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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. Page 2/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 3/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 4/17
• 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)
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 5/17
• 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.
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 6/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 7/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 8/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 9/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 10/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 11/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 12/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 13/17
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
the mentioned condition is fulfilled 00 00-12
4 DG Not
Running
Switch on the assigned contact if
the mentioned condition is fulfilled 00 00-12
5 Fail to Start Switch on the assigned contact if
the mentioned condition is fulfilled 00 00-12
6 Fail to Stop Switch on the assigned contact if
the mentioned condition is fulfilled 00 00-12
7 LLOP Fault Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
8 HCT/HWT
Fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
9 Low Fuel Switch on the assigned contact if
the mentioned condition is
fullfilled
01 00-12
10 DG Voltage
fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
02 00-12
11 DG Frequency
Fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
03 00-12
12 DG Overspeed Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
13 DG O/L Fault Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
14 V belt/ Alt
Fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
15 Mains O/L
Fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
16 Mains Phase
Sequence Fault
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
17 Mains Vol
Unbal
Switch on the assigned contact if
the mentioned condition is fulfilled 00 00-12
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 14/17
18 RWL Fault Switch on the assigned contact if
the mentioned condition is
fullfilled
04 00-12
19 Battery
Unhealthy
Switch on the assigned contact if
the mentioned condition is
fullfilled
05 00-12
20 Service Due Switch on the assigned contact if
the mentioned condition is
fullfilled
06 00-12
21 BTS1 Voltage
Low
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
22 BTS2 Voltage
Low
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
23 Room Temp.
High
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
24 User Defined
Fault1
Switch on the assigned contact if
the mentioned condition is
fullfilled
00 00-12
25 User Defined
Fault1
Switch on the assigned contact if
the mentioned condition is
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.
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 15/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 16/17
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
AC3 Automatic Controller: 3 Phase
Cat_AC3-12-09-Ver1.0. Page 17/17
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.