched to

generator.

• Mains Restoration supervision

• User programmable Cranking attempt.

• User programmable Crank Time and

delay between two successive cranks

• External signal for remote operation

• Service Due reminder

• History of Faults

• Mains/generator no. Of phases selection

• Installed sensor selections.

• Choke function

• Load management optional

• Measurement of KW,PF and KWhr for

Generator

• Real Time Clock (RTC)

3.0 Measurement & Display 16 segment 2 line LCD displays the following parameters. Some of the parameters are model

dependent and are available in only those models.

• Mains 3 Phase voltage (LL & LN)

• Mains Frequency

• Generator 3 Phase Voltage(LL & LN)

• Load 3 Phase current

• Generator Frequency

• Battery Voltage

• Generator Run Hour

• RPM

• Fuel Level, HWT and LLOP

• KWh of generator

• KW and PF of generator

• Up to BTS Voltage (Optional)

• One Room temperature (Optional)

• Service Hour Due


Cat_AC3-12-09-Ver1.0. /17

• Fault History • Programmable settings

Normally the display auto scrolls and displays a set of parameter for 10 seconds, but any time the

Next key (�) can be pressed to select the next parameter window.

4.0 Annunciations Window

AC3 is equipped with the following annunciations for system status and faults

• Load on generator (GON)

• Load on Mains (MON)

• Mains : Healthy/Unhealthy

• Generator On

• DG Fail to Start (fault)

• DG Fail to Stop (fault)

• Emergency (Shut down Command)

• LLOP (Fault)

• HWT(Fault)

• Fuel (Fault)

• DG frequency(Fault)

• DG Voltage (Fault)

• DG Over Speed (Fault)

• Charging Alternator/V-Belt (Fault)

• Over Current (Fault)

• Battery (Warning)

• RWL (Fault)

• Service Due(Warning)

• Phase Sequence (Fault)

• Auto (Annunciation)

• Manual (Annunciation)

• Test (Annunciation)

• Off (Annunciation)

5.0 Contacts The following potential contacts are provided. Annunciation contacts are available in models

requested with Annunciation features.

• Mains Contactor: MCB (NC)

• Generator Contactor: GCB (N0)

• Crank (NO)

• Fuel Solenoid (NO)

• Heater (NO)

• Fuel Pump(NO)

• Hooter (NO)

• Load Management (NO).

6.0 Timers AC3 is equipped with the following timers:

• Mains voltage supervision timer

(variable)

• Mains frequency supervision

timer(variable)

• Mains voltage unbalance supervision

timer (variable)

• Mains phase Sequence timer(Variable)

• Generator start delay(Variable)

• Generator voltage supervision timer

(variable)

• Generator Frequency Unhealthy

supervision timer (variable)

• Generator over speed supervision timer

(Variable)

• Choke pre start timer (Variable)

• Choke post start timer (Variable)

• Max. crank duration timer (variable)

• Crank gap timer (variable)

• No. of crank attempts (variable)

• DG warm up timer(variable)

• Mains restoration timer (variable)

• DG re-cooling timer (variable)

• Stop Solenoid on time (variable)

• Fuel level supervision time (variable)

• LLOP supervision time (variable)

• HWT supervision time (variable)

• BTS Voltage Supervision

Time(Variable)

• Room Temperature Supervision

Time(Variable)

• Auxiliary Supply Under/Over voltage

supervision & warning timer (Fixed)

• Charging Alternators / V-Belt

supervision timer(variable)

• Over Current supervision

Timer(variable)

• Delay between GCB to MCB switching

(Variable)


Cat_AC3-12-09-Ver1.0. /17

• Generator max. On Time(variable)

• Generator Rest Time(Variable)

• Hooter Reset Time(variable)

7.0 Switches Description AC3 has 12 switches provided on its front panel. The table below describes the operation of these.

S.No. Switch Symbol Switch Function Description

1 � Next Normal operation mode: In this mode, it is

used to change the parameters being displayed

on LCD.

Programming Mode: Next key is used to

select the next parameter to be programmed.

2 � Increment This key is only active during Programming

Mode and is used to increment the value of the

parameters under programming.

3 - Decrement This key is only active during programming

mode and is used to decrement the value of the

parameter under programming.

4 R Reset Reset key resets the Hooter and Fault signals.

The first press shall reset the hooter and next

shall reset the faults. A long press of 1 Sec shall

reset both.

5 � & - Programming

/History Fault

Mode Entry

If both the keys are pressed simultaneously the

unit will enter in Programming Mode/History

Fault/Service Hours

6 START To start Generator in Manual Mode.

7 STOP To stop Generator in Manual Mode.

8 MCB In Manual Mode this toggles the mains

contactor, On/Off

9 GCB In Manual Mode this toggles the generator

contactor, On/Off

10 Auto To select Auto Mode.

11 Man. To select Manual Mode.

12 Test To select Test Mode.

13 Off To select Off Mode.

Auto, Man., Test & Off are Radio buttons and only one can be active at a time.

8.0 Setting Procedure AC3 has provision to program the operating parameters, Potential Free Annunciation mode,

resetting the service hours and viewing the last 20 fault history.

Press�& - switches simultaneously. The LCD shall display, “Enter Para Mode”

To enter parameter setting mode press�.

To go to next menu press�. The LCD shall display “Annunciation Mode”.

This menu can be entered by pressing�.

To go to next menu press�. The LCD shall display “Display History”.

This menu can be entered by pressing�.

Or pressing � again shall bring up “Reset Service Hours” on LCD.

To go to next menu press�. The LCD shall display “RTC Mode”.

To reset service hours press �. The unit shall ask for confirmation. Pressing�, shall reset the

service hours. Pressing - shall terminate the menu.


Cat_AC3-12-09-Ver1.0. /17

In RTC Mode the RTC Time and Date can be easily entered.

9.0 Annunciations Description AC3 has 23 annunciations on its front panel. These either announce the faults or indicated the status

of the system.

S.

No.

Nomenclature Description

1 Fail Start This LED blinks when the engine Fails to Start.

2 Fail stop This LED blinks when the engine Fails to Stop.

3 Emergency This LED blinks when the engine is Stopped in emergency.

4 LLOP This LED blinks when the engine is stopped on LLOP fault.

5 HWT This LED blinks when the engine is stopped on HWT fault.

6 Fuel This LED blinks when the engine is stopped on Low Fuel fault.

7 Service Due This LED blinks when to remind that engine service is Due

8 DG Freq This LED blinks when the engine is stopped on frequency fault.

9 DG Vol This LED blinks when the engine is stopped on voltage fault.

10 Over Speed This LED blinks when the engine is stopped on over speed fault.

11 ChgAlt/V-Belt The LED is continuously on when the charging alternator supply is

available to the unit.

This LED blinks when the engine is stopped on Charging Alternator

/V-Belt fault.

12 Battery This LED blinks when the Auxiliary supply is outside the limits.

Warning only.

13 Over load This LED blinks when the engine is stopped on over current fault.

14 RWL This LED blinks on Low water Radiator level..

15 Ph Seq This LED lights up when the Phase Sequence is wrong(Negative).

16 Mains Steady while Main is healthy else starts blinking.

17 MCB Steady when MCB is engaged.

18 GCB Steady when GCB is engaged.

19 Generator Steady while generator is running.

20 Auto This LED is On if the unit is in Auto Mode.

This LED Blinks in Semi Auto Mode

21 Man. This LED is On if the unit is in Manual Mode.

22 Test This LED is On if the unit is in Test Mode.

23 Off This LED is On if the unit is in OFF Mode.

10.0 Lamp Test Switching on the power of the unit with RESET switch pressed shall force the entire annunciation

LEDS to blink and display shall show the AC3 Model type along with the version number of the

software. This state shall persist till the switch is kept pressed and on release of the switch AC3 shall

start functioning normally.

11.0 Operating Mode AC3 is equipped with 5 operation modes, namely Auto, Manual, Test, Off and Remote Mode. The

first four modes can be selected by pressing the corresponding switch, from the front panel. The

remote mode is selected by a digital signal at its terminal.

11.1 Auto Mode AC3 monitors the Mains supply, if Mains supply varies beyond set limit of under/over

voltage or under/over frequency or voltage unbalance for more than their individual

programmed supervision time, AC3 releases the MCB contactor (to protect the contactor

from failure because of low input voltage) and attempts to starts the generator after the


Cat_AC3-12-09-Ver1.0. /17

programmed delay start duration has expired. In case the mains becomes healthy during

this waiting period the MCB contact is switched on and the crank cycle is aborted.

In case the heater time is set Heater contact along with Fuel Pump contact is switched on

else only the Fuel Pump contact is switched on.

After 1 second the AC3 gives cranks the engine by activating the inbuilt, potential free,

crank contact. Crank command is withdrawn if the engine start is detected, either by LLOP

pressure or by build up of generator voltage, as per the setting done by the user. Max

duration of crank command is user settable.

In case of non start of the engine AC3 re-cranks it till it starts or user programmed crank

attempts are exhausted. If generator fails to start after the maximum programmed crank

attempts, Fail to Start LED starts blinking, indicating start failure and the hooter is

switched on.

After successful start of the generator, it is allowed to warm up for a user programmed

time before the load is transferred to generator.

While the generator is running AC3 monitors it for external fault (Digital Inputs:

Emergency, V-Belt, RWL, user fault 1 and 2) and internal faults( Measured Values faults:

:LLOP, HWT, Fuel, Over Load, voltage and frequency).

On persistence of any fault for more than the programmed supervision delay, for that fault,

generator is stopped, corresponding fault is announced & hooter is switched on.

On restoration of healthy mains supply, continuously, for the programmed duration the

load is transferred to the mains and generator is stopped after expiry of re-cooling time. In

case mains again become unhealthy during the re-cooling period the load is switched to

generator.

After successful stopping of the generator either normally or on fault the Fuel Pump

Contact is removed. In case of fail to stop, the Fuel Pump Contact is not removed to avoid

air locking.

11.2 Manual Mode AC3, in this mode is under the manual control of the operator for starting and stopping of

the generator. Engine has to be started manually by manually pressing “Start” switch. The

“Start” switch shall not operate if GCB contact is closed, to provide protection to

generator. Once the generator is started the load can be switched to generator by pressing

“GCB” switch or to mains by pressing MCB switch. At any given time, either of GCB or

MCB can be operational. Attempt to switch on GCB while MCB is on will be ignored and

vice versa. Both MCB and GCB key have dual function of either switching ON or OFF the

respective contactor. A press shall toggle the state. Continuously pressing these keys shall

keep toggling the status. To stop the generator, switch off the GCB contactor and press

“STOP” key. Any attempt to stop the generator, while the GCB contact is engaged, shall

be ignored.

While the generator is running AC3 protects the generator by monitoring all internal and

external faults.

11.3 Off Mode This mode is selected to completely shut down the system. By default the load is

transferred to Mains, but Mains contactor can also be switched off/On manually.

11.4 Test Mode This mode helps the engineer to test the health of the engine. The engine can be started, as

in Auto Mode, even when the Mains voltage is healthy. The load is not transferred to the

generator. In case of Mains failure, while in this mode, the load is automatically

transferred to the generator. Please note that the generator will not automatically switch off

in this mode. To switch off the generator select either Auto, Manual or Off mode. “GCB”

& “MCB” keys are active in this mode. AC3 protects the generator by monitoring all

internal and external faults.

11.5 Semi Auto Mode This mode can be selected by pulling the pin 15(Semi Auto) low and selecting auto mode

from the front panel. The Auto LED will blink indicating that the unit is in Semi-Auto Mode.

In this mode the unit does not automatically starts the engine after the mains has failed and

mains supervision timer has expired but waits for an external start signal pin 16(Remote


Cat_AC3-12-09-Ver1.0. /17

Start). Once the start signal is given the unit now functions like auto mode with 3 crank

attempts.

The unit can be stopped by pulling low Pin 17(Remote Stop). Both Remote start and remote

stop are one touch and hence should not be continuously activated. These pins shall only

function during semi auto mode.

12.0 Programming mode The following tables gives the detailed descriptions.

Please note that 20sec of inactivity will take the unit back in normal mode and all the changes done

shall be cancelled.

12.1 Parameter Mode

S.No Parameter

name on first

row of LCD

Explanation of parameter Factory

setting

Setting Range

Mains Parameter 1 Mains O/V Max. Permissible voltage, above

this the voltage is treated unhealthy

& Generator is started.

270V 80-300V

2 Mains U/V Min. permissible voltage, below

this the voltage is treated unhealthy

& Generator is started

180V 80-270V

3 Mains Sup

Delay

Time for which the Mains voltage

has to be unhealthy (Under or Over

voltage as defined above in 1 & 2)

before starting the Generator.

10Sec 1-999Sec

4 Mains O/F Max. Permissible Mains

frequency, above this frequency

the Mains is treated unhealthy &

Generator is started.

55Hz 40-65Hz, disable

5 Mains U/F Min. permissible Mains frequency,

below this frequency the Mains is

treated unhealthy & Generator is

started.

45Hz 40-65Hz, disable

6 Mains Freq

Delay

Time for which the Mains

frequency has to be unhealthy

(under or over voltage as defined

above in 4 & 5) before starting the

Generator.

10Sec 1-999 Sec.

7 Mains

O/Current

The current above which the over

current fault monitoring has to

start. The timer for it is as

described in 8.. This fault is only

enabled when the MCB is closed.

On expiry of the timer the MCB is

opened and reset key has to be

pressed for reclosing the MCB

6Amps *

for /5

40Amps

for

Procom

Make Cts

1-999Amps

8 Mains O/C Duration for which the external or 2Sec 1-999Sec

Please note: Operating Mode cannot be changed if the unit

has stopped on a fault condition or the engine is cranking


Cat_AC3-12-09-Ver1.0. /17

Delay internal over current (for models

which have internal current

measurement) be recognized as a

fault and action initiated.

9 Mains Rest

Delay

Mains restoration Delay:

The time for which Mains should

be continuously healthy before

stopping the Generator.

30Sec 1-999Sec

Generator Parameter

1 Generator O/V Max. Permissible Generator

voltage, above this the Generator

voltage is treated unhealthy & the

Generator is stopped on voltage

fault.

270V 80-270V

2 Generator U/V Min. permissible Generator

voltage, below this the Generator

voltage is treated unhealthy & the

Generator is stopped on voltage

fault.

180V 80-270V

3 Gen Sup Delay Duration for which generator

Over/Under voltage condition can

be tolerated before stopping the

Generator.

30Sec 1-999Sec

4 Generator O/F Max. Permissible Generator

frequency, above this the

Generator frequency is treated

unhealthy & the Generator is

stopped on frequency fault.

55Hz 40-65Hz

Disable*

5 Generator U/F Min. permissible Generator

frequency, below this the

Generator frequency is treated

unhealthy & the Generator is

stopped frequency fault.

45Hz 40-65Hz

Disable*

6 Gen Freq Delay Duration for which Generator

Over/Under frequency condition

can be tolerated before stopping

the Generator.This setting is not

available if (4)&(5) are disabled

10Sec 1-999 Sec.

7 Generator O/S The maximum Generator

frequency beyond which over

speed is detected

65Hz 40-80Hz

Disable*

8 Gen O/S Delay Time for which over speeding is

allowed. This parameter is not

available if (7) is disabled.

2 Sec 1-999Sec

9 Gen Over

Current

The current above which the over

current fault monitoring has to

start. The timer for it is as

described in 10. This fault is only

enabled while the generator is

running. On expiry of the timer the

generator is stopped

6Amps

for /5

40Amps

for

Procom

Make Cts

1-999Amps

10 Gen O/C Delay Duration for which the external or

internal over current (for models

which have internal current

2Sec 1-999Sec


Cat_AC3-12-09-Ver1.0. /17

measurement) be recognized as a

fault and action initiated. This fault

is only enabled while the generator

is running.

11 Gen Recool

Time

The time for which generator is

allowed to run on no load before

switching off

30Sec 1-999Sec

System Parameter-1

1 No Of Crank The maximum number of cranks

that shall be issued to start the

Engine

3 0-10

2 Crank Time Maximum crank time 5Sec 0-25 sec

3 Crank Delay The delay between two successive

cranks

5Sec 0-100Sec

4 Gen Pick Vol This parameter specifies the

generator voltage at which the is

presumed to have started and crank

has to be terminated

100V 80-150V

5 Warm Up Time Generator warm up time. The load

is transferred to generator after

expiry of this time

1Sec 1-999Sec

6 Stop Sol On

Time

The time for which stop solenoid

will be kept active while stopping

the engine

30Sec 1-999Sec

7 Gen Start Delay The starting of generator is delayed

by this time after the mains

unhealthy timers have expired and

the mains contact has been

released. This is required in certain

applications where immediate

generator starting is not required

but the mains contactor are to be

protected. This timer is

automatically reset, if during this

duration the mains become

healthy for “Mains Restoration

Delay”

Disable* 1-999

8 Gen Start Unit The generator start delay(7) can be

programmed in seconds or

minutes. This parameter is not

available if (11) is disabled.

Sec Sec-Min

9 CT Ratio Current Transformer ratio

Available only in /5 CTs model.

Not available in models with

Procom Make CTs

1 1-190

10 V-Belt/Alt

Delay

Duration for which the V-Belt

signal should be continuously

active to be recognized as a fault

and action initiated. This fault is

only enabled while the generator is

running.

2Sec 1-999 *

11 Hooter Reset

Tim

Duration for which the hooter shall

be ON, if not externally reset,

while announcing a fault.

30Sec 1-999Sec

12 Service Time

Hr

Time, in hours, after which the

service is due.

250Hrs 1-999 Hrs


Cat_AC3-12-09-Ver1.0. /17

13 Rad. Water

Delay

Time for which Radiator water

level has to be active before

issuing shut down command

5 Sec 1-999 Sec

14 Fuel Level in % Level of fuel at which the Engine

shall shut down

20% 10-100%

15 Fuel << delay Monitoring time of Fuel Fault 5 Sec 1-999Sec

16 LowLube

Pressure

Level of LLOP at which the

Engine shall shut down

2.0 Kg

/Cm2

0.5-8.5 Kg /Cm2

17 LLOP delay Monitoring time of LLOP Fault 5 Sec 1-999 Sec

18 High Water

Temp

Temperature of water at which the

Engine shall shut down

90 0-150

Degree

centigrade

19 HWT delay

Monitoring time of HWT Fault 5 Sec 1-999 Sec

20 Sensor Type A for Low rating Engines

B for high rating Engines

A A,B,C Note:

This can be

customized

21 User Flt1 delay Delay for user defined fault 05 Sec 1-999 Sec.

22 User Flt2 delay Delay for user defined fault 05 Sec 1-999 Sec.

System Parameter –II

1 Choke Pre Time If the choke function is selected

this defines the time this contact

will energize before the crank.

Disable* 1-100Sec

2 Choke Post

Time

The duration for which the choke

contact will remain energized after

the engine has started.

Disable* 1-100Sec

3 LM Active Curr

(Optional)

If the current level crosses this

limit the contact is energized after

the programmed supervision time.

5Amps 0-999Amps

4 LM Reset Curr

(Optional)

If the current level falls below this

limit the contact is de-energized

after the programmed supervision

time.

2Amps 0-999Amps

5 LM Delay

(Optional)

The supervision time for the above

2 parameters.

5 Sec 1-999Sec

6 Enigne RPM Engine RPM Type 1500RPM 1500RPM

3000RPM

7 Disp Auto

Scroll

Setting ON will enable Auto Scroll

of display.

OFF: No scroll and next parameter

can be viewed by pressing next

switch

ON/OFF ON

8 Sensor Status Can Select The installed sensors All

Sensors

1) All Sensors

installed

2) LLOP &

HWT installed

3) LLOP and

Fuel installed

4) Fuel and

HWT installed

5) Only fuel

6) Only HWT

7) Only LLOP

8) No sensor

9 Start No.PH

Fail

Start The engine when Any one

phase of mains fails or All the

Any phase

fails

Any Phase /All

Phases


Cat_AC3-12-09-Ver1.0. /17

phases fails

10 System Config The Mains/Generator Phases

selection

Mains 3ph

Generator

3 Ph

Mains 3P GEN

3P, Main 3P

Gen 1P, Mains

1P Gen 3P,

Main 1P Gen 1P

11 GCB to MCB

Delay

User programmable delay when

the load is transferred from

Generator to Mains.

2 Sec 1-5 Sec

12 Gen Max On

Time

Max. duration for which the

generator is allowed to work

continuously

Disable* 1-999Min

13 Gen Rest Time If the generator has run

continuously as per (12), the

generator is given rest irrespective

of the mains condition. In case of

mains unhealthy during this time

the mains contact is deactivated

but the generator is not started.

This is unavailable if (12) is

Disabled

This timer is automatically reset, if

during this duration the mains

become healthy for “Mains

Restoration Delay”

Disable* 1-999Min

14 Mains Vol

Unbal

Max. Permissible voltage

difference between two phases of

mains. Above this the voltage is

treated to be unbalanced and

Generator is started.

Disable* 10-100 Disable*

15 Unbalance

Delay

Duration for which unbalance can

be allowed before starting the

Generator. This parameter is not

available if (14) is set to disabled.

10Sec 1-999Sec

16 Mains Ph Seq Enabled/Disabled OFF ON/OFF

17 Phase Seq

Delay

Duration for which the unhealthy

phase sequence is acceptable. After

this time the mains is treated as

unhealthy and the engine is started

10Sec 1-999Sec

18 DC O/V Max. permissible Auxiliary supply

voltage. If Auxiliary voltage is

higher than this for 10sec the

Battery LED starts blinking (only

warning).

30V 10-40V

Disable*

19 DC U/V Min. permissible Auxiliary supply

voltage. If Auxiliary voltage is

lower than this for 10sec the

Battery LED starts blinking (only

warning).

10V 10-40V

Disable*

20 Comm 232 or

SMS

This is available if the unit is with

communication facility.

The normal RS232 communication

over a RS232 link to other device

such as a PC can be selected

OR

The unit can be programmed to get

RS-232 • RS-232

• SMS


Cat_AC3-12-09-Ver1.0. /17

interfaced with a GSM Modem and

can send SMS on faults or could be

queried through SMS

21 Start Thr SMS DG starting via SMS enabled/

disabled

Disable Disable/ Enable

22 Crank Cut

Method

Auto disconnects the crank

command on detection of either

voltage buildup/ voltage or oil

pressure build up

Voltage

Only

Voltage or LLOP

23 Cont Prot in

Main

Contactor coil protection for mains

contactor

ON ON/OFF

Annunciation Setting

1 Mains OK Switch on the assigned contact if

the mentioned condition is fulfilled

07 00-12

2 Mains

Unhealthy

Switch on the assigned contact if

the mentioned condition is fulfilled 00 00-12

3 DG Running Switch on the assigned contact if


4 DG Not

Running



5 Fail to Start Switch on the assigned contact if


6 Fail to Stop Switch on the assigned contact if


7 LLOP Fault Switch on the assigned contact if

the mentioned condition is

fullfilled

00 00-12

8 HCT/HWT

Fault



fullfilled

00 00-12

9 Low Fuel Switch on the assigned contact if


fullfilled

01 00-12

10 DG Voltage

fault



fullfilled

02 00-12

11 DG Frequency

Fault



fullfilled

03 00-12

12 DG Overspeed Switch on the assigned contact if


fullfilled

00 00-12

13 DG O/L Fault Switch on the assigned contact if


fullfilled

00 00-12

14 V belt/ Alt

Fault



fullfilled

00 00-12

15 Mains O/L

Fault



fullfilled

00 00-12

16 Mains Phase

Sequence Fault



fullfilled

00 00-12

17 Mains Vol

Unbal




Cat_AC3-12-09-Ver1.0. /17

18 RWL Fault Switch on the assigned contact if


fullfilled

04 00-12

19 Battery

Unhealthy



fullfilled

05 00-12

20 Service Due Switch on the assigned contact if


fullfilled

06 00-12

21 BTS1 Voltage

Low



fullfilled

00 00-12

22 BTS2 Voltage

Low



fullfilled

00 00-12

23 Room Temp.

High



fullfilled

00 00-12

24 User Defined

Fault1



fullfilled

00 00-12

25 User Defined

Fault1



fullfilled

00 00-12

BTS Parameter

01 Room Temp The max. permissible room

temperature. The generator shall

not be started, even if the mains

voltage becomes unhealthy till the

Room temperature is below this

limit

27Deg 18-60Deg

02 Room Temp

Delay

Room Temperature has to

continuously above (01) limit for

this duration for starting the

generator

5Sec 0-999Sec

03 BTS1 Under

Vol

The min. permissible voltage of

BTS. The generator shall not be

started, even if the mains voltage

becomes unhealthy till the BTS

voltage is above this limit.

42V 18-59.9V/

Disable

04 BTS2 Under

Vol

The min. permissible voltage of

BTS. The generator shall not be

started, even if the mains voltage

becomes unhealthy till the BTS

voltage is above this limit.

42V 18-59.9V/

Disable

05 BTS Vol Delay BTS voltage has to continuously

below (03,04) limit for this

duration for starting the generator

5Sec 0-999Sec

* This parameter can be disabled while programming

12.2 Programming Solenoid Mode For changing the solenoid mode first press (R) (reset) button, than simultaneously press +ve

and –ve button while the reset button is pressed. The first row of LCD shall display “

FuelSolType”. There are two possible modes.


Cat_AC3-12-09-Ver1.0. /17

FUEL SOLENOID: In this mode fuel solenoid contact changes from Open to Close at the

time of cranking and remains close till the genset is running. For stopping the generator this

contact opens.

STOP SOLENOID: In this mode fuel solenoid contact remains open at the time of cranking

and till the genset is running. For stopping the generator this contact closes for a user

programmed time.

Don’t change the mode while generator is running. It’s a good practice to switch OFF and

than switch ON the battery supply after changing this mode.

13.0 Faults There are two categories of faults

o Internal Faults

o External faults

13.1 Internal Faults Internal faults are the faults, which do not need any external signals and are detected by

the system itself. They are:

o Generator Fails to Start.

o Generator Voltage Unhealthy

o Generator Frequency Unhealthy.

o Generator Over Speed.

o Generator Fails to Stop.

o Over Current

o Battery Under or Over voltage (Warning only).

13.2 External Faults Those faults which cannot be sensed by the unit itself (these faults are not reflected by the

generator voltage) and are to be provided externally. They are:

o LLOP

o HWT

o RWL

o Fuel

o Emergency

o V-Belt

o User fault 1 & 2

13.3 Fault Reset o Internal Faults & LLOP fault: All internal faults and LLOP fault can be reset by pressing

(R) switch after the generator is stopped.

o External Fault except LLOP & V-Belt faults: These faults cannot be reset till the engine

is running and/or fault conditions persist. Once the faults are rectified, the fault can be reset

by pressing Reset switch (R). In case the engine fails to stop “STOP KEY” can be pressed

for manual attempt to stop engine

14.0 Communication

The unit can communicate over an RS232 Network with another device or

The unit can be connected with a GSM modem for SMS based communication.

SMS Operation: AC3 can store up to five GSM enabled telephone numbers. In case of any fault, or starting/stopping

of the generator, a SMS shall be send to all the active telephone numbers. This SMS shall include the

fault details, the engine running/not running information, the voltage, current, battery voltage and run

hour information.

The owner of the first 2 telephone numbers can, on demand, access the above information through

SMS by sending an SMS toAC3. The SMS is “STATUS”, without quotes and all capital.

1.11.2 Feeding Telephone numbers:

Up to five telephone numbers can be stored inAC3. To feed the numbers switch offAC3. Press the

Reset and � Switch and while they are pressed power on the unit. The display shall display


Cat_AC3-12-09-Ver1.0. /17

X C.No

+91ZZZZZZZZZ

The first row “X” indicates the cursor position.

The second row displays the telephone number.

The first number is always +.

If the next digit is 0. It signifies that this particular number is not in used.

The digit at the cursor positions can be modified by pressing - key. The digits shall change from 0-9

and blank.

The blank digit signifies the end of the telephone number. The digits after this shall be discarded.

To go to next digit press � key.

Continue till the desired number is programmed.

Make sure that the last digit after the valid number is a blank.

To go to next telephone number press �Key.

The process can be terminated and all previous programmed numbers can be stored by pressing

R(Reset) Key

15.0 Load Management(Optional) AC3 has programmable contact Load management function.

The load management contact will switch on when the current on the generator has crossed a

programmed limit and will reset when the current has fallen below the reset programmed limit. This

function can be used to cut-off un necessary loads or start a second generator when the load goes

above a limit.

16.0 Model Selection

The AC3 can be ordered as

AC3-BA

INCT for /5CT

6500T for Procom Make CTs

AC3-RT (Real Time Based Contact ON Off) Please refer its

manual

AC3-MT (Mitsubishi Engines) Please refer its manual

AC3-BTS

17.0 Terminal Number Description

1 Mains R Phase Voltage

2 Mains Y Phase Voltage

3 Mains B Phase Voltage

4 Mains Neutral

5 Generator R Phase Voltage

6 Generator Y Phase Voltage

7 Generator B Phase Voltage

8 Generator Neutral

9-10 R Phase Current

11-12 Y Phase Current

13-14 B Phase Current

15 Auto/Semi Auto Mode

16 Remote Start( In Semi Auto Mode only)

17 Remote Stop (In Semi Auto Mode only)

18 Emergency

19 RWL Switch

20 Auxiliary supply +ve

21 Auxiliary supply -ve

22,23 Mains Circuit Breaker Contact


Cat_AC3-12-09-Ver1.0. /17

24,25 Generator Circuit Breaker Contact

26 Crank Contact

27 Hooter Contact

28 Common For Crank and Hooter

29 Fuel Sol Contact

30 Heater Contact

31 Common for Heater and Fuel Sol

32 Load Management Contact

33 Fuel Pump Contact

34 Common for LNM and Fuel pump Contacts

35 V-Belt/Charging Alternator input

36 Sensor Fuel/Switch

37 User defined fault 1

38 User defined fault 2

39 LLOP Sensor/Switch

40 HWT Sensor/Switch

41 Room Temperature Sensor Low

42 Room Temperature Sensor High

43 BTS 2 Low

44 BTS 2 High

45 BTS 1 Low

46 BTS 1 High

47-50 Potential free Annunciation Cards connections from A-D

18.0 Specifications AC voltage withstand 330 VAC (Phase to neutral)

Measurement Accuracy

Voltages & Current 1% of Measurement

Power & Energies 2%

Surge 1.2/50Usec 2.5KV

Battery Voltage Suitable for 12V/24 VDC System

Min. voltage to power on 9V

Min Running Voltage after

Power on 4V

Max. Battery Voltage 35V

DC Interruption time 1 Sec.

Contact(MCB) NC, 230V / 6A

Contact(GCB) NO, 230V / 6A

Contact(Hooter) NO, 24V / 6A

Contact(Fuel Sol) NO, 24V / 6A

Contact(Crank) NO, 24V / 6A

Contact Choke NO, 24V / 6A

Contact(Fuel Pump) NO, 24V / 6A

Contact(Load Management) NO, 24V / 6A

Cut out Dimensions 186mm X 90mm

Depth 120mm

Digital Input Level Battery Voltage (Negative) except charging

Alternator which is positive.

It is our endeavour to constantly upgrade our products, hence specifications are subject to change without any notice.

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