Amf Controller
Amf Controller
Index
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
Introduction
Protection, Supervision Salient features
Measurement & Display
Annunciations
Contacts
Timers
Switches Description
Setting Procedure
Annunciations Description
Lamp Test
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 Model Selection
16.0 Terminal description
17.0 Specifications
Cat_DGC11-09-05-Ver1.3
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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)
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
Unit.
Backlit LCD Display for easy reading
and parameter settings
Fully operational up to 4V. Can
withstand a voltage dip up to 0V for
1sec.
23 LED Indication..
Cat_DGC11-09-05-Ver1.3
RPM
Fuel Level, HWT and LLOP
KWh of generator
KW and PF of generator
Service Hour Due
Fault History
Programmed settings
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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
DGC-11 is equipped with the following annunciations for system status and faults
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 (NO)
Hooter (NO)
Choke (NO).
6.0 Timers
DGC-11 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 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 supervision time (variable)
LLOP supervision time (variable)
HWT 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)
Hooter Reset Time(variable)
DGC-11 has 12 switched are provided on its front panel. The table below describes the operation of
these.
S.No.
1
Switch Symbol
Switch Function
Next
Increment
Decrement
Reset
&
6
7
8
START
STOP
MCB
GCB
10
11
12
13
Auto
Man.
Test
Off
Programming
/History Fault
Mode Entry
Description
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.
This key is only active during Programming
Mode and is used to increment the value of the
parameters under programming.
This key is only active during programming
mode and is used to decrement the value of the
parameter under programming.
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.
If both the keys are pressed simultaneously the
unit will enter in Programming Mode/History
Fault/Service Hours
To start Generator in Manual Mode.
To stop Generator in Manual Mode.
In Manual Mode this toggles the mains
contactor, On/Off
In Manual Mode this toggles the generator
contactor, On/Off
To select Auto Mode.
To select Manual Mode.
To select Test Mode.
To select Off Mode.
Auto, Man., Test & Off are Radio buttons and only one can be active at a time.
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DGC-11 has 23 annunciations on its front panel. These either announce the faults or indicated the
status of the system.
S.
No.
1
2
Nomenclature
Description
Fail Start
Fail stop
3
4
5
6
7
8
9
10
11
Emergency
LLOP
HWT
Fuel
Service Due
DG Freq
DG Voltage
Over Speed
ChgAlt/V-Belt
12
Battery
13
14
15
16
17
18
19
20
Over load
RWL
Ph Seq
Mains
MCB
GCB
Generator
Auto
21
22
23
Man.
Test
Off
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 DGC-11 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 DGC-11
shall start functioning normally.
11.0
Operating Mode
DGC-11 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
DGC-11 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, DGC-11 releases the MCB contactor (to protect the
contactor from failure because of low input voltage) and attempts to starts the generator.
DGC-11 gives cranks the engine by activating the inbuilt, potential free, crank contact.
Crank command is withdrawn if the engine start is detected, either by external engine start
input or by build up of generator voltage. Max duration of crank command is user settable.
Cat_DGC11-09-05-Ver1.3
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In case of non start of the engine DGC-11 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 DGC-11 monitors it for external fault (Digital Inputs:
Emergency, V-Belt, RWL) 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.
11.2
Manual Mode
DGC-11, 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 DGC-11 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. DGC-11 protects the generator by monitoring all
internal and external faults.
11.5
This mode can be selected by pulling the pin 37 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 31. Once the start
signal is given the unit now functions like auto mode with 3 crank attempts.
Cat_DGC11-09-05-Ver1.3
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12.0
Programming mode
12.1
Parameter Mode
S.No
Parameter
name on first
row of LCD
Explanation of parameter
Factory
setting
Setting Range
Mains O/V
270V
80-300V
Mains U/V
180V
80-270V
Mains Sup
Delay
10Sec
1-999Sec
Mains O/F
55Hz
40-65Hz
Mains U/F
45Hz
40-65Hz
Mains Freq
Delay
10Sec
1-999 Sec.
Mains Vol
Unbal
Disable*
10-100 Disable*
8
9
Mains Ph Seq
Phase Seq
Delay
OFF
10Sec
ON/OFF
1-999Sec
10
Unbalance
Delay
10Sec
1-999Sec
11
Disable*
1-999
Cat_DGC11-09-05-Ver1.3
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12
13
Generator O/V
14
Generator U/V
15
16
Generator O/F
17
Generator U/F
18
19
Generator O/S
20
21
22
Choke Post
Time
23
No Of Crank
Cat_DGC11-09-05-Ver1.3
Sec
Sec-Min
270V
80-270V
180V
80-270V
30Sec
1-999Sec
55Hz
40-65Hz
Disable*
45Hz
40-65Hz
Disable*
10Sec
1-999 Sec.
65Hz
40-80Hz
Disable*
2 Sec
1-999Sec
Disable
1-100Sec
Disable*
1-100Sec
Disable*
Disable
0-10
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24
25
Crank Time
Crank Delay
26
27
Warm Up Time
28
Mains Rest
Delay
29
Gen Recool
Time
30
Stop Sol On
Time
31
Gen Over
Current
32
33
Mains
O/Current
34
Mains O/C
Delay
35
CT Ratio
36
V-Belt/Alt
Delay
Cat_DGC11-09-05-Ver1.3
Engine
Maximum crank time
The delay between two successive
cranks
This parameter specifies the
generator voltage at which the is
presumed to have started and crank
has to be terminated
Generator warm up time. The load
is transferred to generator after
expiry of this time
Mains restoration Delay:
The time for which Mains should
be continuously healthy before
stopping the Generator.
The time for which generator is
allowed to run on no load before
switching off
The time for which stop solenoid
will be kept active while stopping
the engine
The current above which the over
current fault monitoring has to
start. The timer for it is as
described in 32. This fault is only
enabled while the generator is
running. On expiry of the timer the
generator is stopped
Duration for which the external or
internal over current (for models
which have internal current
measurement) be recognized as a
fault and action initiated. This fault
is only enabled while the generator
is running.
The current above which the over
current fault monitoring has to
start. The timer for it is as
described in 34.. 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
Duration for which the external or
internal over current (for models
which have internal current
measurement) be recognized as a
fault and action initiated.
Current Transformer ratio
Available only in /5 CTs model.
Not available in models with
Procom Make CTs
Duration for which the V-Belt
signal should be continuously
active to be recognized as a fault
and action initiated. This fault is
5Sec
5Sec
0-25 sec
0-100Sec
100V
70-150V
0Sec
1-999Sec
30Sec
1-999Sec
30Sec
1-999Sec
30Sec
1-999Sec
6Amps
for /5
40Amps
for
Procom
Make Cts
1-999Amps
2Sec
1-999Sec
6Amps
for /5
40Amps
for
Procom
Make Cts
1-999Amps
2Sec
1-999Sec
10
1-199
2Sec
0-999
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1-5 Sec
0-999Sec
10-40V
Disable*
10-40V
Disable*
10-999Min
10-999Min
1-999 Hrs
ON
1-999 Sec
10-100%
1-999Sec
0-8.5 Kg /Cm2
51
HWT delay
5 Sec
1-999 Sec
0-150
Degree
centigrade
1-999 Sec
52
Sensor Type
Cat_DGC11-09-05-Ver1.3
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be customized
5 Sec
5 Sec
5 Sec
1-999Sec
1-999 Sec
1-999 Sec
13.0
Faults
13.1
o
o
o
o
o
o
o
13.2
o
o
o
o
o
o
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:
LLOP
HWT
Canopy Temperature
Fuel
Emergency
Over Current (External)
V-Belt
13.3
o
Internal Faults
Internal faults are the faults, which do not need any external signals and are detected by
the system itself. They are:
Generator Fails to Start.
Generator Voltage Unhealthy
Generator Frequency Unhealthy.
Generator Over Speed.
Generator Fails to Stop.
Over Current
Battery Under or Over voltage (Warning only).
Fault Reset
Internal Faults & LLOP fault: All internal faults and LLOP fault can be reset by pressing
(R) switch after the generator is stopped.
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
o
Cat_DGC11-09-05-Ver1.3
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14.0
Communication
Half Duplex, RS232 or RS485 communication running in slave mode: The communication can be
used for the following:
Programming the parameters
Reading instantaneous parameters
Reading system conditions
Reading fault status.
15.0
Model Selection
15.1 With provision for sensor for LLOP, HWT & Fuel
15.2 Without these Sensors
Cat_DGC11-09-05-Ver1.3
Description
Mains R Phase Voltage
Mains Y Phase Voltage
Mains B Phase Voltage
Mains Neutral
Generator R Phase Voltage
Generator Y Phase Voltage
Generator B Phase Voltage
Generator Neutral
R Phase Current
Y Phase Current
B Phase Current
Sensor Fuel
Sensor Temperature
Sensor LLOP
Not Connected
Auxiliary supply +ve
Auxiliary supply -ve
Mains Circuit Breaker
Generator Circuit Breaker
Crank
Fuel Sol
Hooter
Choke
Common for hooter, fuel & Choke
Remote
LLOP Switch
HWT Switch
Fuel Switch
Emergency
RWL Switch
Auto/Semi Auto Mode
V-Belt/Charging Alternator
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17.0
Specifications
AC voltage withstand
Measurement Accuracy
Voltages & Current
Power & Energies
Surge 1.2/50Usec
Battery Voltage
Min. voltage to power on
Min Running Voltage after
Power on
Max. Battery Voltage
DC Interruption time
Contact(MCB)
Contact(GCB)
Contact(Hooter)
Contact(Fuel)
Contact(Crank)
Contact Choke
4V
35V
1 Sec.
NC, 230V / 6A
NO, 230V / 6A
NO, 230V / 6A
NO, 230V / 6A
NO, 230V / 6A
NO, 230V / 6A
186mm X 90mm
120mm
Battery Voltage (Negative)
1% of Measurement
2%
2.5KV
Suitable for 12V/24 VDC System
9V
It is our endeavour to constantly upgrade our products, hence specifications are subject to change without any
notice.
Cat_DGC11-09-05-Ver1.3
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