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User manual AMF controller TE

1. 440 Vit 254 Vin PO801 Amax KVA max GU26L 40 31 GU30J 44 34 GU42J 62 48 GU65J 100 76 GU85J 121 93 GU105J 162 124 GU125J 182 139 Te 804 REV02 10 04 04 Page 31 of 38 460 Vi 266 Vin PO801 Amax KVA max GU26L 38 31 GU30J 42 34 GU42J 59 48 GU65J 95 76 GU85J 116 93 GU105J 155 124 GU125J 174 139 480 Vit 277 Vin PO801 Amax KVA max GU26L 37 30 8 GU30J 41 33 8 GU42J 57 47 5 GU65J 92 76 3 GU85J 111 92 5 GU105J 149 123 8 GU125J 167 138 8 4 2 4 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram CONNECT TO CONNECT TO 42 TERMINAL 30 OF 44 TERMINAL 32 OF When the System is configured for this voltage it is necessary to use a Standard 2 wire ATS 4 2 5 VOLTAGE ADJUSTMENT Carefully start the generating set and Check ph ph and ph N voltage values between phase have not to be different max difference 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R If output voltage is not inside preset limits before the preset time expires you will get an alarm Te 804 REVO2 10 04 04 Page 32 of 38 4 3 DOG LEG ZIG ZAG CONNECTIONS 120 240V 1ph I
2. KVA max Amax KVA max 208 120 76 3 27 5 69 4 25 3 1 4 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram 41 45 CONNECT TO 427 a TERMINAL 30 O Warning Voltage between 42 44 and N is 120V Carefully verify compatibility with ATS If necessary connect a transformer In case of use of an No Logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS It is not necessary to use transformers 3 1 5 VOLTAGE ADJUSTMENT Carefully start the generating set and 2 Check ph ph and ph N voltage values between phase has not to be different max difference 2 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R 2 If output voltage is not inside preset limits before the preset time expires you will get an alarm 3 2 HIGH WYE STAR CONNECTIONS 240V 277 480V 3PH In order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done m Warning Internal connections modification can only be made by trained personnel Local codes mus
3. 1 key to select the parameter property and then oo or key to change it Press the EXIT key to return to the previous menu Te 804 REV02 10 04 04 Page 7 of 38 2 14 COMMANDS MENU To enter the menu press the OFF RESET key and simultaneously the ENTER key for 5 seconds and then release them Press the EXIT key to exit the menu C01 Energy meter reset C02 Maintenance reset C03 Engine hour meter reset C04 Starting counter reset C05 Parameters to default C06 Save parameters to flash C07 Load parameters from flash C08 Rent hours reset 2 14 a HIDDEN COMMANDS Maintenance hour counter setting To set the maintenance counter press the OFF RESET key and subsequently ENTER and U keys for 5s after that release them Set the hours using the or key and press the EXIT key to store and exit RPM W ratio When the engine is running press START ENTER keys to self configure the RPM W ratio value 2 15 ADVANCED MENU To enter the menu keep the OFF RESET key pressed then push in the following sequence key twice key three times and U key four times then finally release the OFF RESET key 01 UTILITY LANGUAGES wer 7x Range HS GU D Diesel Units G Gaseous Units Pait MT English ltalian P0101 Languages English English French German
4. 130 130 110 140 P0303 MIN voltage limit 75 75 60 100 P0304 MIN MAX voltage delay s 10 10 0 30 04 ENGINE STARTING Default HS Default GU Range P0401 Alternator voltage engine started V 6 6 OFF 3 30 P0402 Generator voltage engine started 20 20 OFF 10 100 P0403 Generator frequency engine started 20 20 OFF 10 100 P0404 W signal engine started RPM 20 20 OFF 10 100 P0405 Glow plugs preheating s 8 8 OFF 1 60 P0406 Starting attempts number 5 5 1 10 P0407 Attempts starting time s 8 8 1 30 P0408 Pause between starting s 10 10 1 30 P0409 Aborted starting amp subsequent s 3 3 OFF 1 20 P0410 Deceleration time s OFF OFF OFF 1 180 P0411 Cooling time s 10 10 1 3600 P0412 Stop magnet time s OFF OFF OFF 1 60 P0413 Gas valve delay s OFF OFF OFF 1 10 P0414 Priming time s D OFF OFF OFF 1 10 G 1 P0415 Choke valve time s OFF OFF OFF 1 10 P0416 Choke OFF limit 5 5 0 100 Te 804 REV02 10 04 04 Page 9 of 38 05 ENGINE CONTROL Default HS Default GU Range P0501 Pressure sensor selection VEGLIA VEGLIA 1 P0502 Temperature sensor selection VEGLIA VEGLIA 1 P0503 Fuel sensor selection D DATCOM DATCOM 1 G OFF P0504 MIN pressure warning 11 6 11 6 0 1 180 0 P0505 MIN pressure limit 4 4 4 4 0 1 180 0 P0506 MAX temperature warning 203 203 40 285 P0507 MAX temperat
5. Spanish P0102 Year 1989 2089 P0103 Month 1 12 P0104 Day of the month z 1 31 P0105 Day of the week 1 7 P0106 Hour 0 23 P0107 Minutes 0 59 P0108 Seconds 0 59 P0109 Clock setting at power up ON OFF OFF ON P0110 Default page return s 60 60 OFF 5 999 P0111 Display contrast 50 50 0 100 Te 804 REVO2 10 04 04 Page 8 of 38 02 GENERAL Default HS Default GU Range 0201 CT ratio 20 0 U26L 10 1 0 2000 0 GU30J 16 GU42J 16 GU65J 20 GU85J 30 U105J 30 U125J 50 P0202 VT ratio 1 0 1 0 1 0 500 0 P0203 Wiring configuration L1 L2 L3 N L1 L2 L3 N 3N 3 2N 1N P0204 Rated voltage V 208 208 100 50000 P0205 Frequency Hz 60 60 50 60 P0206 RPM W ratio D 4 444 0 001 50 000 G 29 464 P0207 Rated engine speed RPM D 1800 1800 750 3600 G 2400 P0208 Unit of measure F psi F psi C bar F psi P0209 MAINS GEN interlock s 0 5 0 5 0 0 60 0 P0210 M G feedback delay s 5 5 1 60 P0211 RESET mode at power up ON ON OFF ON P0212 Siren time s OFF 5 OFF 1 60 P0213 Siren before starting s OFF 5 OFF 1 60 Caution The calculation system of the TE804 can handle power value up to 999 000 000 VA 999MVA 03 BATTERY Default HS Default GU Range P0301 Battery voltage V 12 12 12 24 P0302 MAX voltage limit
6. This is done before or during the installation of the Genset There are three different menus in order to have access to the parameters setting and relative data All operating times and calculations that affect the system functioning can be set up and the parameters are stored in a permanent memory Only trained personnel can reach this function and it is password protected Starting Cycles The sequence of diesel Genset starting is as follows First glow plugs are energized programmable duration and then the fuel solenoid valve is activated After these two steps the control panel enters into a start interval programmable duration alternating with intervals of cool down programmable duration Once the engine is on the starting attempts stop immediately The sequence of gaseous Genset starting is as follows First the gas valve is activated for the first starting attempt primer is energized The Electronic Ignition is energized at the same time as the gas Te 804 REVO2 10 04 04 Page 2 of 38 valve to avoid over speed alarm RPM governor this device is described in Appendix B is energized after a time delay after cranking After these steps the control panel enters into a start interval programmable duration alternating with intervals of cool down programmable duration Once the engine is on the starting attempts stop immediately Genset Stopping Procedure The transfer switch opens and the Genset continues to run for a cool dow
7. particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature a It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 4 4 1 GENERATOR TERMINAL BOARD CONNECTIONS Modify internal terminal board connections as per above drawing Te 804 REV02 10 04 04 Page 35 of 38 4 4 2 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to a a 240 3ph L1 L2 L3 M02 General P0203 Wiring configuration 120 240V 1ph L1 N L2 P0204 Nominal voltage V 240 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 4 4 3 RATED POWER CURRENT WITH DIFFERENT VOLTAGE High delta connection Program values 1 ph L1 N L2 PO801 120 Vin 240 Vit 240V 1 12 Amax Current KVA max 3ph L1 L2 L3 PO801 Amax KVA max 240V 1 12 GU26L 74 17 8 GU26L 74 30 7 37 4 4 GU30J 81 33 6 GU30J 81 19 4 GU42J 114 47 3 41 4 9 GU65J 184 76 4 GU42J 114 27 4 GU85J 223 92 5 57 6 8 GU105J 298 123 7 GU65J 184 44 1 GU125J 334 138 8 92 11 GU85J 223 53 5 111 13 3 GU105J 298 71 5 149 17 9 GU125J 334 80 1 167 20 44 4 A T
8. s 5 5 0 600 P0705 Generator into limits delay s 10 10 0 600 P0706 MIN MAX hysteresis limits 96 3 0 3 0 0 0 5 0 P0707 MAX asymmetry limit 15 15 5 20 P0708 MAX asymmetry delay s 5 5 0 600 P0709 MAX frequency limit 26 105 110 100 120 OFF P0710 MAX frequency delay s 3 0 0 200 P0711 MIN frequency limit 95 95 OFF 80 100 P0712 MIN frequency delay s 5 5 0 600 P0713 Gen Control INTERNAL INTERNAL OFF INT EXT OFF internal external Page 10 of 38 08 GENERATOR PROTECTION Default HS Default GU Range P0801 Rated generator current A D 76 3 GU26L 85 OFF 5 10000 NG 62 5 GU30J 94 LPG 69 GU42J 132 GU65J 212 GU85J 257 GU105J 344 GU125J 386 P0802 MAX current limit 250 250 100 500 OFF P0803 MAX current delay s 3 3 0 0 60 0 P0804 Thermal protection curve selection P3 P3 1 P0805 Generator protection reset time s 20 20 0 5000 09 EXERCISE AND MAINTENANCE Default HS Default GU Range P0901 EXERCISE beginning day MONDAY MONDAY 1 7 P0902 EXERCISE beginning hour h 12 12 00 23 P0903 EXERCISE beginning Minutes m 0 0 00 59 P0904 Interval between EXERCISES 07 07 1 30 days P0905 EXERCISE duration m OFF OFF OFF 1 60 P0906 EXERCISE with load OFF OFF OFF ON P0907 Maintenance interval h 50 50 OFF 1 999 oo EXERCISE with remote external OFF OFF OFF ON 10 COMUNICATI
9. 0 0 6000 0 P1203 Input terminal 8 3 DISABLED DISABLED 1 8 3 Contact type NO NO NO NG 8 3 Opening delay s 0 0 0 0 0 0 6000 0 8 3 Closing delay s 0 0 0 0 0 0 6000 0 P1204 Input terminal 8 4 UA1 DISABLED 1 8 4 Contact type NO NO NO NC 8 4 Closing delay s 0 0 0 0 0 0 6000 0 8 4 Opening delay s 0 0 0 0 0 0 6000 0 P1205 Input terminal 8 5 UA2 DISABLED 1 8 5 Contact type NO NO NO NG 8 5 Closing delay s 0 0 0 0 0 0 6000 0 8 5 Opening delay s 0 0 0 0 0 0 6000 0 P1206 Input terminal 8 6 D DISABLED REMOTE STOP 1 G Remote Stop 8 6 Contact type NO NO NO NG 8 6 Closing delay s 0 0 0 0 0 0 6000 0 8 6 Opening delay s 0 0 0 0 0 0 6000 0 P1207 Input terminal 8 7 DISABLED DISABLED 1 8 7 Contact type NO NO NO NC 8 7 Closing delay s 0 0 0 0 0 0 6000 0 8 7 Opening delay s 0 0 0 0 0 0 6000 0 P1208 Input terminal 8 8 DISABLED DISABLED 1 8 8 Contact type NO NO NO NC 8 8 Closing delay s 0 0 0 0 0 0 6000 0 8 8 Opening delay s 0 0 0 0 0 0 6000 0 P1209 Input terminal 8 9 DISABLED DISABLED 1 8 9 Contact type NO NO NO NG 8 9 Closing delay s 0 0 0 0 0 0 6000 0 8 9 Opening delay s 0 0 0 0 0 0 6000 0 P1210 Input terminal 9 1 WATER TEMP WATER TEMP 1 9 1 Contact type NO NO NO NG 9 1 Closing delay s 0 0 0 0 0 0 6000 0 9 1 Opening delay s 0 0 0 0 0 0 6000 0 P1211 Input terminal 9 2 OIL PRESSURE OIL PRESSURE 1 9 2 Contact type NC NC NO NG 9 2 Closing delay s 1 0 1 0 0 0 6000 0 9 2 opening delay s 1 0 1 0 0
10. 0 6000 0 P1212 Input terminal 9 3 FUEL LEVEL FUEL LEVEL 1 9 3 Contact type NO NO NO NG 9 3 Closing delay s 0 0 0 0 0 0 6000 0 9 3 Opening delay s 0 0 0 0 0 0 6000 0 1 See the list of the available functions in the Programmable inputs table Programmable inputs Function Disable Oil pressure Engine temperature Te 804 REVO2 10 04 04 Page 12 of 38 Fuel level Emergency stop Remote stop Remote starting Remote starting without cooling Automatic test start Generator protection Supervision Off Setup block External MAINS control External GEN control Automatic changeover MAINS contactor feed back GEN contactor feed back Fuel tank too empty Fuel tank empty Fuel tank filled Fuel tank too full User s alarm 1 User s alarm 2 User s alarm 3 User s alarm 4 13 PROGRAMMABLE OUTPUTS Default HS Default GU Range P1301 Output terminal 5 3 Function GLOBAL ALARM GLOBAL ALARM 1 P1302 Output terminal 6 2 Function D SIREN 1 G PRIMING VALVE SIREN P1303 Output terminal 6 3 Function D GLOW PLUGS GLOW PLUGS 1 G N A P1304 Output terminal 6 5 Function D FUEL VALVE FUEL VALVE 1 G GAS VALVE P1305 O A 6 Disabled P1306 O A 8 Disabled 1 See the list of the available functions in the Programma
11. 2 1 KEYBOARD HELP key The illuminated LED means a help message is available By pressing the key a help message concerning the current operation is displayed ENTER and EXIT keys Press ENTER to confirm operations or to enter the menu Press EXIT to refuse an operation or to exit a menu and help message ll and N arrow keys Press these keys to shift to the different pages of data display or to select parameters and keys Press these keys to display alternative data of the selected data page or to modify the parameters OFF RESET MAN AUT and TEST keys Press these keys to select the operating mode The illuminated LED indicates the selected operating mode if it is flashing remote control is active START and STOP keys These keys work in MAN operating mode only to start and stop the engine By quickly pressing the START key one start attempt takes place by keeping the START key pressed the duration of the start attempts can be extended The flashing LED of the engine symbol denotes engine started with alarms inhibited and is constantly on at the end of the alarms inhibition time The engine can be stopped using the OFF RESET key MAINS and GEN keys They are enabled only in MAN operating mode only they are used to control the ATS and switch the load from utility to generator and vice versa The illuminated Leds of the utility and generator symbols indicate the respective voltages are within preset limit
12. Page 27 of 38 3 4 5 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram E 11 L 7 L2 12 L2 22 L L3 2 h N 24 41 4 7 X See e CONNECT TO CONNECT TO 47 TERMINAL 30 O 44 mx TERMINAL 32 OF g ATIS Warning Voltage between 42 44 and N is 120V Carefully verify compatibility with ATS If necessary connect a transformer In case of use of a no logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS it is not necessary to use transformers 3 4 66 VOLTAGE ADJUSTMENT Carefully start the generating set and Check ph ph and ph N voltage values between phase has not to be different max difference 296 Quickly adjust output voltage on VOLT potentiometer on generator A V R If output voltage is not inside preset limits before the preset time expires you will get an alarm Te 804 REVO2 10 04 04 Page 28 of 38 4 CONNECTIONS INSTRUCTIONS GU SERIES ONLY 4 1 0 LOW WYE DOUBLE STAR CONNECTIONS 120 208V 3PH Factory Default This is the on factory set connection In order to verify remake this connection it is necessary to pro
13. X X A17 Charger alternator failure X X X X X Xx X A18 W signal failure X X X X X X A19 Low engine W speed X X X X X Xx A20 High engine W speed X X X X X Xx A21 Starting failure X X X X X X A22 Emergency stop X X X X X Xx A23 Unexpected stop X X X X X Xx A24 Engine stop failure X X X X X X A25 Low generator frequency X X X X X X Xx X A26 High generator frequency X X X X X X X A27 Low generator voltage X X X X X X Xx X A28 High generator voltage X X X X X X Xx A29 Generator asymmetry X X X X X X X X A30 Generator short circuit X X X X X X Xx A31 Generator overload X X X X X Xx X A32 External generator protection tripping X X X X X A33 Incorrect generator phase sequence X X X X X A34 Incorrect utility phase sequence X A35 Wrong system frequency setting X A36 Generator contactor failure X X X A37 Utility contactor failure X X X A38 Maintenance requested X X X A39 System error A40 Fuel transfer too empty X X A41 Fuel transfer too full X X A42 Rent hours exhausted X X UA1 User s alarm 1 UA2 User s alarm 2 Dirty air filter X X X X X Xx UA3 User s alarm 3 UA4 User s alarm 4 Te 804 REVO2 10 04 04 Page 14 of 38 2 17 f o Ble s sie 3 ME dE S lol O w
14. case of disconnection of the electrical input and cannot be set to zero by the user Te 804 REV02 10 04 04 Page 5 of 38 2 8 ALARMS When an alarm arises the alarm is displayed in the lower section of the display In case of two alarms or more they are individually shown in sequence A help message is available for every alarm to assist in locating the possible alarm source Alarm conditions can be reset by means of the OFF RESET key this is to prevent any unintentional engine starting during alarm conditions If the alarm does not reset this means the cause of the alarm is still present During event log sessions and set up operations no alarms are displayed 2 9 ALARM PROPERTIES Eight different properties can be assigned to each user alarm including User Alarms Q Alarm enabled If not enabled the alarm will not work Retentive alarm The alarm is latched even if the cause of the alarm is removed Global alarm It activates the output assigned to this function Siren It activates the output assigned to this function Immediate Engine shutdown Shutdown with Engine cool down Active only with engine running Modem auto call A modem connection is performed according to the modality scheduled by preset parameters OOOOoodO All these properties are preset to a default value for the specific applications Diesel or Gaseous Generating set To change these properties enter the ADVANCED MENU find the ALARMS menu press th
15. low wye connection it is possible to obtain 208 Vic 208 Vit 120 Vin PO801 Amax KVA max 120 Vin PO801 Amax KVA max GU65J 212 76 GU26L 85 31 GU85J 257 93 GU30J 94 34 GU105J 344 124 GU42J 132 48 GU125J 368 139 Te 804 REV02 10 04 04 Page 29 of 38 4 1 4 A T S CONNECTIONS Warning Voltage between 42 44 and N is 120V In case of use of an No Logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS 4 1 5 VOLTAGE ADJUSTMENT Carefully start the generating set and 44 mw TERMINA CONN m ki CT TO 32 OF gt I Check ph ph and ph N voltage values between phase has not to be different max difference 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R If output voltage is not inside preset limits before the preset time expires you will get an alarm 4 2 HIGH WYE STAR CONNECTIONS 240V 277 480V 3PH In order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done personnel should have access to this key Te 804 REVO2sas 10 4 2004 Page 30 of 38 m Warning Inter
16. on generator A V R 3 If output voltage is not inside preset limits before the preset time expires you will get an alarm Te 804 REVO2 10 04 04 Page 22 of 38 3 3 DOG LEG ZIG ZAG CONNECTIONS 120 240V 1ph In order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death Warning Always check that the Genset voltage connection corresponds to your specific requirements a Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 3 3 1 GENERATOR TERMINAL BOARD CONNECTIONS 1 12 a4 4 3 A fe L2 Ta 2 1 Modify internal terminal board connections as per above drawing 3 3 2 ELECTRICAL PANEL CONNECTIONS SEE B0172 dwg B0192 dwg In order to do not damage Utility presence lamp Zero start device block heater Battery cha
17. select a sub menu or a command in the case of Commands menu Press the ENTER key to access parameter setting or to perform the command Press U or fl keys to select the parameter and press or to modify it Press the EXIT key to close the sub menu and push it again to close the set up J fo ENTER RESET Data safety copy A safety copy of the adjustable keyboard set up data can only be made in Te804 flash memory The same data can be restored whenever required to Te804 work memory The commands and data restore of the safety copy are available in the Commands menu Te 804 REVO2 10 04 04 Page 6 of 38 2 11 SET UP BY MEANS OF PERSONAL COMPUTER PC The set up can be more easily done modified via PC connected to Te804 RS 232 port Using the software set up it is possible to transfer parameters previously set from Te804 to the PC and vice versa In addition to the parameters set up with the PC it is possible to define o Help text of the alarms descriptions and help text of the User Alarms o All the data related to the curve characteristic of the pressure temperature fuel level sensors and generator thermal protection Q Custom logo that appears on the display at power up and at set up exit via keypad An information page where one can write information data characteristics e
18. sensor fault X X X X X A10 Fuel level warning analog sensor X X Xx A11 Low fuel level analog sensor X X X A12 Level analog sensor fault X X X X A13 Low fuel level digital sensor X X X Xx A14 High battery voltage X X X X X A15 Low battery voltage X X X X X A16 Inefficient battery X X X X X X A17 Charger alternator failure X X X X X Xx X A18 W signal failure X X X X X X A19 Low engine W speed X X X X X Xx A20 High engine W speed X X X X X Xx A21 Starting failure X X X X X X A22 Emergency stop X X X X X Xx A23 Unexpected stop X X X X X Xx A24 Engine stop failure X X X X X X A25 Low generator frequency X X X X X X Xx X A26 High generator frequency X X X X X X X A27 Low generator voltage X X X X X X Xx X A28 High generator voltage X X X X X X Xx A29 Generator asymmetry X X X X X X X X A30 Generator short circuit X X X X X X X Xx A31 Generator overload X X X X X X Xx X A32 External generator protection tripping X X X X X A33 Incorrect generator phase sequence X X X X X A34 Incorrect utility phase sequence X A35 Wrong system frequency setting X A36 Generator contactor failure X X X A37 Utility contactor failure X X X A38 Maintenance requested X X X A39 System error A40 Fuel transfer too empty X X X A41 Fuel transfer too full X X X A42 Rent hours exhausted X X X A43 Low Radiator Level UA1 User s alarm 1 UA2 User s alarm 2 UA3 User s alarm 3 UA4 U
19. to the following points Do not run the generating set before all these steps have been done Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death Warning Always check that the Genset voltage connection corresponds to your specific requirements a Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperatures m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 4 4a HIGH DELTA CONNECTIONS 240V 3ph 120 240V 1ph In order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done m Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements m Electrical connections must be carried out in compliance with local codes AC cables
20. 0 or 460 or 480 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 3 2 4 RATED POWER CURRENT WITH DIFFERENT VOLTAGE With high wye connection it is possible to obtain Voltage HSD 22 HSG 20 LPG VLL VIN Amax KVAmax Amax KVA max 440 254 36 1 4 32 8 460 266 34 5 i 31 4 480 277 33 0 30 0 3 2 5 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram Na CONNECT TO CONNECT TC 42 TERMINAL 30 OF 44 TERMINA C FILIOTT ATS ELLIOTT Warning Voltage between 42 44 and N is 277V with 480V Ph PH Carefully verify compatibility with ATS If necessary connect a step down transformer In case of use of an No Logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS It is necessary to use step down transformers to reduce voltage up to 120V 3 2 6 VOLTAGE ADJUSTMENT Carefully start the generating set and 1 Check ph ph and ph N voltage values between phase have not to be different max difference 2 2 Quickly adjust output voltage on VOLT potentiometer
21. BLUE UTILITY L2 moe F4 A BLACK UTILITY L1 _ pa SA H BLACK UTILITY L1 UTILITY PRESENCE RED ZA 5 TPG LAMP BLOCK HEATER 0 Z Se BATTERY CHARCER s j f L 31 OI unury sense Li 7 BLACK L1 UTILITY SENSING L2 SREY L 2 aoe See ROWN NG 5 HA fase eae Ses UTILITY SENSING N LUE UT 14 O JTILITY COM ZIA a UNLIMACON a FG S BLUE UTILITY L2 ZERI F4 5A BLACK UTILITY L1 BATTERY CHA PATER SNES BS SA BLACK UTILITY L1 As soon as you connect utility verify input voltage on above devices it must not exceed 240V 3 4 3 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration 240 3ph L1 L2 L3 120 240V 1ph L1 N L2 P0204 Nominal voltage V 240 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 3 4 4 RATED POWER CURRENT WITH DIFFERENT VOLTAGE With high delta connection it is possible to obtain Voltage HSD 22 HSG 20 LPG System V Amax KVA max Amax KVA max 3ph L1 L2 L3 240 66 2 27 5 60 1 25 KW max KW max 1ph L1 N L2 Vir12 240V 88 75 18 LIM Vu m 120V 44 5 3 37 4 5 Te 804 REV02 10 04 04
22. H DIFFERENT VOLTAGE With dog leg zig zag connection it is possible to obtain Voltage HSD 22 HSG 20 LPG V 1 12 Vin Amax KW max Amax KW max 240 120 88 21 75 18 Te 804 REVO2 10 04 04 Page 24 of 38 3 3 5 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram L1 H 1 L1 Ei 1 L2 12 L2 22 LS 13 L 23 14 N 24 4 43 Z n CONNECT TO O OF Ss 42 TERMINAL AG nC Warning Voltage between 42 44 and N is 120V Carefully verify compatibility with ATS If necessary connect a transformer In case of use of an No Logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS It is not necessary to use transformers 3 3 6 VOLTAGE ADJUSTMENT Carefully start the generating set and 1 Check ph ph and ph N voltage values between phases neutral has not to be different max difference 2 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R 3 If output voltage is not inside preset limits before the preset time expires you will get an alarm 3 4 HIGH DELTA CONNECTIONS 240V 3ph 120 240V 1ph In order to obtain this conne
23. O o r Alarm properties gt 5 ba T a Os PG Sallie E E c 2 5 List of the alarms for HSG E s 35 s D5 d 5FE g lt x aa O D Lui wu lt 3 3 A01 Engine temperature warning analog sensor X X X X X A02 High engine temperature analog sensor X X X X X X X A03 Temperature analog sensor fault X X X X A04 High engine temperature digital sensor X X X X X X X A05 Oil pressure warning analog sensor X X X X X A06 Low oil pressure analog sensor X X X X X Xx X A07 Pressure analog sensor fault X X X X A08 Low oil pressure digital sensor X X X X X X X A09 Pressure digital sensor fault X X X X X A10 Fuel level warning analog sensor X X X A11 Low fuel level analog sensor X X X A12 Level analog sensor fault X X X X A13 Low fuel level digital sensor X X X A14 High battery voltage X X X X X A15 Low battery voltage X X X X X A16 Inefficient battery X X X X A17 Charger alternator failure X X X X X X X A18 W signal failure X X X X X X A19 Low engine W speed X X X X Xx X A20 High engine W speed X X X X X X A21 Starting failure X X X X X X A22 Emergency stop X X X X X X A23 Unexpected stop X X X X X X A24 Engine stop failure X X X X X X A25 Low generator frequency X X X X X X A26 High generator frequency X X X X X X X A27 Low generator voltage X X X X X X Xx X A28 High generator voltage X X X X X X X X A29 Generator asymmetry X X X X X X X X A30 Generator short circ
24. ON PORT Default HS Default GU Range P1001 Serial port address 01 01 1 99 P1002 RS 232 baud rate 9600 9600 OFF 1200 38400 P1003 RS 485 baud rate OFF OFF OFF 1200 38400 P1004 Modem channel RS232 RS232 RS232 RS485 11 MISCELLANEOUS Default HS Default GU Range P1101 Max engine power starting OFF OFF OFF ON P1102 Engine start threshold kW 0 0 0 9999 P1103 Engine start threshold delay s 0 0 0 999 P1104 Engine stop threshold kW 0 0 0 9999 P1105 Engine stop threshold delay s 0 0 0 999 P1106 Dummy load OFF OFF OFF ON P1107 Dummy load ON kW 0 0 0 9999 P1108 Dummy load ON delay s 0 0 0 999 P1109 Dummy load OFF kW 0 0 0 9999 P1110 Dummy load OFF delay s 0 0 0 999 P1111 Rent hours h OFF OFF 0 60000 P1112 Mode select NORMAL NORMAL Normal EJP EJP T SCR P1113 Start motor delay 25 25 0 99 P1114 Changeover delay 5 5 0 30 P1115 Changeover block OFF OFF OFF ON Te 804 REV02 10 04 04 Page 11 of 38 12 PROGRAMMABLE INPUTS Default HS Default GU Range P1201 Input terminal 8 1 EMERG STOP EMERG STOP 1 8 1 Contact type NG NG NO NG 8 1 Opening delay s 0 0 0 0 0 0 6000 0 8 1 Closing delay s 0 0 0 0 0 0 6000 0 P1202 Input terminal 8 2 REMOTE STAR REMOTE 1 STAR 8 2 Contact type NO NO NO NG 8 2 Opening delay s 0 0 0 0 0 0 6000 0 8 2 Closing delay s 0 0 0 0
25. S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram No NI CONNECT TO CONNECT TO 47 u TERMINAL 30 OF 44 e TERMINAL 32 OF A T S ATS Warning Voltage between 42 44 and N must be 120V Te 804 REVO2 10 04 04 Page 36 of 38 4 45 VOLTAGE ADJUSTMENT Carefully start the generating set and 1 Check ph ph and ph N voltage values between phase has not to be different max difference 2 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R 3 If output voltage is not inside preset limits before the preset time expires you will get an alarm 5 0 ATS CONECTIONS 5 1 How to program the TE804 to operate with an Intelligent ATS Program the Te 804 as follows e Press and hold the Reset button e Press the button 2 times e Press the button 3 times e Press the down arrow button 4 times e Release the Reset button This will place you in the Extended Menu Scroll down with the down arrow to M06 UTILITY CONTROL Press Enter button Scroll down to P0612 MAINS control Right side will read INTERNAL Press button and this will change to OFF Press the EXIT button You have now turned off the internal ATS control Scroll down to M12 Prog
26. Te 804 Electronic Controller Service Operation amp Technical Information Manual E WARNING Technical descriptions and data given in this document are accurate to the best of our knowledge but can be subject to change without prior notice so no liabilities for errors omissions or contingencies arising there from are accepted Moreover the TE804 should be set up and used by trained personnel and in any case in compliance to current installation standards to avoid damages or safety hazards Te 804 REVO2sas 10 4 2004 Page 1 of 38 1 OPERATING PROCEDURES FOR AUTOMATIC CONTROL PANEL 1 1 1 2 Warning Carefully study the instructions of your automatic control panel before starting your Genset set so you will be able to operate your Genset safely Warning Before starting your generator check that there are no obstructions around it Caution When starting the Genset the first time or after a long storage let the engine warm up at least 5 minutes This prolongs the life of the Genset Warning The automatic control panel should only be set up and operated by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death Caution Always check that the technical data printed on the nameplate corresponds to your specific requirements These products have been manufactured to mi
27. W WYE DOUBLE STAR CONNECTIONS 120 208V 3PH Factory Default This is the on factory set connection In order to verify remake this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been checked done o Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements o Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperatures a It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key Te 804 REVO2 10 04 04 Page 18 of 38 3 1 1 GENERATOR TERMINAL BOARD CONNECTIONS Verify modify internal terminal board connections as per above drawing 3 1 2 ELECTRICAL PANEL CONNECTIONS SEE B0172 dwg B0192 dwg To avoid damages to z Utility presence lamp Zero start device block heater Battery charger Other devices with maximum voltage 240V i
28. ble outputs table Programmable outputs Function Disable Global alarm Fuel solenoid valve Siren Decelerator Stop magnet Glow plugs Gas valve Air valve Priming valve Filling pump Dummy load A1 A43 and UA1 UA4 alarms Te 804 REV02 10 04 04 Page 13 of 38 2 16 s e NE 4 3 0v ja 5 5 Pa Alarm properties gt E 5 3 E 3 3 5 5 o i E 5 pa 2 e Joel List of the alarms for HSD 5 s 3 S gt 5 55 3 lt x pl O D LI wu lt 3 2 A01 Engine temperature warning analog sensor X X X X Xx A02 High engine temperature analog sensor X X X X X Xx X A03 Temperature analog sensor fault X X X A04 High engine temperature digital sensor X X X X X X Xx A05 Oil pressure warning analog sensor X X X X X A06 Low oil pressure analog sensor X X X X X X Xx A07 Pressure analog sensor fault X X X X A08 Low oil pressure digital sensor X X X X X X X A09 Pressure digital sensor fault X X X X X A10 Fuel level warning analog sensor X X X Xx A11 Low fuel level analog sensor X X X X A12 Level analog sensor fault X X X X Xx A13 Low fuel level digital sensor X X X Xx A14 High battery voltage X X X X X A15 Low battery voltage X X X X X A16 Inefficient battery X X X X
29. ceed according to the following points Do not run the generating set before all these steps have been checked done m Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements m Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperatures m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 4 1 1 GENERATOR TERMINAL BOARD CONNECTIONS GND 1 3 s7 on O ae ai ean et ee 2 v Verify modify internal terminal board connections as per above drawing 4 1 2 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 L2 L3 N P0204 Nominal voltage V 208 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 4 1 3 RATED POWER CURRENT WITH DIFFERENT VOLTAGE With
30. ction it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death Warning Always check that the Genset voltage connection corresponds to your specific requirements m Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperatures m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key Te 804 REV02 10 04 04 Page 25 of 38 3 4 a HIGH DELTA CONNECTIONS 240V 3ph 120 240V 1ph In order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done m Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements m Elect
31. e U or 1 key to select the alarm press the or key to select the property and then press the ENTER key to enable or disable the property Press the EXIT key to return to the previous menu Warning Changing the Alarm Properties could result in equipment damage or personal injury and loss of warranty coverage 2 10 SET UP VIA KEYBOARD There are three different menus in order to have access to the parameters setting and related data o User s menu Access the setting of those parameters that final user can modify To enter the menu press the OFF RESET key for 5 seconds then release it OQ Commands menu Access to data resetting parameter copy and their restore It is necessary to access this menu for maintenance hours reset To enter the menu press the OFF RESET key and simultaneously the ENTER key for 5 i seconds and then release them Press the EXIT key to exit the menu o Advanced menu Access to all parameters setting This menu is protected by a password To enter the menu keep the OFF RESET key pressed then push in the following sequence key twice key three times and ll key four times then finally release the OFF RESET key Warning Only trained personnel should do the parameters set up Changing the Set up Values could result in equipment damage or personal injury and loss of warranty coverage Moving within the menu After entering the menu press the U or f keys to
32. e inside the fixed limits The transfer switch function will depend on the selected operating procedure Generator On Generator On signal works as the utility on signal described above The Voltages Frequencies and delay intervals are independent Utility Genset and Generator Utility Switching The remote control switches between the utility and Genset A delay time occurs to avoid simultaneous connections OPERATING MODES Note Please refer to Te804 controller instructions if you need more eU yet el el information rest NUT aan ane The digital controller has 4 different modes Reset Automatic S Manual o a Test ar kla You select the mode you need by pressing the corresponding button EE and its LED lights up Itis always possible to skip from one operating fans Ny e procedure to another C No Warning For safety reasons on controller power up the operating Mode will always be RESET When one of the four operating Mode LED s is flashing it indicates that the unit is being controlled by a supervision system remote control Te 804 REV02 10 04 04 Page 3 of 38 2 Te 804 Controller Instructions for HS and Master GU Series a pa ka aaa my E pacercceesevepensesepeecensersopnosersecoeentepernenaenesas ma
33. g inputs Pressure sensor current 20mA max Temperature sensor current 7mA max Level sensor current 10mA max Analog ground voltage 0 5V 0 5V Voltage inputs Maximum rated voltage 480VAC L L 277VAC L N Measuring range 50 620V L L 358VAC L N Frequency range 45 65Hz Measuring method True RMS Te 804 REVO2 10 04 04 Page 17 of 38 Measuring input impedance gt 1 1MQ L L 5570k2 L N Wiring mode 1 2 or 3 phases with or without neutral Current inputs Rated current le 5A Measuring range 0 02 6A Measuring method True RMS Overload capacity 20 le Overload peak 50A for 1 second Power consumption lt 0 3VA Measuring characteristics 10 45 C Voltage 1 1digit Frequency 0 2 1 digit Current 1 1 digit Power 2 1digit Energy 2 1 digit Ambient operating conditions Operating temperature 20 60 C Storage temperature 30 80 C Relative humidity lt 90 Maximum pollution degree 3 Reference standards IEC EN 60255 6 IEC 60664 1 IEC EN 61000 4 5 IEC EN 61000 4 4 IEC EN 61000 4 3 IEC EN 61000 4 6 IEC EN 60255 22 2 IEC EN 55011 IEC EN 60255 21 2 IEC EN 60068 2 6 LROS Lloyd s Register Of Shipping IEC EN 60068 2 52 RINA Italian Naval Register IEC EN 60028 2 61 and IEC EN 61010 1 3 CONNECTIONS INSTRUCTIONS HS SERIES ONLY 3 1 LO
34. generator If the auto mode is enabled the controller will transfer the load to the Utility and will start the stop cycle of the generator It is possible to program the controller so that the load will be transferred from utility to Genset even if the utility is present 2 5 AUTOMATIC TEST EXERCISE The automatic test EXERCISE is a periodic check that is carried out by the control panel at programmed intervals If the control panel is in automatic mode and the automatic test has been enabled the Genset runs for a fixed period before it stops It is possible to program the controller so that the load will be transferred from utility to Genset even if the utility is present It is also possible to program the controller in order to carry out the automatic test even if the external remote stop is activated 2 6 PERIODIC MAINTENANCE INTERVAL By means of set up a periodic maintenance interval expressed in hours is set When the working hours reach the fixed amount the display shows a message noting maintenance is required The System will not shut down and continues to work normally It is possible to reset anytime the remaining hours Command Menu This means that periodic maintenance can be carried out before the end of the fixed amount of working hours 2 7 WORKING HOUR CALCULATION As the Engine runs the working minutes are counted The calculation expressed in hours can be shown on the display The calculation continues even in
35. n period programmable at the end of which the fuel solenoid valve or the gas valve Electronic Ignition rpm governor are switched off and the engine stops In case of emergency stop the above mentioned procedure takes place without considering the cool down time Engine On The engine is considered on when the engine ON signal which comes out of the engine alternator battery charger exceeds the programmed value Its led shows the engine on signal For safety reason generator output voltage is also monitored to verify that the engine is running Alarms On Oil pressure and high temperature alarms are enabled after a delay time programmable greater than the engine on signal time The engine ON led flashing indicates the engine is on but the alarms are not enabled and becomes on steady when the engine is running and the alarms are enabled During the stopping cycle the alarms are disabled and the fuel solenoid valve close simultaneously Utility Off The utility off signal occurs when the utility voltage frequency is out of the fixed limits lower than the minimum fixed values or higher than the maximum fixed values and remains in that state longer than the programmable time This causes the transfer switch to transfer to the emergency position after the Generating set has started and met requirements Utility On In the same way the utility on signal occurs when as a programmable time is exceeded the voltage frequency ar
36. n order to obtain this connection it is necessary to proceed according to the following points Do not run the generating set before all these steps have been done Warning Internal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death Warning Always check that the Genset voltage connection corresponds to your specific requirements o Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature o It is necessary to check that cables have not loosened at the respective terminals o To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 4 3 1 GENERATOR TERMINAL BOARD CONNECTIONS GND F 5 Ee Modify internal terminal board connections as per above drawing 4 3 2 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 N L2 P0204 Nominal voltage V 240 M08 Generator Protection P0801 Nom Gen Current A See following table Amax Te 804 REV02 10 04 04 Page 33 of 38 4 3 3 With dog leg zig zag connection it is po
37. nal connections modification can only be made by trained personnel Local codes must be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements m Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature a It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained 4 2 1 GENERATOR TERMINAL BOARD CONNECTIONS 10 11 2 3 6 7 CH WY a a 1 5 9 e ee eee e Ll L2 L3 Modify internal terminal board connections as per above drawing When the System is set up for 254 440V 266 460V 277 480V it is necessary to use a standard 2 wire logic ATS 4 2 2 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 L2 L3 N P0204 Nominal voltage V 440 or 460 or 480 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 4 2 3 RATED POWER CURRENT WITH DIFFERENT VOLTAGE High wye connection Controller values
38. nimize RFI that could damage or interfere with equipment Note Due to a constant drive to improve the product through research and development all procedures specifications and equipment are subject to change without notice OPERATING PROCEDURES GENERAL e Trained personnel should do programming of the control panel e Any programming done to the control panel should be performed with the Engine off and the load disconnected e Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature e Itis necessary to check that cables have not loosened at the respective terminals and to remove any dust or other materials that have fouled the control panel during installation The cleaning must be done by means of a vacuum avoiding blowing dust into the control panel with air e Connections to the terminal board must be made using a cable of correct cross section per electric diagram e To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key e To protect from electric shocks and any atmospheric discharges it is necessary to provide adequate earthen ground TECHNICAL TERM DEFINITION Refer to the following definitions whenever these terms are mentioned in the manual Set up This is the set up of the controller
39. rammable input Press enter Scroll down to P1202 18 2 Disabled Press the button 6 times or until the Disabled changes to Remote starting Press enter this will get you into the definition of the input change NA to NO Press the Exit button 2 times All the lights will blink and the Te 804 will restart with the changes in place This has programmed the 8 2 contact to be the remote Start input The Remote start contact is 8 2 on the back of the Te 804 controller Place the system in AUTO mode When 8 2 contact is shorted to ground the unit will start and run When 8 2 is disconnected from ground the unit will shut down Auto exercise will be enabled when the unit is in the AUTO mode Te 804 REVO2 10 04 04 Page 37 of 38 5 2 How to connect the Te 804 to the no logic ATS 3 Phase ATS Interconnection diagram Z Oe mana Ha Limit 21 22 el Switch rouna if a NLS ELS L1 L2 L3 N1 N2 N3 ATS connections O Genset Connections Te 804 REVO2 10 04 04 Page 38 of 38
40. rger Other devices with maximum voltage 240V it is necessary to maintain voltage between terminals 30 and 31 of internal terminal board between 208V and 240V For this reason in case of 120 240V 1ph connection it is necessary to connect terminal 31 with terminal 1 L1 and terminal 30 with terminal 12 L2 V30 31 240V All above devices will be supply between phase phase Te 804 REV02 10 04 04 Page 23 of 38 CEL UTILITY PRESENCE RED Na S Ad 5S a ia AMP BLOCK HEateRrd FZ E BATTERY CHARGER or KI vG ad NS UTLITY sensing 11 a LACK L1 UTILITY SENSING L2 A REY L2 2 ma eee a Al BROW gies Ng AA ee bag kaa peg ny erga se Seo a pai UTILITY SENSING N x LUE UT 14 O UTILITY COM TA S i BIEMASOMA igo S BLUE UTILITY L2 ZERO START F4 BLACK UTILITY L1 BATTERY CHARGER E7 BLACK UTILITY Li As soon as you connect utility verify input voltage on above devices it must not exceed 240V 3 3 3 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 N L2 P0204 Nominal voltage V 240 M08 Generator Protection P0801 Nom Gen Current A See following table Amax 3 3 4 RATED POWER CURRENT WIT
41. rical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key 3 4 1 GENERATOR TERMINAL BOARD CONNECTIONS L1 U Modify internal terminal board connections as per above drawing 3 4 2 ELECTRICAL PANEL CONNECTIONS SEE B0172 dwg B0192 dwg In order to do not damage utility presence lamp zero start device block heater battery charger other devices with maximum voltage 240V it is necessary to maintain voltage between terminals 30 and 31 of internal terminal board between 208V and 240V For this reason in case of this connection it is necessary to connect terminal 31 with terminal 11 L1 and terminal 30 with terminal 12 L2 V30 31 240V All above devices will be supply between phase phase Te 804 REVO2 10 04 04 Page 26 of 38 LAMP UTILITY PRESENCE RED BLOCK HEATER 30 SKE ER aR Ee eee UTILITY SENSING L1 a Soa UITVEE SENSING I 12 GREY L2 UTILITY SENSING L3 ae BLUE UT Wun co 55 S
42. s The illuminated Leds of the changeover symbols indicate the actual closing of switching devices when flashing there is a incorrect feed back signal for the actual closing or opening of the switching devices 2 2 LCD SCREEN The LCD shows data and information in graphic and alphanumeric forms Press the U or fl keys to view the data pages Press the or keys to see alternative data on the same page Te804 is set to return to the main page 60 seconds after the last key was pressed 2 3 POWER UP At power up Te804 is automatically set to OFF RESET mode The option to return to the mode present prior to power down can be enabled in the program section Te 804 REVO2 10 04 04 Page 4 of 38 2 4 OPERATING MODES RESET MAN AUT and TEST RESET In reset mode the controls are not operational The engine can not operate If the utility is present the load will default to the utility When changing modes with the engine running from TEST AUT or MAN to the OFF RESET mode the engine is immediately stopped and the alarms are reset If the cause of the alarm is still present it can not be reset and will continue to be displayed on the LCD display The LCD display will continue to show measures as well as any valid alarms AUTOMATIC In the Automatic mode the Genset starts when the utility voltage goes out of limits and its respective control switch is off After the programmed delay Utility remote control switch gets s
43. ser s alarm 4 Te 804 REVO2 10 04 04 Page 16 of 38 2 19 TECHNICAL CHARACTERISTICS Power supply Battery rated voltage 12 VDC Voltage range 9 15 6 VDC Minimum voltage at the starting 6 7VDC Maximum current consumption 320mA at 12VDC Stand by current 150mA at 12VDC Micro interruption immunity 200ms Digital inputs Input type Negative Current input lt 10mA Input low voltage lt 1 5V typical 2 9V Input high voltage gt 5 3V typical 4 3V Input delay 250ms Speed input W Input type AC coupling Voltage range 5 50Vpp Frequency range 40 2000Hz Engine running input for pre excited generator D Voltage range 0 40VDC Maximum input current 12mA Maximum voltage at D terminal 12 VDC battery voltage Pre excitation current 170mA 12VDC Relay output 4 1 4 2 4 3 4 4 terminals voltage free Contact type 1 NC for utility 1 NO for generator Rated voltage 250VAC 440VAC max Rated current at 250VAC 8A AC1 2A AC15 Relay output 5 3 5 4 5 5 terminals voltage free Contact type 1 changeover Rated voltage 250VAC max Rated current at 250VAC 8A AC1 2A AC15 Relay output 6 2 6 3 6 4 6 5 terminals battery voltage output Contact type 1 NO Rated voltage 30VDC Rated current at 30VDC 5A DC1 Analo
44. ssible to obtain RATED POWER CURRENT WITH DIFFERENT VOLTAGE 240 V L2 120 Vin PO801 Amax KVA max GU26L 103 24 6 GU30J 113 27 GU42J 158 38 GU65J 254 61 GU85J 308 74 GU105J 412 99 GU125J 465 111 4 3 4 A T S CONNECTIONS Te804 controller can control an external A T S two contacts are available and connected as per following diagram E 11 Mo NI CONNECT TO 47 TERMINAL 30 As Dad Warning Voltage between 42 44 and N must be 120V In case of use of an No Logic A T S it is necessary to consider Terminal 42 UTILITY ON has to be connected to terminal 30 of ATS Terminal 44 GENSET ON has to be connected to terminal 32 of ATS 4 3 5 VOLTAGE ADJUSTMENT Carefully start the generating set and CONNECT TO 44 e TERMINAL 32 OF ATIS 1 Check ph ph and ph N voltage values between phases neutral has not to be different max difference 2 2 Quickly adjust output voltage on VOLT potentiometer on generator A V R 3 If output voltage is not inside preset limits before the preset time expires you will get an alarm Te 804 REVO2 10 04 04 Page 34 of 38 4 4 HIGH DELTA CONNECTIONS 240V 3ph 120 240V 1ph In order to obtain this connection it is necessary to proceed according
45. t be followed in order to avoid equipment damage and or personal injury up to and including death m Warning Always check that the Genset voltage connection corresponds to your specific requirements m Electrical connections must be carried out in compliance with local codes AC cables particularly must be sized and placed so that the cable does not attain temperatures over 50 C Ambient temperature m It is necessary to check that cables have not loosened at the respective terminals m To open the control panel front door use the special key supplied with the control panel Only trained personnel should have access to this key Te 804 REVO2 10 04 04 Page 20 of 38 3 2 1 GENERATOR TERMINAL BOARD CONNECTIONS L1 U 1 Bo Modify internal terminal board connections as per above drawing 3 2 2 ELECTRICAL PANEL CONNECTIONS SEE B0172 dwg B0192 dwg In order to do not damage utility presence lamp zero start device block heater battery charger other devices with maximum voltage 240V it is necessary to maintain voltage between terminals 30 and 31 of internal terminal board between 208V and 240V For this reason in case of 240 416V it is necessary to connect terminal 30 with terminal 14 V35 31 240V All above devices will be supply between phase neutral in case of 254 440V 266 460V 277 480V it is necessary to connect a suitable step down transformer transformer rated po
46. t is necessary to maintain voltage between terminals 30 and 31 of internal terminal board between 208V and 240V For this reason in case of 120 208V connection it is necessary to connect terminal 31 with terminal 11 L1 and terminal 30 with terminal 12 L2 V39 31 208V All above devices will be supply between phase phase UTILITY PRESENCE RED J LAMP BLOCK HEATER 90 S BATTERY CHARGER l a ET O ki JTILITY SENSING 11 4 44 25A LACK CEL aL JTILITY SENSING L2 H 17 GREK UTILITY SENSING L3 13 5A BROWN L3 umm sensro Y 14 ea As soon as you connect utility BE verify input voltage on above mun COM 75 S PATOL devices it must not exceed ZERO START F TOPAS 240V F4 5A BLACK UTILITY L1 BATTERY HARBER F3 SA f BLACK UTILITY L1 13 1 3 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 L2 L3 N P0204 Nominal voltage V 208 or 220 M08 Generator Protection P0801 Nom Gen Current A See following table Amax Te 804 REV02 10 04 04 Page 19 of 38 3 1 3 RATED POWER CURRENT WITH DIFFERENT VOLTAGE With low wye connection it is possible to obtain Voltage HSD 22 HSG 20 LPG Vit Vin Amax
47. tc concerning a certain application 2 12 RECOMMENDATIONS ABOUT SET UP Safety copy of set up data It is highly recommended to save the set up data on the PC hard disk and make a safety copy on floppy disk because of the large amounts of data involved with Te804 set up Moreover it is advisable to update set up data files each time data parameters are adjusted via keyboard Bear in mind that a safety copy of adjustable keyboard set up data can only be made in Te804 flash memory This same data can be restored whenever required to Te804 work memory The commands of safety copy and data restore are available in the commands menu 2 13 DIGITAL PROGRAMMABLE INPUTS AND OUTPUTS All the outputs and a part of the inputs are assigned set to specific functions depending on specific application See the table in the following pages To change the function assignment enter INPUTS or OUTPUTS menu press the U or i keys to select the exact input or output and press or keys to select the function The following properties can be assigned to each input Q NO Normally Open command at the input contact closing or NC Normally closed command at the input contact opening Q Delay before the contact closes o Delay before the contact opens To set these properties enter the INPUTS menu press the J or fl key to select the exact input press the ENTER key to access the parameter properties press the U or
48. uit X X X X X Xx X A31 Generator overload X X X X X X Xx X A32 External generator protection tripping X X X X X X X X A33 Incorrect generator phase sequence X X X X X X X A34 Incorrect utility phase sequence X A35 Wrong system frequency setting Xx A36 Generator contactor failure X X X X X A37 Utility contactor failure X X X X X A38 Maintenance requested X X X X X A39 System error X A40 Fuel transfer too empty X X A41 Fuel transfer too full X X A42 Rent hours exhausted X X UA1 User s alarm 1 UA2 User s alarm 2 Dirty air filter X X X X X X UA3 User s alarm 3 UA4 User s alarm 4 Te 804 REVO2 10 04 04 Page 15 of 38 2 18 s e NE 4 3 0v ja 5 5 Pa Alarm properties gt E 5 3 E 3 3 5 5 o i E 5 pa 2 e Joel List of the alarms for GU 5 s 3 S gt 5 55 3 lt x pl O D LI wu lt 3 2 A01 Engine temperature warning analog sensor X X X X Xx A02 High engine temperature analog sensor X X X X X Xx X A03 Temperature analog sensor fault X X X X A04 High engine temperature digital sensor X X X X X X Xx A05 Oil pressure warning analog sensor X X X Xx X A06 Low oil pressure analog sensor X X X X X X Xx A07 Pressure analog sensor fault X X X X X A08 Low oil pressure digital sensor X X X X X X X A09 Pressure digital
49. ure limit 230 230 40 285 P0508 MIN fuel warning 20 20 0 100 P0509 MIN fuel level 10 10 0 100 P0510 Alarms inhibition at starting s 8 8 1 30 P0511 MAX W speed limit 96 110 110 100 120 P0512 MAX W speed delay s 3 3 3 20 P0513 MIN W speed limit 96 90 90 80 100 P0514 MIN W speed delay s 5 5 0 600 06 MAINS CONTROL Default HS Default GU Range P0601 MIN voltage limit 90 90 70 100 P0602 MIN voltage delay s 5 5 0 600 P0603 MAX voltage limit 110 110 100 120 P0604 MAX voltage delay s 5 5 0 600 P0605 MAINS into limits delay s 10 10 1 600 P0606 MIN MAX hysteresis limits 3 0 3 0 0 0 5 0 P0607 MAX asymmetry limit 15 15 5 20 P0608 MAX asymmetry delay s 5 5 0 600 P0609 MAX frequency limit 103 103 100 120 OFF P0610 MIN frequency limit 26 97 97 OFF 80 100 P0611 MIN MAX frequency delay s 5 5 0 600 P0612 MAINS control INTERNAL INTERNAL OFF INT EXT OFF internal external P0613 MAINS control in RESET OFF OFF OFF OFF ON OFF GLOB ON GLOB mode P0614 MAINS control in MAN mode OFF OFF OFF ON OFF GLOB ON GLOB Te 804 REVO2 10 04 04 Note The phase sequence control can be enabled by means of the alarm properties table menu 07 GEN CONTROL Default HS Default GU Range P0701 MIN voltage limit 90 90 70 100 P0702 MIN voltage delay s 5 5 0 600 P0703 MAX voltage limit 96 110 110 100 120 P0704 MAX voltage delay
50. wer Minimum 1 2kVA UTILITY PRESENCE RED UTILITY PRESENCE RED 30 S 30 LAMP BLOCK HEATER JATTERY CHARGER 7 AS Ok 31 Op f a BLACK L1 UTILITY HACK L1 UTILITY SENSING L1 4 25A eee ue 1 25A B ACRL np F GREY L2 UTILITY SENSING L2 2 UTILITY SENSING L2 12 BY 12 Ii 2 12 EY L2 P ROWN L3 UTILITY SENSING L3 ROWN L3 UTILITY SENSING L3 13 BROWN L TILT L3 1 BROWN L z LUE UT UTILITY SENSING N 2 3LUE UT UTILITY SENSING N 4 O BLUE UT JTILITY SENSING N 4 O BLUE UT BE BE UTILITY COM 5 UTILITY COM 7 x NUUR OM Tag S 3LUE UTILITY N re 136 O 3LUE EERO START FEA 5A k BACK UTILITY L1 F4 BLCK JA tY CHARGER aes s Fs SATTERY CHARGER oe a BATTERY CHARGERS E sa k BLACK UTILITY L1 BATTERY CHARGER lite sa k BLACK As soon as you connect utility verify input voltage on above devices it must not exceed 240V Te 804 REVO2 10 04 04 Page 21 of 38 3 2 3 CONTROLLER SETUP Following parameters have to be adjusted verified on controller set up Menu Parameter Adjust to M02 General P0203 Wiring configuration L1 L2 L3 N P0204 Nominal voltage V 44
51. witched off and the Genset start cycle begins When the Genset is running and its voltage frequency are within the programmed limits the Genset remote control switch closes The Genset will continue operating until the utility voltage is restored Once the utilities are within programmed limits for the programmed time the remote control switches exchange position and the Genset carries out the stop cycle When the Genset is running however it can always be stopped by means of the RESET or STOP buttons In automatic procedure both the remote start and stop are enabled MANUAL The engine can be manually started or stopped using the START and STOP keys The ATS can only be switched by holding down on the Manual key and then pressing the MAINS or the GEN keys Keeping the key pressed for an extended time can prolong the preset starting time Keeping the Stop key pressed for more than 6 seconds will result in the fuel valve being disabled for 4 minutes The start button begins the start cycle while the stop button begins the stop cycle After pushing the stop button you can stop it from beginning the stop cycle by immediately pushing the start button TEST In test mode the Genset begins the start cycle even if the utility is present If the Utility power drops out while the Genset is in test mode the controller will over ride this function and switch the Generator to the load Once the Utility voltage returns the load will stay on the

User manual AMF controller TE

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