ELCOS CEM-330/00 Instruction Manual

CONTROL AND PROTECTION PANEL
FOR IRRIGATION MOTORPUMP
TYPE CEM-330/00
MADE TO:
Motor pump sets by stopping them in the
event of :
oil pressure
over-temperature
belt breakage
minimum fuel level
air filter clogging
low coolant level
low water pump pressure
• low
•
•
•
•
•
•
On the front the functions of :
hour meter
pump protection exclusion
protection intervention
•
• timer
•
• oil and battery lights
•
GB CEM-330/00 /1 1
BY SIMPLY STARTING, IT AUTOMATICALLY CONTROLS THE MOTOR PUMP.
ALL THE OTHER FUNCTIONS ARE EASY TO USE WITH JUST TWO PUSH-BUTTONS
PROTECT DISPLAY
Assembly on the machine and in the open air.
Suitable for stopping both with solenoid and with electromagnet, for engines fitted with charge alternator,
both with pre-excitation and with permanent magnets.
INSTRUCTION AND USER MANUAL
®
PARMA ITALY
E-mail: [email protected] - HTTP://www.elcos.it
Fax [phone]
Tel. [phone]

CONTROL AND PROTECTION PANEL FOR IRRIGATION MOTORPUMP
TYPE CEM-330/00
Only for starting and surveillance of the motor pump and stops it if there are anomalies in the parts controlled
by probes.
It has been designed to be installed also on the machine.
NOTICES
Warning:
adhere closely to the following advice
- Always install under other equipment which produces or spreads heat. .
- Always follow the Wiring Diagram on pages 6-7 when making connections.
- Check that the line loading and the consumption of the connected equipment are compatible
with the technical characteristics on page 11.
- All technical interventions must be performed with the engine stationary and terminal 50 of the
Starter motor disconnected.
- Never use a battery charger for the emergency start-up, this could damage the control panel.
- To protect the safety of persons and the equipment, before connecting an external battery
charger, disconnect the electrical plant terminals from the battery poles.
- Never disconnect the battery terminals with the engine running.
THIS CONTROL PANEL IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING CONDITIONS:
- Where the environmental temperature is outside the limits indicated in the Technical Data on page 11.
- Where there are high levels or heat from radiation caused by the sun, ovens or the like.
- Where there is the risk of fire or explosions.
- Where the panel can receive strong vibrations or knocks.
The following maintenance operations should be performed every week:
- check that the indicators function;
- check the batteries;
- check that the conductors are tight, check the condition of the terminals.
CONDUCTION AND MAINTENANCE
ELECTROMAGNETIC COMPATIBILITY
This protection device functions correctly only if inserted in plants which conform with the CE marking standards;
it meets the exemption requirements of the standard EN50082-1 but it cannot be excluded that malfunctions
could occur in extreme cases due to particular situations.
The installer has the task of checking that the disturbance levels are within the requirements of the standards.
YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT THIS CONTROL
PANEL BY TELEPHONING ONE OF OUR TECHNICIANS
UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS CONTROL PANEL IS
NOT SUITABLE FOR USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE FOR
KEEPING PERSONS OR OTHER LIVING BEINGS ALIVE
GB CEM-330/00 /1
2

FUNCTIONING
IGNITION KEY
TWIN FUNCTIONS INDICATORS
ENGINE PROTECTIONS
- REST
- MANUAL STOP
- RESET PROTECTIONS, CANCELLING PROTECTION EXCLUSION
AND TIMING
- PANEL SUPPLY
- START MOTOR-PUMP
0
AUT.
AVV.
The engine protections are enabled when the ENGINE PROTECTIONS ACTIVE light comes on (20
seconds after the end of starting impulse and however 1 minute after positioning the key on “AUT”).
Intervention of the protection probes (fitted on the engine), indicated by the relevant lights, stops the engine,
it is memorised and can be split into two groups:
Pump protection is enabled when the PUMP PROTECTIONACTIVE light comes on
(after 1 consecutive minute of sufficient water pressure, indicated by the
PUMP PRESSURE REGULAR light and however 10 minutes after starting the engine pump).
Protection intervention ( 6 seconds after the pressure drop detected by the PUMP WATER PRESSURE
SWITCH fitted on the water pump) stops the engine, it is memorised and is indicated by the LOW
WATER PUMP PRESSURE light.
( See PUMP WATER PRESSURE SWITCH ADJUSTMENT on page 6)
RESET : by turning the starter key onto "ZERO".
Delayed by 5 seconds for:Immediate for:
- OIL PRESSURE SWITCH
- OVER-TEMPERATURE
SWITCH
- AIR FILTER SWITCH
- COOLANT LEVEL PROBE
- BATTERY CHARGE ALTERNATOR
(ALTERNATOR BELT BREAKAGE)
- FUEL LEVEL SWITCH
These are on when the key is turned to "AUT". They switch off when the engine is
running and the oil pressure and battery recharger are regular.
The push-button excludes pump protection:
-
-
exclusion is obtained by keeping it pressed for at least 3 consecutive seconds; the function is indicated by
the two intermittent lights .
this exclusion is cancelled by pressing the push-button again or by turning the starter key onto "ZERO".
GB CEM-330/00 /1 3
PROTECTION PUMP
PUMP PROTECTION EXCLUSION

GENERAL ALARM
HOUR METER
The unit shut down the engine in three conditions:
- turning the starter key onto "ZERO"
- protection intervention
- timer intervention at the end of the work period.
The unit adapts to two different stop system (during which the STOP light is activated ):
- by working the ELECTROMAGNET for 20 seconds which pulls the STOP lever
- by cutting off power to the SOLENOID VALVE shutting off the flow of fuel.
This can be obtained by fitting on the outside an optical and/or acoustic signaller to be connected to its
connector.
It is activated on protection intervention.
RESET : is obtained by turning the starter key back onto "ZERO".
The HOUR METER is displayed at the first tripping of the key ("AUT").
In this condition and with the engine running, the light pulsates, indicating that the instrument is
working properly The HOUR METER keeps the hours of work in memory even with the battery
disconnected.
.
CORRECTING THE SET TIME
CANCELLING THE TIMER
Enabled with the key on "AUT" it makes it possible, if necessary, to have the engine pump work for an
adjustable length of time ( 24 hours maximum ) , at the end of which it stops and the WORK TIME OVER
sign lights up.
The work time is set by pressing the TIMER push buttom (lights up ) until the desired
value appears on the DISPLAY .
On releasing the push-button, the timer automatically starts working, continously displaying the
remaining work time.
To ZERO the set time:
- keep the TIMER push-button pressed until it reaches zero;
To INCREASE the set time:
- press the TIMER push-button.
To DECREASE the set time:
- zero the time (see above)
- set the desired value once more, pressing the TIMER button again.
This is done in two ways :
- by zeroing (see above) the set time (the engine pump does not have to be stopped).
- by turning the starter key onto "ZERO" (the engine pump will stop).
STOPPING THE ENGINE PUMP
FUNCTIONING
GB CEM-330/00 /1
4
TIMER

NOTE: WHEN THE TEST HAS BEEN COMPLETED RECONNECT THE PROBES.
ENGINE PROBES TEST
FUNCTION PERFORMED TEST
CHARGE
ALTERNATOR
(BELT
BREAKAGE)
LOW OIL
PRESSURE
OVER-
TEMPERATURE
FLOAT
RESERVE
ENGINE
STATIONARY
ENGINE
STATIONARY
ENGINE RUNNING
WITH REGULAR
BELT
ENGINE RUNNING
WITH REGULAR
PRESSURE
ENGINE WITH
NORMAL
TEMPERATURE
SUFFICIENT
FUEL
ENGINE RUNNING
WITH BROKEN
BELT
ENGINE RUNNING
WITH LOW
PRESSURE
ENGINE
OVERHEATING
INSUFFICIENT
FUEL
D+
B+
GRGB LC
R LE +~~
YELLOW
YELLOW
RED
PERMANENT
MAGNET
ALTERNATOR
PRE-EXCITATION
ALTERNATOR
OIL PRESSURE
SWITCH
THERMOSTAT
FLOAT
W
3W
3W
3W
3W
NORMALLY THE
RELEVANT
TERMINAL OF THE
BATTERY CHARGE
ALTERNATOR IS
NEGATIVE WITH
THE ENGINE
STATIONARY
NORMALLY THE
TERMINAL OF THE
OIL PRESSURE
SWITCH IS
NEGATIVE WITH
THE ENGINE
STATIONARY
NORMALLY THE
TERMINAL OF THE
THERMOSTAT IS
NEGATIVE WHEN
THE ENGINE IS
TOO HOT
NORMALLY THE W
TERMINAL OF THE
FLOAT IS
NEGATIVE WHEN
THE FUEL IS
RUNNING OUT
RADIATOR PROBE
W
RESISTANCE BETWEEN
PROBE AND EARTH:
- WITH LIQUID MAX. 6000
- WITHOUT LIQUID, ABOVE 6000
W
W
LOW
COOLANT
LEVEL
AIR FILTER
CLOGGING
GB CEM-330/00 /1
LOW WATER
PUMP
PRESSURE
MOTORPUMP
RUNNING
WITH REGULAR
WATER PRESSURE
MOTORPUMP
RUNNING
WITH LOW
WATER PRESSURE
MOTORPUMP
STATIONARY
PRESSURE
SWITCH
GREY
PURPLE WIRE
NORMALLY THE
PURPLE WIRE OF
THE WATER
PRESSURE SWITCH
IS NEGATIVE
WHEN THE PUMP
IS STATIONARY
5
UNCLOGGED
FILTER
CLOGGED
FILTER
NORMALLY
THE TERMINAL
OF THE AIR FILTER
SWITCH IS’
NEGATIVE WHEN
THE FILTER IS
CLOGGED
AIR FILTER
CLOGGING
SWITCH
(WITH PROBES DISCONNECTED)

COOLANT LEVEL PROBE
PUMP WATER PRESSURE SWITCH ADJUSTMENT
(On the control panel mounted)
FOR RADIATORS WITH PLASTIC
EXPANSION TANKS
FOR RADIATORS WITH METAL
EXPANSION TANKS
BRIEF INSTRUCTIONS
REST
MANUAL STOP
RESET
UNIT POWER
SUPPLY
ENGINE PUMP START
(2/7) ELECTROMAGNET OR SOLENOID-VALVE
(4) THERMOSTAT
(15) WATER PUMP PRESSURE SWITCH
(16) FUEL FLOAT
(155) COOLANT LEVEL PROBE
GB CEM-330/00 /1
155
SCREW
ELECTRODES
155
ROD
ELECTRODE
6
Turn the knob to a value two bar less than the pressure indicated on the pressure
gauge.
It will not be necessary to regulate the pressure switch again if the working pressure
remains unchanged.
AFTER STARTING, (THE ENGINE PUMP PROTECTS ITSELF AUTOMATICALLY)
IT IS POSSIBLE TO ACCESS THE OTHER FUNCTIONS BY SIMPLY USING
JUST 2 PUSH-BUTTONS.
AUT.
0
AVV.
ENGINE PUMP START
0AUT.
AVV.
STOPPAGE DUE TO
LOW ENGINE OIL
PRESSURE
STOPPAGE DUE TO LOW
ENGINE OIL PRESSURE
STOPPAGE DUE TO LOW
FUEL LEVEL
STOPPAGE DUE TO
CLOGGED AIR FILTER
STOPPAGE DUE TO LACK OF
BATTERY CHARGING (BROKEN BELT)
STOPPAGE DUE TO ENGINE
OVER-TEMPERATURE
STOPPAGE DUE TO LOW
COOLANT LEVEL
ENGINE PROTECTIONS ARE
ACTIVE
PRESS IF YOU WANT TO
SET WORKING TIME
( UP TO 24 HOURS)
STOP FOR END
OF WORK TIME DISPLAY PUMP PROTECTION
EXCLUDED
PUMP PROTECTION
ACTIVE
PUMP WATER PRESSURE
IS REGULAR
STOPPAGE IN PROGRESS
ACCUMULATED OPERATION
HOURS ARE DISPLAYED
PRESS UNTIL
TO EXCLUDE PUMP
PROTECTION.
THE 2 SIGNS START
FLASHING
TO RE-ACTIVATE
PROTECTION, PRESS AGAIN UNTIL
THEY SWITCH OFF.
TIMER IS DISPLAYED
(IF SET)
STOPPAGE DUE TO LACK
OF BATTERY CHARGING
STOPPAGE DUE TO LOW
PUMP WATER PRESSURE
THE FUSES ARE INSIDE THE CONTROL
PANEL.
- TO HAVE ACCESS TO THE INSIDE, LOOSE
THE SCREWS
THAT SECURE THE COVER.
REPLACE WITH FUSES OF THE SAME VALUE.
FUSE REPLACEMENT
If the function - :
Is not used:
Connect the ORANGE/YELLOW wire to earth
LOW COOLANT LEVEL

WIRING DIAGRAM
To stop with SOLENOID cut and
insulate the BLUE/BROWN
wire.
STOP SYSTEM ARRANGEMENT
The control panel is arranged to command
stop with ELECTROMAGNET.
(3) OIL PRESSURE SWITCH
(26/28)
(27) ALTERNATOR REGULATOR
(40) STARTER MOTOR
(41) BATTERY
(150) AIR FILTER CLOGGING SWITCH
(157) INDICATOR (MAIN ALARM)
PERMANENT MAGNETS OR PRE-EXCITATION
CHARGEALTERNATOR
(2/7) ELECTROMAGNET OR SOLENOID-VALVE
(4) THERMOSTAT
(15) WATER PUMP PRESSURE SWITCH
(16) FUEL FLOAT
(155) COOLANT LEVEL PROBE
(2/7) ELECTROMAGNET OR SOLENOID-VALVE
(4) THERMOSTAT
(15) WATER PUMP PRESSURE SWITCH
(16) FUEL FLOAT
(155) COOLANT LEVEL PROBE
AVAILABLE ON REQUEST
ACCESSORIES
CHARGE BATTERY ALTERNATOR:
MOUNTED ON ENGINE
123
456
123
456
789
11 10
155
3
40
4
150
157
30
+ BATTERY
ORANGE
SKY BLUE
RED
BLACK (40A MAX)
CONNECTOR
CONNECTOR
41
50
26/28
3A MAX
(3A MAX )
3A MAX
RED/GREEN
GREY
YELLOW
WHITE
BROWN(ONLY FOR PERMANENT MAGN. )
GREEN
INSULATE
POSSIBLE
CABLES
NOT CONNECTED
ORANGE /YELLOW
2/7
GB CEM-330/00 /1 7
FROM 15/54 OF START
KEY; USABLE FOR
HEADLIGHT AND
OTHERS
ORANGE/BROWN
PURPLE
16
15
EXCITED IN STOP MODE
ELECTROMAGNET:
activates the engine
stop lever.
EXCITED IN DRIVE
SOLENOID:
to close the fuel
YELLOW
YELLOW
RED
PERMANENT MAGNETS
PRE-EXCITATION
27
27
NOT TO BE USED
28
26
+ BATTERY
GREEN
RLE
+
GLG+ BR C
W
D+
B+
+ BATTERY
GREEN
BROWN
BROWN
*
*
*
*
*
*
For loads with
current above 3A,
a relay must be
used
WARNING

CONTROL PANEL TEST
(SIMULATION)
FUNCTION PERFORMED
PROTECTIONS ARE ACTIVE)
(WITH INDICATOR ON
INTERVENTION SIMULATION
FUNCTIONS INTERVENTION
CHARGE
ALTERNATOR
(BELT BREAKAGE)
LOW OIL
PRESSURE
OVER-
TEMPERATURE
FUEL RESERVE
AFTER 5 SECONDS
AFTER 5 SECONDS
AFTER 5 SECONDS
IMMEDIATELY
IMMEDIATELY
DISCONNECT THE GREEN WIRE FROM
THE CONNECTOR OF THE PANEL AND
CONNECT IT TO EARTH
DISCONNECT THE WIRE FROM THE
OIL PRESSURE SWITCH TERMINAL
AND CONNECT IT TO EARTH
DISCONNECT THE WIRE FROM THE
THERMOSTAT TERMINAL AND
CONNECT IT TO EARTH
DISCONNECT THE WIRE FROM THE
TERMINAL OF THE FLOAT AND
CONNECT IT TO EARTH
W
NOTE
(STOP, GENERAL ALARM
AND VISUAL INDICATOR ON)
WHEN THE SIMULATION HAS BEEN COMPLETED ENSURE THAT ALL OF THE CONNECTIONS
ARE RETURNED TO THEIR ORIGINAL POSITIONS
AFTER 5 SECONDS
AIR FILTER
CLOGGING
LOW COOLANT
LEVEL
AFTER 5 SECONDS
DISCONNECT THE ORANGE/BROWN
WIRE FROM THE AIR FILTER SWITCH
TERMINALAND CONNECT IT TO EARTH
SIMULATION OF INTERVENTION
(WITH PUMP PROTECTION ACTIVE
INDICATOR ON). DISCONNECT THE
PURPLE WIRE FROM THE PRESSURE
SWITCH TERMINAL AND CONNECT IT
TO EARTH
GB CEM-330/00 /1
8
LOW WATER PUMP
PRESSURE
DISCONNECT THE TERMINAL
FROM THE ROD MOUNTED
ON THE RADIATOR (155)

TROUBLESHOOTING
THE STARTER MOTOR
FUNCTIONS BUT THE
ENGINE DOES NOT
START
- Lack of fuel
- Fuel supply circuit defect
- Fill the tank
- Check that the stop system (solenoid or
electromagnet) functions
- Consult the engine instruction manual
ENGINE STOPS FOR
ANOMALY
- Check the condition of the alternator belt
- Check the engine oil level
- Check the engine cooling system
- Check that the knob of the water pump
pressure switch has been set at 2 bars
below the plant pressure
- Check the air filter and, if necessary, clean it
(consult the engine instructions manual).
TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS
THE STARTER MOTOR
DOES NOT FUNCTION
- Flat battery
- Starter motor is defective
- An anomaly indicator is on
- Defective ignition key
- Recharge the battery and clean the
connection terminals
- Check that there are +12V or + 24V on
terminal 50 of the starter motor during the
start phase.
Check and, if necessary, replace
the starter relay.
- See below ENGINE STOPS FOR
ANOMALY
- Replace the ignition key and check
the connecting fastons.
- The low oil pressure
indicator lights up
- The belt breakage
indicator lights up
- The overtemperature
indicator lights up
- The air filter switch
indicator lights up
- The low coolant level
indicator lights up
- Check the coolant level
- The low water pump
pressure lights up
GB CEM-330/00 /1 9

TROUBLESHOOTING
ENGINE DOES NOT
STOP UNDER ANY
CONDITIONS
- Fuse(s) blown (inside junction
box)
- Stop system does not function
- Defective engine probes
- Replace with similar fuses
- Check the correct mechanical or electrical
functioning of the stop system. If the
problem persists, check the eventual stop
Servo-relay.
- Test the probes (see ENGINE PROBES
TEST on page 5) and if necessary replace
them.
- Check that during the stop phase there is
voltage on terminal (2) (see STOP on page
4), simulate the function (see PANEL
TEST on page 8 and if necessary replace
the panel (*)
- Control panel defective
- The low oil pressure
indicator lights up
ENGINE STOPS FOR
ANOMALY THOUGH ALL
APPEARS TO BE
REGULAR
THE HOUR METER DOES
NOT FUNCTION
- Simulate the functioning of the device for
the anomaly indicated (see PANEL TEST
on page 8) and if necessary replace it (*)
- Check that:
[*].
• starter key is in aut
• engine is running
• oil pressure switch is disconnected
- If under these conditions the hour meter does
not function, if necessary, replace the control
panel
- Test and, if necessary, replace pump water
pressure switch
- Test and, if necessary, replace thermostat
- Test and, if necessary, replace the air filter
clogging switch
- Test and, if necessary, replace oil pressure
switch
- Check charge alternator function
- Defective panel
- The belt breakage
indicator lights up
- The overtemperature
indicator lights up
- The air filter switch
indicator lights up
- Defective display
- Defective device
- The low water pump
pressure lights up
- Fuse(s) blown (inside junction
box) - Replace with similar fuses
- The low coolant level
indicator lights up
- Test probe, clean and, if necessary, replace
it
TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS
GB CEM-330/00 /1
10

[*] ASSISTANCE REQUEST
Before replacing the panel, the client should consult our technician.
When he telephones, your electrical technician must have the chart shown on page 6-7 of the manual available
together with the following information:
- The type of equipment installed
- The problem encountered
- The state of the dashboards indicators when the problem arose
- Any previous corrective action taken
DIMENSIONS TECHNICAL DATA
- BATTERY VOLTAGE SUPPLY
12 VDC (MAX 16 VDC)
Or
24 VDC (MAX 32 VDC)
-
- MAX CURRENT OUTPUT
• YELLOW 3 A
• RED/GREEN (GENERAL ALARM) 3 A
- TEMPERATURE RANGE -10 ÷ +60 °C
- DEGREE OF PROTECTION
• BOX IP 23
• CONNECTOR IP 20
-
FOR EXTERNAL USE
- CONTROL PANEL WEIGHT 1.600 g
• BLACK (STARTER) 40 A
(STOPPING)
• BROWN (AUXILIARY) 3 A
- HOURMETER 4 DIGITS
- TIMER 1÷ 24h
INSTALLATION CONDITIONS:
- TOTAL WEIGHT (PANEL,
ACCESSORIES AND PACKAGE) 3 100 g
CIRCUIT LOADING WITH KEY AT ZERO 11 mA
GB CEM-330/00 /1 11
156
198 77
29 50
224
190
210 mm
==
6MA
FRONT
REAR

ACCESSORIES AVAILABLE ON REQUEST
RADIATOR COOLANT LEVEL PROBE
ROD ELECTRODE
(COMPLETE WITHI: RIVET
CONNECTION, BOLT, NUT,
WASHER, GASKET AND
FEMALE CONNECTOR)
SCREW ELECTRODES
(COMPLETE WITH: LUGS)
Type AST-015/00
Type E 25
Code 24.10.12
Code 19.01.15
SUPPLIED ACCESSORIES
PRE-WIRED FEMALE CONNECTOR
Type CodeCEM-330/00 80.43.36
ORDERING DATA
Type CodeCEM-330/00 12V 21.10.31
Type CodeCEM-330/00 24V 21.10.32
FOR OHTER ACCESSORIES AVAILABLE ON REQUEST SEE PAGE 7
GB CEM-330/00 /1
12
CONFORMITY DECLARATION
The company ELCOS s.r.l. assumes full responsability for declaring that
the equipment:
when used in the ways and for the purposes described in the enclosed
documents is in conformity with the following directive:
89/336/CEE concerning electromagnetic compatibility
modified by the directive 93/68/CEE
being manufactured and functioning in accordance with the harmonized
standards:
EN 50081-1, EN 50082-1, EN 60529.
Type:CEM-330/00
®
E-mail: [email protected] - HTTP://www.elcos.it
Via Naviglio Alto, 24/a
43100 PARMA ITALIA
S.r.l.
Fax [phone]
Tel. [phone]
Walter Consigli
Parma, 7/7/2000
President