COLOGICX PROTOGEN EGCP-03 User manual

COLOGICX SYSTEMS PVT LTD
2nd Floor, 35, Electronic Co-Op Estate,
Pune-Satara Road, Pune 411 009, India
Tel: [phone]
Web: www.cologicx.com
Email: [email protected]
User’s Manual
PROTOGEN (EGCP-03)

[2]
1.1
Introduction
03
1.1
Features
03
1.2
Operation
03
Auto Mode
03
Manual Mode
04
Display Scanning Feature
04
Program Mode
04-05
1.3
Description of Programming Parameters
06-09
1.4
LED Indications
10
1.5
Display-Table of Messages Displayed
11
1.6
Fault Handling Procedure
12
1.7
Clearing the Alarm
13
1.8
General Characteristics
13
1.9
“EGCP-03”- Details of Electrical Connection
13
2.0
Electrical connection Diagram
14
2.1
Special Note
15
2.2
Connection Details.
15-16
TABLE OF CONTENTS

[3]
1.0 INTRODUCTION
EGCP-03 is a 3-phase Automatic/Manual Generator Controller module that includes protection for GEN-SETS. Use
of advanced micro controller in the design platform provides easy and trouble free control and operation mechanism
of GEN-SETS in case of failure of mains power. Upon failure of mains power (due to faults like loss of power, over
voltage, under voltage, phase reversal, phase unbalance etc.), EGCP-03 initiates Start Cycle including transfer of load
to GEN-SET by using the Generator contactor. When the mains power gets restored, the load gets automatically
transferred back to the mains and the GEN-SET stops after a cool-down time. During runtime, the GEN-SET is
protected against malfunction. All alarms occurring at abnormal GEN-SET conditions are computed and displayed
either via LED or on the LCD through alphanumeric messages.
Values of over/under voltage, frequency and overload current, cooling-down time are programmable. EGCP-03
provides Forty-five programmable parameters to suit customer’s needs.
1.1. FEATURES
45 Programmable Parameters, Programmable Site Code
Programmable Current Transformer Ratio
Display of 3 Phase Generator voltage, 3 Phase Mains voltage, 3 Phase Load Current
Frequency and RPM, 11 Digital Inputs, 12 Digital Outputs
Outputs for Mains and Generator contactor
KWH for Mains and DG Set, Power Factor of R, Y, B Phases,
99 Fault Log Data & DG start-stop events, DG Battery Voltage monitoring
Remote Monitoring of parameters RS232 on request
Three Phase OR Single Phase selection (3 Phase EB/3Phase OR 3 Phase EB/1 Phase DG)
1.2 OPERATION
EGCP-03 has two basic operating modes, namely AUTO and MANUAL mode. In AUTO mode, EGCP-03 controls the
GEN-SET automatically according to the parameter settings. Two push buttons (“START” and “STOP”) have been
provided to operate the engine manually (MANUAL mode).
AUTO MODE:
To enter into the AUTO mode Switch ON the Auto/Manual Switch of the Control Panel to “AUTO” Position. “AUTO
MODE OPERATION.” message will be displayed on the LCD.
Mains Fail:
When mains power fail due to any fault in the system, EGCP-03initiates an auto-start sequence to start the
GEN-SET. After successful start of the GEN-SET, the load is transferred from mains to EGCP-03automatically.
However, in case of phase reversal, “Phase Reverse Message” appears on the LCD for corrective action.
Starting Sequence: -
Crank will be given to the Generator. The LCD will display “DG START MODE….” message.
If the Generator starts within the number of attempts set in the program (programming parameter no.8), the load will get
shifted to the Generator. If the Generator does not start within the programmed number of attempts, “FAIL TO
START” message will be displayed for corrective action.
Restoration of Load to Mains Power:
When mains supply returns to normal condition, EGCP-03 will transfer the load automatically from generator
to mains after “mains restore time” (programming parameter no.4), through the mains contactor. The generator cool-
down time will start thereafter. During the cool-down period the generator will run without load.

[4]
MANUAL MODE:
The EGCP-03unit is by default in MANUAL mode when power is ON. To enter MANUAL mode, switch on the
“Auto/Manual Switch” of the Control Panel to MANUAL position.
“MANUAL MODE OPERAT.” message will be displayed on the LCD.
In MANUAL mode, the GEN-SET can be started and stopped by means of two push buttons “START” and “STOP” on
the front panel. The start/stop sequence relates to the parameter settings.
For Starting Sequence: Refer Parameter No.: 3, 7, 8, 9, and 11
For Stop Sequence: Refer Parameter No.: 6, 10
DISPLAY SCANNING FEATURE:
This mode is automatically activated after 5 minutes if no operation is performed on the keys of the front panel. In this
mode, all the parameters get scanned and are displayed continuously in any key is pressed.
PROGRAM MODE:
To enter in the mode option, Press the “HORN” key
EGCP-03LCD display shows following menu options
“PROGRAM” mode and “CALIBRATION” mode
To Enter in Program Mode Option:
Set the courser pointer with the help of Up &
Down arrow Key in front of PROGRAM option. UP DOWN
Then press ENTER key.
EGCP-03LCD display shows following menu options
To Enter in Set Date/Time Menu Option:
To exit from this Menu option press ESC key
For escape/exit from the option press ESC key
Set the cursor pointer with aid of Up & Down Key in front of Set Date / Time.
Then press ENTER key.
The “SET DATE” is displayed and next line shows the intended date.
To change the date “DD-MM-YY”, move the cursor on particular digit with the help of ENTER KEY. Selected digit
will start blinking. The digit can be changed with the UP/ DOWN keys and move to the next digit by pressing ENTER
key.
To save the changed values press ENTER key. It will automatically go in next option i.e. “SET TIME” option.
The time can be set in the same manner. EGCP-03LCD Display shows present time (For e.g.
“13: 16: 53”). Move the cursor may be moved to on particular digit with the help of ENTER KEY. Selected digit
will start blinking. The value of digit value can be changed with the UP/ DOWN keys. For changing the next digit,
press ENTER key and repeat the operation.
To save the changed values press ENTER key. It will automatically exit from option i.e. “SET DATE/TIME”
option.
SET DATE
16-06-15
Set Date/ Time
Fault / Data log
Set Parameters

[5]
To Enter Fault/ Data Log Menu display shows following menu options
Set the cursor with the help of “UP and DOWN” arrow key
in front of “Fault/ Data Log” menu.
Press ENTER key. LCD display will show following Sub menu options
DG Log Data:
To Enter in DG Log Data, set the cursor with “UP and DOWN” key Press Enter Key. In this mode LCD shows DG
“START and STOP” events with Date and Time. To exit from DG Log Data press ESC key.
Fault Log Data:
To Enter In Fault Log Data, set the cursor with ”UP and DOWN” key in front of Fault Log Data.
Press the Enter Key.
In this Mode LCD shows all fault events with their name, Date & Time.
To exit from DG Log Data press ESC key.
KWH Log Register:
To Enter KWH log register, set the cursor with “UP and DOWN” key in front of KWH log register.
Press Enter Key, display shows Mains KWH and DG KWH.
To enter Mains KWH set cursor in front of Mains KWH, then press the Enter key, Display shows Date &
Mains KWH.
To exit from DG Log Data press ESC key.
To Enter “Set Parameters” Menu:
Set the cursor with UP and DOWN” key in front of “Set Parameter”.
Press ENTER key.
LCD display shows:
To set the “1000” password press UP key, the display shows
1000 message on the display and “1”digit is blinking
Press “ENTER” key one time-now next digit will blink. & enter 3 time to set the ‘000’
Select next digit by pressing ENTER key and increase or reduce digit value by pressing UP/DOWN keys.
When LCD display shows “1000”. Press ENTER key. If the Password is incorrect, EGCP-03will display
message “INVALID PASSWORD”
In set parameter Menu there are 41 parameters for setting.
LCD display shows Following Message
Press “START” and “HORN” key to increase or decreas
Respectively the parameter nos.
To change the significant value first select digit by ENTER key and
Then press “UP” key to increase and “DOWN” key to decrease.
Value of parameter is saved only by pressing the ENTER key. After that it automatically increases the
parameter number. For e.g. if 172 is required to be set, instead of 170, press ENTER key 3 times. Last digit
“1” would start blinking. Change the value to “2” by pressing UP key. Save this value by pressing the ENTER
key.
Next Parameter will be displayed on LCD.
To exit from Option press ESC key.
DG Log Data
Fault Log Data
KWH Log Register
Set Date/ Time
Fault / Data log
Set Parameters
Parameter = 1
Mains Low voltage
Range 90-210 Volt
170

[6]
1.3 DISCRIPTION OF PROGRAMING PARAMETERS
Para.
No.
Parameters
Explanation of Parameters
Setting
Range
Default
Setting
1.
Mains Low Voltage
It is the minimum voltage less than or equal to (e.g.
170V), which mains fault will occur and “EB Low volt
fault” will be displayed on LCD. This parameter can
accept values in the range 90V to 240V
90–240
Volt.
170
2.
Mains High Voltage.
It is the maximum voltage greater than or equal to
(e.g. 270V), which “EB Over Volt fault” will be
displayed on LCD. This parameter can have values in
the range 240V to 285V.
240–285
Volt.
270
3.
Engine Start Delay
It is the time duration between Mains Failure/Faulty &
the first crank to the Generator
0–3600 Sec
5
4.
Mains Restore Time
It is the time duration in which mains supply comes
back in specified range of voltage and the load is
changed over from Generator to mains.
0–3600 Sec
15
5.
LLOP Bypass Time
Lube oil pressure switch fault bypass time, the
parameter value lies within the range of 0 to 99
seconds
0–99 Sec.
15
6.
Stop Solenoid Time
The stop solenoid activation time value can be set
within the range of 10 to 99 seconds.
5–99 Sec.
25
7.
Crank Time
This is the time period for which generator starter is
engaged or the crank to the Generator remains hold.
1–30 Sec.
3
8.
Crank Attempts
It defines the number of crank attempts.
1–5 Time
3
9.
Crank Rest Time
It is the time period between two successive cranks.
1–99 Sec
15
10.
Engine Cooling Time
This is the time period during which the Generator
runs without load before switching off.
0–900 Sec
60
11.
Engine Warm-up
Time
This is the time interval after generator switching ON
in which Generator runs without load before taking full
load.
0–900 Sec
10
12.
DG Low Voltage
It is the minimum voltage less than or equal to (e.g.
190V), which “DG Low volt fault” will occur and
Generator indication will be off.
180–240
Volt.
190
13.
DG High Voltage
It is the maximum voltage greater than or equal to (e.g.
270V), when “DG Over Volt fault” will occur and
Generator indication will be off.
240–285
Volt.
265
14.
DG Max Run Time
It is the Maximum time period for which generator is
in ON Condition. (If not Required set 0)
01440
Minute
0
15.
DG Low Frequency
If the Generator frequency is less than or equal to the
set value (e.g. 47 Hz), generator will get shut off.
40–60 Hz
46
16.
DG High Frequency
If the Generator frequency is greater than or equal to
the set value (e.g. 57 Hz) for time period of 6 seconds,
Over Speed LED will start blinking and generator will
be shut off.
50–70 Hz
53
17.
Over Load Current
This parameter is the maximum load current (e.g.50A)
that Generator can supply. If load current increases
above this value (greater than or equal to one than set
value) overload fault will occur. The Generator will be
shut OFF after 4 seconds validation of overload
condition.
05000 Amp.
30

[7]
Para.
No.
Parameters
Explanation of parameters
Setting
Range
Default
Setting
18.
Load C.T. Ratio
It is the ratio of primary current to the secondary
current. Put ratio value and it has the range from 1 to
1000 (e.g. if primary current is 60A and secondary is
5A then ratio is 60/5=12 so set the value at 12.
11000 Ratio
1
19.
Phase Unbalance
If the EB or DG voltage difference between two
phases goes greater than or equal to (e.g. 50 Volts) the
set value, the LCD display would show “EB Phase
Unbalance” or “DG Phase Unbalance” message
respectively.
10100 Volt
50
20.
Device ID
This is a used for serial communication.
0–255
32
21.
Remote Start
Remote Start - Yes means-“Enable”
Remote Start - No means-“Disable”
(Read the Note for special Inputs)
YesEnable
NoDisable
No
22.
Remote Stop
Remote Stop œ Yes means-“Enable”
Remote Stop œ No means-“Disable”
YesEnable.
NoDisable
No
23.
GSM Modem
(optional)
GSM modem œ Yes means-“Enable”
GSM modem œ No means-“Disable”
YesEnable
NoDisable
No
24.
Event Reporting
Thr. Modem
(optional)
This parameter allows retrieval of data of the Gen-set
from the site through modem and is optional.
Report
All Event;
Report Fault
Event;
Disable
Disable
25.
Engine Preheat Time
This parameter is used specially in cold regions to
preheat the Generator before starting. This parameter
will set the time period to preheat the generator.
0–900 Sec
0
26.
Engine Periodic
Start
This parameter is used to start and stop the
Generator automatically after specific interval of
time (Days/ Hours) for test and safety purpose of
the Generator. If it is set to 0 it will be disabled.
This parameter lies within the range of 0 to 90
days. This parameter works only in auto mode.
090 Days
0
27.
Engine Rest Time
This parameter is used to Set Engine Rest time (0-
10Hrs). After a DG MAX Run Time (Para.No.14) is
completed, the Engine Rest time will start for which
DG-SET remains in the off condition.
0–10 Hrs
0
28.
Engine Periodic Run
The Generator will run for this set time duration (e.g.
5 Minutes) for periodic start. And the Generator will
automatically shut off after completion of this time
period
0–300 Minute
0
29.
Set Low Battery
Voltage
The battery voltage less than or equal to (e.g. 10.0v),
which Low battery fault occurs and “Low battery
Fault” will be displayed on LCD.
8.0V to 24.0
VDC
10.0VDC
30.
Set Hooter Timeout
The Hooter alarm will be on for this set duration.
0300sec
(0Disable)
120sec
31.
Change password
For Security purpose, password can be changed. It has
also the default password.
0 - 9999
1000

[8]
Para.
No.
Parameters
Explanation of parameters
Setting
Range
Default
Setting
32.
Alphanumeric Site
ID
To set the ID Set the cursor pointer with the help
ENTER key and increment/decrement digit values.
One digit value can be changed from “0 to 9”and “ A
to Z” Press ENTER Key to save the Alphanumeric
Site ID. Number of digits in the Site ID are 20.
20 digit; Can
set
0-9
and
A-Z
000000
33.
Setting Options
Set via PC:
By using serial communication, Set Parameter via PC.
First run Cologicx Software on PC. Now select option
Set via PC in Program mode of Protogen After
Pressing Enter key Protogen will display
“CHECKING CONNECTION” and then transmit
data to PC.
Factory Setting mode:
Press ENTER Button to apply Default standard
parameter settings except the DG overload current and
CT ratio, Parameter no. 31,32,33&35
*Note: Before Using this option disconnect 3 ph
DG and Mains Supply.
Factory
Setting mode,
OR
Set via PC.
Set Via PC
34.
DG Stop option
Energize To Stop (ETS):
If ETS fuel control has been selected then the Fuel
output will be energized (fuel block) for the Stop
solenoid Time or until the engine stops. If the Genset
does not stop then the alarm output is activated and
‘DG FAIL TO STOP’ is displayed on the LCD.
Energize To Run (ETR):
If ETR fuel control has been selected then the Fuel
output will be energized (Fuel ON) and proceeds
immediately to the CRANK state. If DG fails to start
after specified CRANK attempts, ‘DG Fail to Start’ is
displayed and STOP relay will be off.
*Note: DG Stop options to be modified when DG is
OFF.
ETS
OR
ETR
ETS
35.
LCD Back light
options:
Continuous ON:
LCD will glow continuously except when Low
battery fault occurs.
Power Saving Mode:
If key not pressed for 5 min. Backlight will be
automatically off. LCD will glow only when any key
pressed or some fault occurs.
Continuous
ON
OR
Power saving
mode.
Continuous
ON
36.
Mains Failure Time
The Engine will start if the Mains Failure persists for
this time.
0900 Sec
6 Sec
37.
Configuration Of DI3
input
DI3 input can be configured as Door open or Fire/ DG
Common fault input.
Door open
OR
DG common
fault
Door open
Fault
38.
Oil sensor / wiring
fault alarm
Oil sensor fault / wiring fault can be set On Or OFF
Enable
OR
Disable
Enable
39.
Mains Fail alarm
Mains Fail/Faulty alarm can be set On or OFF.
ON /OFF
OFF

[9]
NOTES:
1. If You Enable Periodic start, automatically Engine Start Delay, Remote Start and Remote Stop
Function is Disabled. It will not Work.
2. Horn remains activate for Set Time. To put it on mute mode, press HORN key.
3. Faults can be reset by STOP/RESET key.
Special Inputs and their functions:
Remote (Terminal DI6): External device is used to start the DG via REMOTE terminal. When this terminal is
open Wait DG on Hold message is displayed on LCD display. When this terminal is closed (low) module starts the
DG Crank Sequence. (At that time parameter no. 21 & 22 is enabled)
If Remote starts and stop parameters are disabled then after mains failure, module goes to start delay and then gives
start command to ON the DG.
Remote Start and Stop works only in Auto Mode, and When Parameter No. 14,26,27,28 are disable.
In upgraded firmware Version 3.3 you can use Remote with Run-Time (parameter no. 14) and Rest time (parameter
no.27 having range of 0-240 minutes)
Flow chart of “DG Max Run Time” and DG rest time as below.
Para.
No.
Parameters
Explanation of Parameters
Setting
Range
Default
Setting
40.
Crank disconnect
mode
Auto Crank Disconnect Mode: Protogen
immediately disconnect the crank (Stater Motor) after
the DG Start.
Crank Till Crank Time Mode: The crank to the
Generator remains hold for settable Crank Time.
Auto Crank
Disconnect
mode
OR
Crank till
Crank Time
Mode
Auto
Crank
Disconnect
41.
Mains contactor
Timer
This is the period after the generator contactor has
been deactivated and before the mains
1300 Sec.
1.Sec
42.
Mains (EB)
Contactor Logic
The programmable digital inputs are compatible with
both ‘normally open’ and ‘normally closed’
NO OR NC
NO
43.
Low Fuel DG Stop
Time
This is the time out period during which the Generator
runs in case of DG Low Fuel Fault. After time out
Protogen will shut down DG.’’’
0120
Minutes.
2 Minute.
44.
Phase Selection.
The programmable Three Phase System and Single
phase system, select both sources as systems
Three phase System
EB Three phase /DG Three Phase
Single Phase Systems
EB Three Phase/DG Single Phase
Three Phase
OR
Single Phase
Three
Phase
Systems.
45.
Charger Fault Alarm
Connect the charge alternator’s D+ terminal to his
terminal. This terminal will supply the excitation
current and measure the voltage of
the charge alternator. Set ON OR OFF.
ON
OR
OFF
OFF
Auto mode
Mains fail
Engine Start Delay
DG Max Run Time
Engine Rest Time

[10]
1.4 LED INDICATION
The EGCP-03features high performance LED indication that permits the user to get necessary information like faults, Mains and
Generator status etc. These indications are as follows Note: Fault conditions are indicated by steady LED indication.
Sr.no.
Name of indication
Description of Indication
Indication
1.
Low Battery voltage.
Low battery voltage fault.
2.
Low Oil Pressure
Low oil pressure
3.
High Temperature
High Engine temperature fault.
4.
Fail To Start
Fail To Start fault.
5.
Fuel Level
Low fuel fault.
6.
Over Speed
Over speed or upper frequency fault.
7.
Emergency Stop
Emergency stop fault.
8.
Alarm
All DG faults.
9.
Mains
Mains power supply is available.
10.
Mains Contactor
Mains contactor is on.
11.
Generator
Generator is on.
12.
Generator Contactor
DG Contactor is on.
NOTE: In Scanning mode it displays all the parameters continuously for 5 Sec. one by one until any key is
PRESSED and within the 5 min if key is not pressed, it again goes into Scanning Mode.

[11]
.
1.5 DISPLAY - TABLE OF MESSAGES DISPLAYED.
The EGCP-03 features a high quality 16 x 4 LCD display. It displays all the fault messages according when
fault occurs, & the following parameter values with the help of UP and DOWN keys.
R.NO
Message
Description
1
Load current
Value of Load current (Phase I-R, I-Y, I-B) In the range of 0 to 5000
Amps is displayed.
2
Voltage
The value of Mains Phase to Neutral and Line-to-Line Generator
Phase to Neutral and line to line. Voltage in the range of (P-N) 0 to
300 and 0 to 600 (L-L) Volts.
3
Frequency
The value of Generator frequency in the range of 40 to 60 Hz.
4
DG Battery Voltage
The value of battery voltage.
5
DG speed
Speed of the Generator (in rpm 1500).
6
PF-R, PF-Y, PF-B.
The Values of Power Factor of R, Y, B Phase. (Lag/Lead)
7
Mains KWH & DG
KWH
The Values of Mains & DG KWH.
8
Date & Time
The Value display the Real Date & Time.
9
KW–R, KW-Y, KW-B
The Values of Active Power of R, Y, B Phase.
10
SITE ID
Alphanumeric Site ID.
11
Run Time hour
Display DG runs time.
TABLE-2 Messages Shown on the LCD Display:
SR.
NO
Message
Description
1
Site ID
Site ID Alphanumeric is Available.
2
Auto Mode Operated.
Automatic operation mode is activated
3
Manual Mode operated.
Manual mode is activated
4
Engine Start Delay
Start delay is activated
5
DG Stop mode
Engine stop sequence is activated
6
Wait DG on Hold
DG start sequence is hold.
7
DG Under Voltage
Generator Low voltage fault
8
DG Over Voltage
Generator Over voltage fault
9
DG Phase Unbalance
Generator Phase unbalance Fault
10
EB Over Voltage
Mains Over voltage fault
11
EB Under Voltage
Mains Low voltage fault
12
EB Phase Unbalance
Mains Phase unbalance Fault
13
Mains Phase Reverse
Mains phase reverse fault.
14.
DG Load Timing
During this time DG contactor is activated and no Alternator fault will
observe.
15.
Periodic On Time
For Periodic test Time DG is ON without load
16.
DG Rest Time
For this time DG is OFF as part of periodic TEST
17.
Engine Preheat Time
DG preheat relay is activated.
18
Charge Belt Break Fault
Charge alternator failure (or broken belt) fault.

[12]
1.6 FAULT HANDLING PROCEDURE:
SR.NO
TYPE OF FAULT
REMEDY
1.
Fail to start
Check engine for correct operation, check oil pressure switch, check
battery condition, check fuel, level, check relay card, and check fuses
2.
Fail to stop message
Check stop solenoid operation, check stop time on display programming
parameter no.6, check battery voltage, check fuse
3.
Overload
Check load current, check programming parameter 17 &18, and Check wiring.
4.
Low Oil Pressure
Check oil Level, Check oil pressure switch, and Check wiring.
5.
Low Oil Fuel
Check fuel level sensor, and Check wiring.
6.
Over speed
Check Alternator frequency. Check Programming Parameter No.15 &16 DG
low Freq. & DG High freq. Lies between
7.
Low Battery Voltage
Check condition of battery, check wiring
8.
Emergency stop
Check emergency fault switch, check wiring
9.
DG(Alternator)
OV/UV/UB Fault
Check generator voltage, Check Programming parameter No, 12 &13, and
check wiring.
10.
Generator starts OK
but generator
ON & generator
Contactor indication
will not ON in Auto
Mode
Check alternator output voltage Check all fuses, and check wiring.
11
Mains is OK but
Mains indication will
not glow ON and
generator Starts even
if mains are ON
Check all Three Phase voltage and phase sequence, check programming
parameter no.1&2, check all fuses, and check wiring.
12.
Relays on relay card
are not activating
Check Relay card , Check the wiring connection.
13.
Wait DG on Hold
Check the Remote start input is given to “EGCP-03”; Check parameter No.21
& 22 is enabled.
14.
Phase Reverse
Check phase sequence given to Mains Voltage input terminals.
15.
Phase unbalance
Check parameter no 19, The set value defines the difference between the two
phases is increased above the set value at that time module display shows
Phase unbalance
16
Charge Belt Break.
Check charging alternator voltage is between 8 to 12V. If less then display
gives fault, check parameter No.45 and wiring.

[13]
1.7 CLEARING THE ALARM (HORN)
1. When a Fault occurs the cause of a Fault is shown by display message
and by LED indication
2. EGCP-03 activates the Potential free fault relay and stops the. Generator automatically
3. Press “HORN” Key for resetting of HORN
4. Press “Stop / Reset” Key to reset the fault
1.8 GENERAL CHARACTERISTICS:
DC SUPPLY RANGE: 12V Model (7-15VDC) / 24V Model (20-30 VDC)
CURRENT TRANSFORMER: 0.09Amp to 5Amp.
VAC INPUTS RATINGS: 40–300 V @ 50Hz.
VAC MAXIMUM OVER VOLTAGE: 600 VAC
SOLID STATE OUTPUT: 500 mA Max
DIGITAL INPUTS: 32V DC max/Engine Ground
WEIGHT: 950 gms. Approx.
OPERATING TEMPRATURE: 0 to 70 degree Centigrade.
DISPLAY ACCURACY: + / -1% of F.S.D.
BOX DIMENTION: 96 x 192 x 80 mm (H x W x D)
CUTOUT DIMENSION: 92 x 184. (mm)
POWER RATING: <2.5VA (without power saving option)
<1VA (with LCD power saving option)
1.9 EGCP-03Electrical Connection Details:

[14]
2.0 ELECTRICAL CONNECTION DIAGRAM
+12/24V DC Line
DI-6 DI-5 DI-3 DI-2 DI-1
DI-A
DI-9 DI-8 DI-7 DI-0
R-1 R-6 R-5 R-4 R-3 R-2
R-C
R-B
R-A
R-9 R-8 R-7
Fuse/2A
MAINS I/PALTERNATOR I/P
TO LOAD
Generator
Contactor Mains contactor
Genrator contactor Relay
Mains contactor Relay
NN
B B
Y Y
RR
IR-IN
Electrical Interlock
IY-IN IB-IN IB-OUT IR-OUT IY-OUT
M_R M_Y M_B M_N
D_N
11 Digital I/P
D_B D_Y D_R
DI+
BAT+
D+/W.L.
UT -
DI+
Battery 12 /24 VDC connections
12 Relay out puts
RS-232/485 Config. Remote Monitoring & Control
Mains Contactor
Hooter
Engine Start
Engine Stop
Out put from engine Perheat
Low fuel DG Common fault
Mains fail
LLOP
DG Contactor
Engine temp. Alarm
Door open
Door Open / DG Common fault
Hafe fuel
Canopy temp. input LLOP Input
HCT Input
Low fuel
Emergency stop
Auto/Manual I/P
Remote Start
DG contactor input
Mains contactor input
Conected Battery Negative terminal
9 Pin D type connector
+VE ENGIEN STARTER - VE
12V/24V DC
BATTERY
1) DG BOODY & BATTERY NEGATIVE MUST BE
SHORT TO ENSURE PROPERLY EARTHING.
2) IN AUTO MODE - I/P SELECTION MUST
ACTIVE LOW (DI7)
B
Y
R
N
Fuse/2A Fuse/2A
Link
Fuse/2A Fuse/2A Fuse/2A
Link
DI-4
Fuse 4A
NOTE:-
0
B+
D+/W.L.
Half Fuel
ENGINE
STARTER
Connected to Negative Terminal of Battery
(Optional)
Generator Contactor Relay

[15]
2.1 SPECIAL NOTE
Relay should be 12v/24V DC supply.
Max current output 500ma. For better operation of relay and Battery use Higher Coil Resistance Relay
To activate Relay EGCP-03 gives Logic Low output (Battery Negative/ Ear thing)
Connect all relay contact with RC filter / Free wheeling diode across coil.
DG Body (Battery -Ve) should be earthed properly.
Relay output is active low. (Max current 500ma.)
Use separate +Ve & -Ve supply from DG battery terminal for EGCP-03module. Do not Loop these wires to
any other wires inside the Control panel
Use RC snubber networks across contactor coils.
Use RC filter across Start & Stop relay contacts.
Use separate trays for AC & DC wires.
Please make sure that all above conditions are fulfilled properly for trouble free operations of the EGCP-
03module.
2.2 Connection Details:
Battery connections:
UT+ : Connect Battery Positive Terminal
BAT+ : Connect Battery Positive Terminal. (Used For Battery Voltage Measurement)
D+/W.L . : Connect the Pickup positive from alternator’s output. (Optional)
UT- : Connect Battery Negative Terminal.
DI+ : Connect Battery Positive Terminal.
Serial COM: DB9 ONNECTOR (OPTIONAL).
Active low output
Following connections of Digital isolated output for Relay drivers:
1) R-1: Output for HCT (ENGINE TEMP.)
2) R-2: Output for Door Open/Fire alarm.
3) R-3: Output for Low fuel Level.
4) R-4: Output for DG Common Fault.
5) R-5: Output for Mains Fail.
6) R-6: Output for LLOP.(Low Oil Pressure)
7) R-7: Output for DG Contactor On.
8) R-8: Output for Mains Contactor.
9) R-9: Output for Hooter.
10)R-A: Output for Engine Start.
11)R-B: Output for Engine Stop.
12)R-C: Output for Engine Preheat

[16]
Following Connections For Digital input coming from Engine Switch.
1) DI-0: LLOP Input.
2) DI-1: Canopy Temperature Input.
3) DI-2: Half Fuel Input.
4) DI-3: Door open/DG Common fault.
5) DI-4: Mains Contactor On Input.
6) DI-5: DG Contactor On Input.
7) DI-6: Remote Start Input.
8) DI-7: Auto/Manual Mode Select Input
9) DI-8: Emergency Stop Input.
10) DI-9: Low Fuel Input.
11) DI-A: HCT Input.
12) DI-B: Not Used.
Following Connections For Mains Three Phase Voltage
Ø M_R: Connect Mains R Phase.
Ø M_Y: Connect Mains Y Phase.
Ø M_B: Connect Mains B Phase.
Ø M_N: Connect Mains Neutral.
Ø N.C. : No Connection.
Following Connections For DG-SET Three Phase Voltage
Ø D_R: Connect R Phase of DG-SET.
Ø D_Y: Connect Y Phase of DG-SET.
Ø D_B: Connect B Phase of DG-SET.
Ø D_N: Connect Neutral of DG-SET.
Ø N.C.: No Connection.
Following Connections For Load Current Input (Three Phase Current –Max Current is 5.6A)
Ø IR-IN : Connect R phase Current In.
Ø IR-OUT: Connect R phase Current Out.
Ø IY-IN : Connect Y phase Current In.
Ø IY-OUT: Connect Y phase Current Out.
Ø IB-IN : Connect B phase Current In.
Ø IB-OUT: Connect B phase Current Out.