Procom ECON-A User manual

OPERATING INSTRUCTIONS
ECON-A
MRM PR
PRPR
PRO
OO
OC
CC
CO
OO
OM
MM
M Pvt Ltd
An ISO-9001-2008 certified organization
Works: Plot No. 20-21, Sector 59, Phase –II, Faridabad, Haryana -121004
Ph: 0129-4700400 (10 lines)Email: [email protected],
Web: www.mrmprocom.com

INDEX
1.0 Introduction
2.0 Salient features, Protection & Supervision
3.0 Display/ Front Panel
4.0 Switches Description
5.0 LED Annunciations Description
6.0 Lamp Test
7.0 Digital Input
8.0 Analog Input
9.0 Digital Output
10.0 Operating Mode
10.1 Auto Mode
10.2 Manual Mode
10.3 Semi Auto Mode
11.0 Setting Procedure
12.0 Parameter Mode
12.1 System Parameter
12.2 Generator Parameter
12.3 AMF Parameter
12.4 Protection Parameter
12.5 Reset Service Alarm
12.6 Adjust Clock
12.7 Reset Password
13.0 Load Management
14.0 Event Recording
15.0 Faults
15.1 Internal Faults
15.2 External Faults
15.3 Fault Reset
16.0 Communication
17.0 Model Selection
18.0 Terminal description
19.0 Specifications
20.0 Dimension
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1.0 Introduction
ECON-A is a universal controller for DG. ECON is available in three flavours:
•ECON-A
•ECON-S
•ECON-M
ECON-A is super set which can be configured as ECON-S or ECOM-M
ECON-S is next in line and can be configured as ECOM-M
ECON-A: It's basically a complete AMF controller and can operate be configured for :
◦Three Phase Mains Three Phase DG
◦Three Phase Mains Single Phase DG
◦Single Phase Mains Single Phase DG
This controller can be operated as Manual controller with provision to control Shunt trip of MCCB:
◦Single phase with Shunt Trip
◦Three phase with Shunt Trip
If no shunt trip function is required the controller can be configured as manual controller with the
following system configuration
◦Single phase
◦Three phase
Controller can be operated in manual mode even when its configured for AMF mode.
ECON-S: It's a manual controller which can be configured to work with shunt trip or with out it. The
following configurations are possible
◦Single phase with Shunt Trip
◦Three phase with Shunt Trip
◦Single phase
◦Three phase
ECON-M: Its a pure manual controller and can be configured for
◦Single phase
◦Three phase
•Display: 128*64 pixel graphial backlit LCD for ease of readout and symbolic representation.
•Menu driven MM1 for easy in field configuration without PC or any customized equipment.
•Load Management . Load Dependent start/stop of 2
nd
DG in case of two DG application.
•Automatic Start of engine if not used for a predefined time to charge the battery as well as
maintenance.
•ECON reminds user for timely service by indicating service due alarm.
•True RMS measurement of all measured parameters with 1% accuracy of measured value.
•Plug in connectors for error free replacement.
•Programmable DG on delay,DG continuous on time,DG Rest Time,warm-up time along with 33 other
times.
•Automatic real time based DG Start and Stop(Manual Control Configuration.
•Dimensions 167 х 129 х41.8 mm.
2.0 Salient Features, Protection and Supervision
•Mains Measurements
◦1 Phase/ 3 Phase Voltage
◦1 Phase/ 3 Phase Current
◦Frequency
◦PF, KW and KVA.
•Generator Measurements
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◦1 Phase / 3 Phase Voltage
◦1 Phase / 3 Phase Current
◦Frequency
◦PF,KW,Kwh & KVA.
◦Battery Voltage
◦Water Temperature
◦Oil Pressure
◦Fuel Level
◦RPM
◦Run Hour
◦Service Due Hour
• Protection / Supervision Mains
◦Under/Over Voltage
◦Under/Over Frequency
◦Phase Sequence
◦Voltage Unbalance
◦Overload
• Protection / Supervision DG
◦Under/Over Voltage
◦Under/Over Frequency
◦Current Unbalance
◦Over Speed
◦Overload
◦RWL
◦LLOP
◦HWT
◦LFL
◦Charging Alternator/V-belt
◦Emergency off
◦Service Due
◦Fail To Start(only when configured as AMF controllers).
◦Fail To Stop(only when configured as AMF controllers).
•Digital Input : Eight digital(4 fixed and 4 programmable)
•Analog Input: and three Analog input (sensor measurement)
•Output : Nine digital (five fixed and three programmable) and one for charging Alternator
•Modes : Configurable Auto, Semi auto and manual mode of operation.
•Fault Data Recording : Last 32 fault with date and time stamping
•Event Recording : Last 32 event
•Start Stop Recording: Last 100 records
•Password Protection :Three digit password protection for system settings.
•Real Time Clock (RTC)
•Communication : RS232, USB, RS485(Optinal)
•Timers:: Programmable DG on delay, DG continuous on time, DG rest Time, warm up time along
with 33 other time
•Provision for switching ON or OFF the measurement for individual sensors.
•Option of warning or tripping on sensor open.
•Programmable engine on detection based on ignition voltage, oil pressure build up or on both.
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3.0 Display / Front Panel
128x64 pixels Graphical LCD Display for ease of readout.128x64 pixels Graphical LCD Display for ease of
readout. Parameters are displayed in English along with symbolic representation.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 Switches Description
ECON-A has 7 switches provided on its front panel. The table below describes the operation of these.
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5.0 LED Annunciations Description
ECON-A has nine annunciations on its front panel. These either announce the faults or indicate status of the
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7. DG Voltage This indication glows continuously when the
generator is running.
8. Warning This LED blinks in case of a warning.
9. Fault This LED blinks in case of a fault
6.0 Lamp Test
If the ECON-A is switched on while the reset switch is pressed, all the LEDs start blinking till the time reset
switch is kept pressed.. This state shall persist till the switch is kept pressed and on release of the switch ECON-A
shall start functioning normally.
7.0 Digital Input
ECON-A has Eight digital input as below
Fixed Inputs
1) Remote Start,
2) Remote Stop / Semi Auto
3) Emergency
4) Magnetic Pickup unit(Not used)
Programmable 4 inputs each can be programmed as one of the following inputs.
1) RWL Switch
2) LLOP Switch
3) Fuel Switch
4) HWT Switch
5) Oil Level Switch
6) Canopy Temperature Switch
7) Oil Temperature Switch
8) HCT( High Coolant Temperature) Switch
8.0 Analog Input
ECON has three digital input :
1) Low Lube Oil Pressure Sensor
2) High Water Temperature Sensor
3) Low Fuel Level Sensor
4)
9.0 Digital Output
ECON has nine digital outputs :
•Programmable output
Three digital outputs can independently be configured for the any functions from the list below.
1) Unit Healthy
2) Load Warning
3) Fuel Pump
4) Heater/Choke
5) None
•Fixed output
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The remaining 6 digital outputs are fixed:
1) Charging Alt( Battery Voltage)
2) Crank Contact
3) Solenoid Contact
4) Hotter Contact
5) Mains Contactor Contact
6) Generator Contactor Contact
10.0 Operating Mode
AMF Version of ECON (ECON-A) has three programmable operating modes, i.e. Auto/ Semi Auto / Manual
mode.
Manual version of ECON(ECON-M) does not have auto and semi auto mode.
Auto/ Manual Mode can be toggled by pressing MODE switch from the front panel. Semi Auto mode can be
activated by pulling the semi Auto pin low, while the unit was in Auto Mode. This is explained latter. .
10.1 Auto Mode
ECON-A 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,
ECON-A releases the MCB contactor (to protect the contactor from failure because of low input voltage)
and attempts to starts the generator after the programmed delay start duration has expired. In case the
mains become 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 ECON-A 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 ECON-A 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 ECON-A 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.
10.2 Manual Mode
ECON-A, 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 ECON-A protects the generator by monitoring all internal and external
faults.
10.3 Semi Auto Mode
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This mode can be selected by pulling the pin 28(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 29(Remote Start/Stop). 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 29(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.
Please note: Operating Mode cannot be changed if the unit has stopped on a fault condition or the
engine is cranking.
Auto, Man., is Radio buttons and only one can be active at a time.
11.0 Setting Procedure
How to Enter in Parameter Mode
Press Next & Reset switches simultaneously. The LCD shall display, “System Parameter”
To enter System Parameter setting mode, press Next Switch,the LCD shall display, “Enter Password” and
default password is 123 then press Next Switch. For any change in value, press Start switch and
Stop switch. For next parameter,press Next Switch.
To go to next menu press Start Switch the LCD shall display “Generator Parameter”
To enter Generator Parameter setting mode press Next Switch.For any change in value, press Start
switch and Stop switch.For next parameter,press Next Switch.
To go to next menu press Start Switch the LCD shall display “AMF Parameter”
To enter AMF Parameter setting mode press Next Switch. For any change in value, press Start switch and
Stop switch.For next parameter,press Next Switch.
To go to next menu press Start Switch the LCD shall display “Protection Parameter” Start switch
To go to next menu press Start Switch the LCD shall display “Display History”
To View Display History mode press Next Switch.
To go to next menu press Start Switch the LCD shall display “Display Event”
To View Display Event mode press Next Switch.
To go to next menu press Start Switch the LCD shall display “Display Start/Stop”
To View Display Start/Stop mode press Next Switch.
To go to next menu press Start Switch the LCD shall display “Reset Service Alarm”
To enter Reset Service Alarm mode press Next Switch. The LCD shall display
“Press START to Reset
Press STOP to ESC”
The unit shall ask for confirmation to reset the service hours pressing desired Switch.
To go to next menu press Start Key the LCD shall display “Adjust Clock”
To enter Adjust Clock setting mode press Next Key. For settng up of the time, press Start switch and
Stop switch.
Press Next Key the LCD shall display DD/MM/YYYY.For settng up of the date, press switch
and Stop switch.
To go to next menu press Start Key the LCD shall display “Reset Password”
To enter Reset Password setting mode
Press Next Key “Enter Password”
Press Next Key “Change Password”
Press Next Key the LCD shall display
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“Press START to Change
Press STOP to ESC”
The unit shall ask for confirmation to change the password pressing desired
key.
12.0 Parameter Mode
The following tables give 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.
Parameters
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* This parameter can be disabled while programming
13.0 Load Management (Optional)
ECON-A 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
unnecessary loads or start a second generator when the load goes above a limit.
14.0 Event Recording
ECON keeps a log of last 32 events. Setting change and warning are considered as event. Events are stamped
along with date and time
15.0 Faults
There are two categories of faults
•Internal Faults
•External faults
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•
16.1 Internal Faults
Internal faults are the faults, which do not need any external signals and are detected by the system
itself. They are:
•Generator Fails to Start.
•Generator Voltage Unhealthy
•Generator Frequency Unhealthy.
•Generator over Speed.
•Generator Fails to Stop.
•Over Load
16.2 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:
•LLOP
•HWT
•RWL
•Fuel
•Emergency
•V-Belt
16.3 Fault Reset
Internal Faults & LLOP fault:
All internal faults and LLOP fault can be reset by pressing (R) switch after the generator is
stopped.
External Fault except LLOP & V-Belt faults:
These faults cannot be reset till the engine is running and/or fault conditions persist. Once the
faults are rectified, the fault can be reset by pressing Reset switch (R). In case the engine fails
to stop “STOP KEY” can be pressed for manual attempt to stop engine
16.0
Communication
•RS232
•USB
•Modbus on Rs485 (optional)
17.0
Model Selection
ECON-M : Manual Controller with no AMF function.
ECON-A : AMF Controller with built-in Manual Mode.
18.0 Terminal Numbers
Terminal No. Description
1 NC
2 NC
3 NC
4 CT Common
5 CT B
6 CT Y
7 CT R
8 NC
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9 Sensor LLOP
10 Sensor HWT
11 Sensor Fuel
12 V-DG-N
13 V-DG-B
14 V-DG-Y
15 V-DG-R
16 V-Mains-N
17 V-Mains-B
18 V-Mains-Y
19 V-Mains-R
20 NC
21 NC
22 NC
23 D Input 4
24 D Input 3
25 D Input 2
26 D Input 1
27 Emergency
28 Semi/Auto
29. R Start/Stop
30. Pro Output 3
31. Pro Output 2
32. Pro Output 1
33. Hooter
34. Solenoid
35. Crank
36. GCB
37. MCB
38. Chg. Alt. Contact
39. Battery(+ve)(8-35 V DC)
40. Battery(-ve)
41. Sensor(-ve)
19.0 Technical Specifications
AC voltage withstand 330 VAC (Phase to neutral)
Measurement Accuracy
Voltages & Current 1% of Reading
Power & Energies 2% of Reading
Surge 1.2/50Usec 2.5KV
Battery Voltage 9-35 V DC
DC Interruption time 0.4 Sec
Cut out Dimensions 155mm X 117mm
Depth 41.8 mm
Digital Input Level Battery Voltage (Negative)
20.0 Dimensions
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