SUPPLEMENT ACP

AUTOMATIC CONTROL PANEL

Overview

The Automatic/Manual Control Panel model is installed within

the generating-set fully integrated and connected to the
machine.

The panel includes a micro-processor compact control board

model PRAMAC AC03, which embeds the logic devices to
control the generator in either automatic start mode (mains-
failure detection or by external contact) or manual-operation.

ACP panel is installed on the side of alternator, its metal

structure is built in galvanized steel plates and coated with a
high-resistance epoxy layer guaranteeing the highest degree
of protection against atmospheric agents. The control card
AC03 is located on the panel’s door close to the emergency-
stop button.

Main components:

Control Board AC03

Automatic battery static-charger

Emergency-stop push button

Plinth-row for auxiliary devices connection.

1. Control Unit AC03

1.1 System description

The automatic control board AC03 enables either the genset manual start/stop with direct control from
the operator or the automatic operation by direct sensing of mains failure or by remote start.

By selecting the manual operation mode, through the proper switch, the Start (I) Stop (O) buttons are
activated and local generator control is enabled.
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When the operation selector switch is set on Automatic, the mains failure detection system is
activated and the Generating-Set is automatically started if mains voltage gets out of preset
thresholds. Once nominal operating conditions of the generating-set are reached, the electronic
control unit switches the change-over switchgear in order to power the load.

As the mains voltage is restored and stabilized, after a pre-settable time, the AC03 switch loads from
Generator to the mains and after a cooling delay stops the generating-set.

The control board AC03 is provided with RS232C (Serial) communication-port to be interfaced with PC
or Laptop for remote control monitoring through wire or modem.

1.2 Functions

By the use of function keys in front of AC03 it’s possible to select one of the following modes:

OFF/RESET

The generator is inhibited from operations. If this option is selected when the generating-set is running,
the sop-sequence is activated and the switchgear panel is forced on mains supply position.

PROGRAM

The AC03 board is provided with all parameter pre-set on default values. Those can be modified
through a 2-level access protection with password (1st password for the installer, 2nd password for the
operator).

MANUAL

This functioning mode permits the manual start and stop of the generating-set through the local
operation push buttons.

AUTOMATIC

Selecting this operation mode, the AC03 control panel enables the mains failure detection device with
automatic start of the generating set in case of anomalies on the grid power supply. The generation
starting sequence involves a cycle of starting attempts and resting-time pre-set on the control board.
As the generating-set is successfully started, the signal to switch the power supply from mains to
generator is sent to the changeover-panel. The status of the engine and generator is continuously
monitored by the AC03 control-board during the running time of the generating-set. In case of
malfunction, an alarm will sound and a warning message will appear on the LCD screen of the control
board and, if necessary, the machine will be disconnected and stop-sequence will initiate.

TEST

This function, exercises the machine for periodic testing, when the generating-set is in mains-standby.
All protections are activated and the generating-set runs without supplying the load. The
mains/generator changeover switchgear is forced to keep the supply load from the Mains.

1.3 Control buttons

Function keys to select Off/Reset/Program – Manual – Automatic-Test

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Gen-set Start

Gen-set Stop

Changeover Switchgear manual management

Buzzer silencing button

Up scroll button

Down scroll button

1.4 Control card AC03 auxiliary services

The control panel includes:

Acoustic-alarm (buzzer)

Exerciser – Programmable periodic test of the machine

Visualization of generating-set operating parameters

Earth Fault protection 1 – 40 A (protection of the machine)

Automatic fuel transfer pump management with re-fueling forcing operation (Fuel Pump kit
available as a supplement)

Display language selection (English, Italian, French, Spanish, German, Portuguese)

Remote Start from VFC availability.

Tele-management

Historical event log

1.5 Measurements

 Generator Voltage: L1/L2 – L2/L3 – L3/L1

 Mains Voltage: L1/L2 – L2/L3 – L3/L1
 Generator current: I1 – I2 – I3
 Generator frequency-meter (Hz)
 Generator speed-meter (rpm)
 Fuel level (%)
 Battery voltage (V)
 Engine oil pressure (Pa) (not available for Perkins engines) Engine
 coolant temperature (°C) (not available for Perkins engines)

1.6 Calculated values

 Active Power (kW)

 Reactive Power (kVAr)
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 Apparent Power (kVA)

 Power Factor
 Energy-meter (kWh)
 Start-attempt counter
 Running-hours meter (1 off engine, 1 off control board)
 Running-Hours counter (for either servicing intervals or gen-set rental)

1.7 Visual signaling and protections

The AC03 control unit, by using display and led, shows visual status signalization and protections:

STATUS

 Mains presence
 Generator ON
 Mains contactor closed
 Gen-set contactor closed
 Engine running

ALARMS (w/o shutdown)

 Starting battery failure

 Pre-alarm low engine oil pressure
 Pre-alarm high engine water temperature
 Pre-alarm low fuel level

ALARMS (with shutdown)

 High engine water temperature

 Low engine oil pressure
 Over-speed
 Engine crank-cycle failure
 Battery charger failure
 Overload
 No fuel
 Emergency stop activated

ALARMS DISPLAYED

 Engine belt failure

 Overload and short circuit (electronic protections)
 Nominal operating condition not reached
 Generator under-voltage
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 Generator Over-Voltage
 Generator Under-Frequency
 Generator Over-Frequency
 Maximum Power
 Reverse Power
 Changeover switchgear failure
 Gen-set stop failure

All alarms that lead to complete shutdown of the generating-set are stored in the control board. Only
the manual reset of the control panel can restore the normal operation.

1.8 Remote managements system

The control card AC03 is provided with RS232 communication port suitable for remote management
by PC. Connection to PC or laptop can be achieved through wire (10 m maximum length)

2. Automatic battery static charger

2.1 Technical features

The CB is based on “Switching technology” and “Battery Care philosophy” completely automatic and
suited to meet the most advanced requirements of battery manufacturers. The Battery Care concept is
based on algorithms that implement rapid and automatic charging, battery charge optimization during
time, flat batteries recovery and real time diagnostic during installation and operation. The Real Time
Auto-diagnostic system, monitoring battery faults such as, elements in short circuit, accidental reverse
polarity connection, disconnection of the battery, they can easily be detected and removed by help of
Blink Code of Diagnosis Led; during the installation and after sell. Each device is suited for all battery
types, by means of jumpers it is possible setting predefined curves for Open Lead Acid, Sealed Lead
Acid, Gel. They are programmed for two charging levels, boost and trickle. A rugged casing with
bracket for DIN rail mounting provide IP20 protection degree.
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General Data
Insulation voltage (In /Out) 3000 Vac
Insulation voltage (In / PE) 1605 Vac
Insulation voltage (Out / PE) 500 Vac
Protection Class (EN/IEC 60529) IP20
Protection class I, with PE connected
Reliability: MTBF IEC 61709 > 300.000 h
Pollution Degree Environment 2
Connection Terminal Blocks screw Type 2,5mm (24–14AWG)
Dimensions (w-h-d) 100x115x135 mm
Weight 0.85 Kg approx
Input Data
Nominal Input Voltage 115 / 230 – 277
Input Voltage range 90 – 135 / 180 - 305
Frequency 47 – 63 Hz ±6%
Charging. Max Ibatt (In) 10 A ±5%
Boost charge (25 °C) 28.8 Vdc
Max. time Bust Charge (tpy. At In) 15 h
Min. time Bust Charge (tpy. At In) 1 min.
Trickle charge (25 °C) 27.5 Vdc
Recovery Charge 2 – 18 Vdc

3. Engine/alternator connection

All connections on ACP panel to engine/alternator are made by using multipolar connectors for fast
assembly/disassembly in order to facilitate maintenance works.

4. Auxiliary services

The Automatic/Manual Control Panel includes dedicated terminals for auxiliaries supply that is in
charge to the end users. All of each auxiliary supply inside the panel is protected by fuse, while it’s not
included any protection on power supply.