ELCOS CEM-250/10 Instruction Manual

CEM-250 /10 - EN 1
PANEL FOR CONTROL AND PROTECTION
OF IRRIGATION MOTOR PUMPSET
TYPE CEM-250/10
INSTRUCTION AND USER MANUAL
motor pump sets by stopping them
in the event of:
• low oil pressure
• over-temperature
• low pump water pressure
• pump water overpressure
• A1 available fault
• low fuel pressure
• belt breakage
• minimum fuel level
• low coolant level
on the panel the functions of:
• hour-meter
• oil pressure gauge
• water or oil thermometer
• tachometer
• pump water pressure gauge
• timer
• fuel level gauge
• pump protection exclusion
• battery and oil lights
• protections intervention
• emergency stop
PROTECT DISPLAY
MADE TO:
• By simply starting, it automatically
controls the motor pump
• P ater electronic pressure switch
• Assembly also on the machine
and in the open air.
ump w
• Digital pump water pressure gauge
®
PARMA ITALY
E-mail: [email protected] - HTTP://www.elcos.it
Fax [phone]
Tel. [phone]

CEM-250 /10 - EN2
BRIEF INSTRUCTIONS
After starting, the motor pump protects itself automatically
~
~
~
~
MP
BAR
0AUT.
AVV.
®
www.elcos.it
ENGINE WATER OR OIL
TEMPERATURE IS DISPLAYED
ENGINE OIL PRESSURE
IS DISPLAYED
THE FUEL LEVEL IS DISPLAYED
PRESS IF YOU WANT
TO SET WORKING
TIME(UPTO96
HOURS)
EMERGENCY STOP
MOTOR PUMP OPERATING
SPEED IS DISPLAYED
ACCUMULATED OPERATION
HOURS ARE DISPLAYED
PUMP WATER PRESSURE
IS DISPLAYED
A1 AVAILABLE
PRESS TO ADJUST
WATER PUMP
ELECTRONIC
PRESSURE SWITCH
THE BATTERY IS
NOT CHARGING
LOW ENGINE
OIL PRESSURE
ENGINE PROTECTIONS
ARE ACTIVE
STOPPAGE DUE TO LOW
COOLANT LEVEL
STOPPAGE DUE TO LACK OF BATTERY
CHARGING (BELT BREAKAGE)
STOPPAGE DUE TO HIGH
ENGINE TEMPERATURE
STOPPAGE DUE TO INSUFFICIENT
ENGINE OIL PRESSURE
CUMULATIVE ALARM
%
STOP
~
~
~
~
~
~
~
~
h
BAR
°C
RPM
~
~
~
~
!
STOP
BAR
PRESS UNTIL THE 2 SIGNS
START FLASHING TO
EXCLUDE PUMP
PROTECTION.
TO RE-ACTIVATE
PROTECTION, PRESS AGAIN
UNTIL THEY SWITCH OFF.
PUMP PROTECTION
IS ACTIVE
WATER PRESSURE IS
REGULAR
PRESS TO SELECT THE
DISPLAYED FUNCTION,
EACH TIME IT IS PRESSED,
THE INSTRUMENT INDICATED
BY THE DISPLAY CHANGES.
STOPPAGE DUE TO LOW
FUEL LEVEL
START KEY
- OFF
- STOPPAGE IN ALL OPERATING CONDITIONS
- RESTORE PROTECTIONS, CANCEL PUMP PROTECTION EXCLUSION AND TIMER,
DEACTIVATE INSTRUMENTS.
- CONTROL PANEL SUPPLY
- TURNS ALL THE LIGHTS ON FOR 2 SECONDS ( EFFICIENCY CHECK )
- PRESSURE SWITCH ADJUSTING (SEE PAGE 3)
- MOTOR PUMP START UP
0
AUT.
AVV.
STOPPAGE
DUE TO
WATER
LOW
PRESSURE
OR
PUMP
OVERPRESSURE
OR
ELECTRONIC
PRESSURE GAUGE
(TRANSMITTER)
INTERRUPTED.
IN THIS CASE,
THE ANOMALY IS
HIGHLIGHTED BY
THE FLASHING
WARNING LIGHT.
LOW PRESS.
OVERPRESS.
DISCONN'ED
A1
LOW FUEL PRESSURE

CEM-250 /10 - EN 3
0AUT.
AVV.
ADJUSTING THE PUMP WATER ELECTRONIC PRESSURE SWITCH (TRANSMITTER)
It controls the pressure of the system, replacing the conventional pressure switch.
WORKING PRESSURE BAR
PRESSOSTAT
BAR 7
BAR
Press to
select the
pump water
pressure gauge
OVERPRESSURE remains set to two bars, this value is
added to the working pressure (for example, working
pressure 9 bar overpressure 11 bar)
TIMER
Enabled with key on “AUT”, it makes it possible, if necessary, to have the motor pump work for an adjustable length of time (96 hours maximum),
at the end of which it stops and the WORK TIME OVER sign lights up on the display.
The work time is set by pressing the push-button ( lights up) until the desired value appears on the
DISPLAY .
STOP
On releasing the push-button, the timer automatically starts working, continously displaying the remaining work time.
CANCELLING THE SET TIME
To zeroing the set time there are two methods:
- keep the push-button pressed until it reaches zero.
- by turning the starter key onto "ZERO" (the engine pump will stop).
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 start key onto "ZERO".
-
-
Lit up with key on "AUT", they switch off with the engine running and regular oil pressure and battery charge system.
OIL AND BATTERY INDICATOR LIGHTS
M
ENGINE PROTECTIONS
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”).
Interventions of the protection probes (fitted on the engine), indicated by the relevant lights, stop the engine, they are memorised and can be split into
two groups.
Delayed by seconds for2 : Delayed by seconds for5:
- OIL PRESSURE SWITCH
- OVERTEMPERATURE
SWITCH ~
~
~
~
PUMP PROTECTION EXCLUSION
()ENABLED ONLY WITH ENGINE RUNNING
PUMP PROTECTION
The protection of the pump
Intervention of the protection
is enabled when the PUMP PROTECTION ACTIVE information comes on, after the water
pressure has been steady for 2 consecutive minutes and in any case after 10 minutes from starting of the engine.
occurs 5 seconds after the pressure goes up or down by , stops the engine and is shown on
the display:
two bars
Press to adjust
the value of
low pressure
(PRESSOSTAT)
P
-A1
- BATTERY CHARGE ALTERNATOR
(ALTERNATOR BELT BREAKAGE)
- FUEL LEVEL SWITCH
- Fuel reserve flashing signal: 20% fuel reserve
(T) (WITHOUT ENGINE STOP)
- Signal always on: stop for minimum fuel level (W)
- PROBE FOR COOLANT LEVEL
- LOW FUEL PRESSURE
INSUFF. PRESS.
OVERPRESS.
Low
pressure
Pump water
overpressure
or
(low pressure)
LOW PRESS.
It is possibile to change the of the
(low pressure) by using the key
This change is cancelled when
the engine stops.
two bars pressure
lowering
BAR
No adjusting is required

CEM-250 /10 - EN
4
INSTALLING THE CONTROL UNIT
155
SCREW
ELECTRODES
155
ROD
ELECTRODE
COOLANT LEVEL PROBE
FOR RADIATORS WITH
PLASTIC EXPANSION TANK
FOR RADIATORS WITH
EXPANSION TANKMETAL
1/4”
GAS
3/8”
GAS
PUMP PRESSURE TRANSMITTER CABLEWATER
TO REPLACE THE FUSES,
REMOVE THE COVER
FROM THE CONTROL UNIT
STOP SYSTEM SET UP
To stop with the SOLENOID VALVE
cut and isolate the BLUE/BROWN lead
SET UP
• WATER OR OIL
THERMOMETER
• OIL PRESSURE GAUGE
To view the water/oil THERMOMETER and the oil pressure GAUGE,
connect the transmitters to the respective wires of the unit,
then CUT and isolate the BLACK/VIOLET wire
YELLOW/
ORANGE
WARNING
IF THE FUNCTION
- LOW COOLING
LIQUID LEVEL
IS NOT USED:
CONNECT YELLOW/
ORANGE WIRE
TO EARTH
!
STOP SYSTEMS
EXCITED WHILE
RUNNING
EXCITED IN STOP MODE
85 30
86 87
SOLENOID
to close
the fuel
WARNING! :
IT IS NOT
POSSIBLE
TO MOUNT
THE
EMERGENCY
STOP BUTTON
ONASTOP
SYSTEM WITH
ELECTRO-
MAGNETS
YELLOW
85 30
86 87
27
TACHOMETER ADJUSTMENT
YELLOW
BLAC
K
/V
I
O
L
E
T
B
L
UE/
B
R
O
W
N
The unit has
been designed to
control stopping with an
ELECTROMAGNET
ELECTROMAGNET
to activate the
engine stop lever
RPM
until the correct reading appears on the display.
Release the buttons and wait until OK appears on the display.
Run the engine at
a costant and
known rpm
value
(for example by
means of
a portable
revolution counter) BAR
increase decrease
Select the instrument
TACHOMETER,
keep the button
pressed for at
least 5 seconds and simultaneously press
or
1
2
3
4
ORANGE/WHITE
YELLOW
BEFORE CONNECTING THE EMERGENCY
BUTTON REMOVE THE CONNECTOR
WITH THE JUMPERS
ORANGE/WHITE
ORANGE/WHITE
YELLOW
YELLOW
ORANGE/WHITE
YELLOW
YELLOW
ORANGE/WHITE
1
23
4C
1
2
3
4
CONNECTION OF
EMERGENCY BUTTON CONNECTOR C
D
B
D

CEM-250 /10 - EN 5
INSTALLING THE CONTROL UNIT
123
456
123
456
789
11 10
155
3
97
40
18
112
4
191
T
W
30
+ BATTERY
ORANGE
SKY-BLUE
RED
BLACK
GREY
WHITE/RED
BROWN (ONLY FOR PERMANENT MAG.)
YELLOW
WHITE/GREEN
WHITE/VIOLET
ORANGE/BROWN
ORANGE/
BLUE
GREEN
WHITE
RED/GREEN
CONNECTOR CONNECTOR
FROM 15/54 OF START KEY,
USABLE FOR AUXILIARIES
41
INSULATE
POSSIBLE
CABLES NOT
CONNECTED
2/7
157
INDICATOR
RESERVE
50
26/28
3A MAX
3A MAX
40A MAX
3A MAX
YELLOW/ORANGE
CABLE 2,5m
173
STOP
SYSTEMS
SEE PAGE 4
ACCESSORIES AVAILABLE ON REQUEST
(2/7) ELECTROMAGNET OR SOLENOID VALVE
(3) OIL PRESSURE SWITCH
(4) THERMOSTAT
(18) FUEL FLOAT FOR INDICATORAND RESERVE
(97) OIL PRESSURE TRANSMITTER
(112) TEMPERATURE TRANSMITTER
(155) COOLANT LEVEL PROBE
(173) WATER PRESSURE TRANSMITTER (SUPPLIED)
(26) PERMANENT MAGNETS CHARGE ALTERNATOR
(27) BATTERY CHARGEALTERNATOR REGULATOR
(28) PRE-EXCITATION CHARGE ALTERNATOR
(40) STARTING MOTOR
(41) BATTERY
(157) GENERALALARM LIGHT
(191) AVAILABLE FOR PROTECTION PROBE
PUMP
(218) FUEL PRESSURE SENSOR
A1
YELLOW
YELLOW
RED
PERMANENT MAGNETS
PRE-EXCITATION
27
27
DO NOT USE
26
28
WHITE/RED
+ BATTERY
GREEN
BROWN
WHITE/RED
+BATTERY
GREEN
BROWN
RLE
+
GLG
+
BR C
W
D+
B+
CONNECTION SYSTEM
FOR EXTRACTING THE
W TERMINAL IN
PRE-EXCITATION
BATTERY CHARGE
ALTERNATORS.
(BOSCH, MARELLI,
LUCAS, ECC...)
TO TACHOMETER
(WHITE/RED WIRE)
To diode bridge
(inside alternator)
}
CHARGE BATTERY ALTERNATOR:
WIRING DIAGRAM
TO CONNECT THE EMERGENCY BUTTON
see page 4 (connector C)
SELECT LANGUAGE
.
The language set up is ITALIAN; the
languages that can be selected are: ENGLISH, FRENCH, GERMAN,
SPANISH and PORTUGUESE
1
ON Move DIP
switch 1 to ON
ITALIANO
1
ON Move DIP
switch 1 to OFF
ENGLISH
Press to select
the desired language
Press and wait for
OK to be written
A1
218
BLACK/BLUE
3
21
CONNECTOR
D

CEM-250 /10 - EN6
The pump protection is enabled with the switching on of the ACTIVE PUMP PROTECTION (after 2 consecutive
minutes of stable water pressure, indicated by the visual signal REGULAR PUMP PRESSURE and, in any
case, 10 minutes after the start of the motor pump).
The intervention of the protection (5 seconds after the increase or decrease of the pressure) stops the engine and
is indicated by the visual signal for LOW PUMP WATER PRESSURE or
WATER PUMP OVERPRESSURE .
The control unit shuts down the engine in four conditions:
- turning the starter key onto "ZERO”
- protection intervention
- timer intervention at the end of the work period
- through intervention of the external emergency.
The unit adapts to two different stop systems
- 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.
It can be obtained in all functioning conditions, mounting one or more release-type buttons. It is indicated by the
visual signal and enables the general alarm.
This can be obtained by fitting on the outside an optical and/or acoustic signaller to be connected to the RED/GREEN
wire. It is activated on protection intervention.
!
The control unit comprises six instruments:
Each time it is pressed, IT SHOWS the next instrument. WHEN THE TIMER IS set, the duration of the display of
the instrument is limited to 30 seconds from the activating of the button; the TIMER then reappears.
HOUR METER - Total hours of operation (with the engine running the signal pulsates, to
indicate the correct functioning of the HOUR-METER).
INSTRUMENTS WHICH CAN BE SELECTED IN SEQUENCE BY PRESSING THE BUTTON
h
- PRESSURE GAUGE - E il pressure
- THERMOMETER - E oil and water t
ngine o
ngine emperature
TRANSMITTERS FITTED ON ENGINE
ON REQUEST
bar
C
RMP
BAR
%
}
RESET : is obtained by turning the start key onto "ZERO".
OPERATION
PUMP PROTECTION
STOPPING THE ENGINE PUMP
GENERAL ALARM
EMERGENCY STOP
INSTRUMENT SELECTION
- INDICATOR - Fuel level percentage
- PRESSURE GAUGE - Pump water pressure
- TACHOMETER - Speed of motor pump
CONTROLLING THE CONNECTION OF THE PUMP WATER
PRESSURE GAUGE (Transmitter)ELECTRONIC
Turning the key to the AUT position stops the electronic pressure gauge.
Control is activated 1 minute after the completion of the starting pulse.
Intervention is highlighted by the relevant indicators flashing warning light
and stops the motor pump after 2 seconds.
To exclude intervention, press the push-button PUMP PROTECTION EXCLUSION.
DISCONN'ED

h
bar
C
RMP
BAR
%
CEM-250 /10 - EN 7
®
E-mail: [email protected]
Via Arandora Star, 28/a-43122 PARMA ITALIA
S.r.l.
Tel. [phone]
HTTP://www.elcos.it
Fax [phone]
CONTROL AND PROTECTION UNIT
FOR IRRIGATION ENGINE PUMP
TYPE CEM-250/10
Only for starting and surveillance of the diesel motor pump and stops it if there are anomalies in
the parts controlled by probes.
Always install under other equipment which produces or spreads heat
Always follow the Wiring Diagram on pages 4 5 when making connections
Check that the line loading and the consumption of the connected equipment are compatible
All technical interventions must be performed with the engine stationary and terminal 50 of
the
Never use a battery charger for the emergency start-up, this could damage the control unit.
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 UNIT IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING
CONDITIONS:
Where the environmental temperature is outside the limits indicated in the Technical Data on
page
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.
ELECTROMAGNETIC COMPATIBILITY
This control unit functions correctly only if inserted in plants which conform with the CE marking
standards; it meets the exemption requirements of the standard EN61326-1 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.
CONDUCTIONAND MAINTENANCE
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.
It has been designed to be installed also on the machine.
-.
--.
-
with the technical characteristics on page 8.
-
starter motor disconnected.
-
-
-
-
8.
-
-
-
NOTICES
Warning:
:adhere closely to the following advice
UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS CONTROL UNIT IS NOT SUITABLE FOR
USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE FOR KEEPING PERSONS OR OTHER
LIVING BEINGS ALIVE
!
YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT THIS CONTROL
UNIT BY TELEPHONING ONE OF OUR TECHNICIANS

8
ACCESSORIES KIT
- PRE - WIRED FEMALE
CONNECTOR CEM CODE 70804420
- WATER PRESSURE
TRANSMITTER TYPE TPA-200
- NIPPLE F1/4" GAS -M3/8”GAS
-250-256/10
- EMERGENCY BRIDGE CONNECTOR CODE 70804421
PUMP
CODE 70190241
CODE 70500255
ORDERING DATA
TYPE CEM-250/10 CODE. 00211124
- BATTERY VOLTAGE SUPPLY: 12 Vdc 24 Vdc
-: 8
- CIRCUIT LOADING WITH KEYAT ZERO 13 mA at 12 V
9mAat24V
- MAX CURRENT OUTPUT
-(STOPPING) YELLOW 3A
-(STARTING MOTOR) BLACK 40A
-(GENERALALARM) RED/GREEN 3A
-(AUXILIARY) BROWN 3A
- TEMPERATURE RANGE -10 ÷ +60 °C
- HOUR-METER 4 DIGITS
- OIL PRESSURE GAUGE 0 ÷ 7 bar
- WATER PRESSURE GAUGE 0 ÷ 21 bar
- OIL/WATER THERMOMETER +20 ÷ +145°C
- TACHOMETER 4000 rpm
- TIMER 1' ÷ 96 h
- INSTALLATION CONDITIONS FOR EXTERNAL USE
- DEGREE OF PROTECTION
BOX/CONNECTOR IP23/IP20
- PANEL WEIGHT 3,3 kg
- TOTAL WEIGHT 3,7 kg
(PANEL + ACCESSORIES + PACKAGE)
VOLTAGE SUPPLY ÷ 32V
PUMP
ENGINE
- WATER PRESSURE TRANSMITTER:
• ALLOWED MAX. PRESSURE 21 bar
PUMP
• WITH PRESSURE 4 ÷ 14 bar
DIFFERENTIAL 2 bar
• WITH PRESSURE1÷4barDIFFERENTIAL 1 bar
DIMENSIONS TECHNICAL DATA
210mm
2,5 m
265
220
230 153
84
49 20
M6
47,5 85 85 47,5
185
CABLES
CEM-250 /10 - EN
CBAD