BOARDS

CONTROL PANEL FOR GEN-SETS

FOR AUTOMATIC IN
PARALLEL
TO THE MAINS AND FOR
AUTOMATIC PARALLEL
CO-GENERATION MAINS AND
SYSTEM
COGENERATION’S

BOARD FOR PRODUCTION CENTRAL WITH 1000KVA 2000 GEN-SET COMPLETE OF

CONTROL OF TRANSFORMATOR MAINS MT/BT

SPECIFICATIONS
TECHNICAL SPECIFICATION

PARALLEL MAINS Pag 1 di13 Rev. 19/09/01

 CENTRAL
CENTRAL FOR GEN-SETS
FOR GENSET IN
IN AUTOMATIC
PARALLEL TO THE MAINS
AUTOMATIC PARALLEL TO MAINS
GENERALITY
Automatic boards coupled to gen-set enables gen-set automatic start, it times him in parallel with mains, in
case of anomaly of mains it excludes her while privileged user is supplied by gen-set and return of mains to
nominal values it revives the parallel. During the running if the load is higher than power of gen-set, its are
issued two commands of sectioning lines not privileged until to return required power in the admitted value by
gen-set.

The microprocessor logic enables to realize various types of power supplied programs.
2. Fixed if the user is constantly higher than power gen-set or if it supplies on mains.
3. Modulated for the use on load, for not to supply on mains, suitable for installation with users to
variable power also lower than power gen-set.
4. Power modulation on cogeneration water temperature.
5. Transitory parallel with gradual load and download of load.
6. Various on request,etc.

During the running are active suitable protections motor, gen-set and mains.
Are foreseen running programs in automatic parallel, manual and emergency.
The construction is compliance with rules CEI 17-13.1 (EN 60439-1), CEI 11.20, ENEL DV 1601-1602, are
used components of first building firm which: IME, REVALCO, GE, TELEMECANIQUE, ABB, MERLIN GERIN,
TARASAKI, CABUR, ETC..

The project is supported for more 20 years of experience on many fittings, it guarantees the maximal
reliability, safety and use ease.

PARALLEL MAINS Pag 2 di13 Rev. 19/09/01

 CONSTRUCTION
CONSTRUCTION
Board ANS compliance to rules CEI EN :
11-20
17.13 ( EN 60439-1 )
DV 1601 DV 1602
Category 1 electric board
Class 1 isolation
Segregation
Internal protection to direct contacts
Standard external protection
BOX
It is composed by two modules for each gen-set whose
one for the commando and controls and the pther for the
power, which joints are accessibile by rear ( on request
by front with overprice ).
Built-up steel plate with carryng structure of thickness
20/10 welded and closing panels 15/10, protection
degree 15/10.
Lifting eyebolts and base with detachable panels for
possibile entry wires.
Painting cycle done dregreasing, phosphatization and
next painting with polyester thermosetting dusts to 200°
homologated.
Unit color grey siliceous RAL 7032 and internal plates
are galvanized plate.
Connection various panels by earth plait to guarantee
components electric continuity
WIRING AND AUXILIARY CIRCUITS
Executed wiring with section wires not lower to 1,5mmq,
compliance to rules CEI 20.20, diversified coloration
between AC and DC circuits.
Wires numeration corresponding to diagram.
Abutting by cables terminal pliered and preisolated.
Execution within canal in PVC autoextinguish not
propagating homologated, suitable dimensions.
PARALLEL MAINS
Production electric energy units
Equipment made in factory ACF
Rules ENEL
for voltage lower than 1000V.
with connection to earth
Form 3A
IP 20
IP 42 ( different values on request)
Protected circuits by sectionizing fuses type 10x38.
All components numeration in reference to diagram.
Connection type sectional terminal boards, resistant to
high temperature (melanin), with conductors thread in
copper and zinc alloy with nichel antioxide finish and
antiageing and clamping antiloosening screws.
POWER CIRCUITS
Executed with copper bars to rounded edges and on
request solded electrolytic for suitable protection
fungicide and for maximal adaptability and junctions
conductivity.
Assembly on suitable base of support in consolidation
mechanical fixings on possible dynamic currents.
Phase bar and neutral same section while the earth is
to 50% Connections executed with steel galvanized
antioxide bolts and nuts and suitable washer of fitting
holes and antiloosening.
Presetting suitable to connection linking cables.
Protection anti direct contacts by transparent
autoextinguishing PVC not propagating the fire.
Segregation form 3A ( others form on request )
Pag 3 di13 Rev. 19/09/01
 SIZE OF SUPPLY
SUPPLY
31. Fiscal kilowatthour
SECTION COMMANDS AND CONTROLS
· 3 voltage, current and frequency measure analogic It is composed inside by:
instrument, give immediate the condition of unit · Automatic battery charger suitable power.
without to interfere on electronic module where are · Aux feeder IR min. voltage coil.
reported the same measure. · Realy and contactors auxiliary services.
· “PX” microprocessor command and control module · Sectioning fuses 10x38 on auxiliary circuits.
totality programmable with included LCD display · Survey voltage mains and gen-set module.
with two lines by 40 character, 24 led signalation, · Automatic regulation cosfi gen-set
16 input, 16 output, 10 analogic entries and motorpotentiometer.
RS232C serial exit for telecontrol by modem or PC. · Regulator revolutions electronic card ( supplied in
Reported measures on display: work account ).
1. Mains voltage. · Mains protection relay for 27-59 voltage min./max.
2. KW power mains. · Protection gen-set relay for 51 overcurrent.
3. 1-2-3 gen-set voltage. · Protection services auxiliary switchs, batteru
4. Gen-set frequency charger, preheating, fuel pump, etc.
5. 1-2-3 gen-sets current phases. · Acustic signal.
6. KVA apparent power. · Measure power mains converter wattmeter (
7. KW real power. optional ).
8. Power factor (cosphi).
· Kilowatthour ( optional ).
9. KW inverse power.
· Inspection terminal board for kilowatthour.
10. Gen-set differential voltage.
· Connection terminal board.
11. Gen-set differential frequency.
12. Battery voltage.
13. Oil pressure.
14. Motor temperature.
15. Fuel level.
16. Work hours.
17. Speed indicator.
18. Kilowatthour.
19. Kilovarhour.
20. Panel with 8 led signals for state auxiliary
services which switchs battery charger,
preheating, etc.
21. Key selector start board.
22. Key selector aut/man selection.
23. Automatic running, lock and automatic test
selector.
24. Manual command selector switch mains
or gen-sets.
25. Start/stop two button gen-set manual
command.
26. Forced start selector.
27. Automatic programmed start, test and lock
selector.
28. Key selector of running in isola.
29. Silent alarm and reset button
30. Stop emergency button
PARALLEL MAINS Pag 4 di13 Rev. 19/09/01
POWER SECTION
It is foreseen the supply only switch gen-set.
· Automatic threepolar magnetothermic
switch, motorized, in fixed execution, with
min. voltage coil, suitable size for the
electronic protection of gen-set by overload
and short-circuit 50 and 51.
· Measure amperometer transformers.
· Measure kilowatthour amperometer
IR 4poles
transformers ( optional ).
· Sectioning contactor of neutral wire gen-set
during the running in parallel mains.
The switch is assembled subdoor to prevent
the manual manoeuvring.

OPTIONAL
On specification of gen-set are foreseen command
devices for auxiliary services which:
1. battery charger; IG 3poles
2. water preheatings;
3. oil preheatings;
4. electric fan for the radiator;
5. electric fan for room air;
6. fuel pumps;
7. prelubrication pumps;
8. recycling water pumps ;
9. command by pass download ;
10. command of modulation modulator valve of
cogeneration exchanger.

If foreseen manual parallel its are supplied:

1. cycle-converter potentiometer.
2. opening/closing manual parallel two
buttons.
3. regulation voltage and cosfi gen-set
two buttons.

PARALLEL MAINS Pag 5 di13 Rev. 19/09/01

 RUNNING
OPERATION
It is described central running of the block diagram of fig. 1, this diagram
represents the configuration use for cogeneration and auto production units.

QGE

MAIN PX
S CONTROLLER
CW
IR IG
G M
MT
GEN-SET
PPR
DV 601 - 602
KWh

Fig. 1

USE

Central all the automation is controlled by “PX CONTROLLER” which is programmable for various manners of
running. Every time, threshold, cycle incline is programmable, so in the description the word programmable
will not be repeated, why it is understood.

CENTRAL START
Start order can to be programmed with daily program on PX, or by local direct command ( selector ) or
remote, in the days inactivity the parallel running is excluded and the emergency function is active with inverse
synchronization to return mains to avert energy unnecessary interruptions.
With start command and supply condition of use by mains (IR closed), its are produced following functions:
gen-set automatic start; stabilization parameters break; gen-set synchronization and paralleling with mains
with IG closing, supply incline with programmable increase on motor temperature, hited the first limit of
suppliable power, it remains for suitable time to motor to hit work ideal temperature, then it pass in continuous
modulation adjusting supplied power by gen-set so to keep the minimal collecting by mains ( taken by CW)
without to exceed the maximal limit of suppliable power by gen-set.

PARALLEL MAINS Pag 6 di13 Rev. 19/09/01

 2° LIMIT MAX KW

1° LIMIT KW

INCLINE OF SUPLLY
PROGRAMMABLE

If during the running in auto production, power required by load declines to very low value for prolonged times,
it is possible to programme stop gen-set to restart in automatic manner when the power absorbed by unit
doesn’t return in the foreseen values.

ANOMALY MAINS
It causes the intervention of PPR mains protection which open IR switch mains immediately ( supplied on
request ) with MT min. voltage coil and the gen-set supplies the use. To opening of IR a contact is available to
command load reduction on gen-set.

MAINS RETURN
With the mains in the nominal parameters thr PPR enable the PX to inverse resynchronization of gen-set and
load to mains with IR switch mains reclosing. Returning to running of modulation power.

RUNNING IN ISOLA
If there are motives which counsel user supply only by gen-set, it is foreseen the forced command of ISOLA
which: it starts up the gen-set, it parallels him to mains, it does connection gradual load procedure and then it
excludes the mains ( IR opening ) keeping the user supplied by gen-set until to next command. At the
exclusion of Command ISOLA its have the functions of inverse resynchronization.

STOP CENTRAL
To stop command it is activated reduction load incline until to programmed minimal level, hited this level is
opened IG switch gen-set and after cooling motor time it is activated gen-set stop. The gen-set is active in
manner automatic to mains emergency interventions.

EMERGENCY MAINS
If there aren’t changes to programmation, with central stop by clockwork or by command, the gen-set pass to
function emergency mains in automatic manner. If the mains there isn’t: IR opens, the start is activated and
after about 10” prelubrication motor IG closes suppling the load with the gen-set. At return mains detected by
PPR it does the inverse resynchronisation of gen-set with load to mains, IR is closed, the load from gen-set to
mains is trasfered gradually and, hited the minimal power on gen-set, IG is opened and after cooling phase
the gen-set is stopped which remains predisposed to new cycles.

OTHERS MANNERS OF RUNNING

Without any circuit change it is possible to select running different manners:

MODULATED POWER ON TEMPERATURE

It repeats the described preceding functions with the difference that it modulates supplied power on a
temperature, that is when the temperature to exchanger increases over a programmed value, the supplied

PARALLEL MAINS Pag 7 di13 Rev. 19/09/01

power is decreased in automatic manner until to return of temperature in the parameters. Vice versa to
reduction of temperature. With PX it is possible to control the modulator valve of water exchanger/radiator.

TEMPORARY PARALLEL
When the gen-set has a suitable power to supply all the load, it can not to be expedient to remain connected
in parallel to mains; this cycle to command causes: gen-set automatic start; stabilization parameters break;
gen-set synchronization and paralleling with mains with IG closing, supply incline, IR is opened when it is hited
level of minimal collecting by mains, the gen-set is in isola running until to command central stop, with which it
actives the inverse resynchrinization of gen-set and load to mains with reclosing IR switch mains, it is actived
reduction load incline on gen-set until to programmed minimal level, hites this level switch gen-set IG is
opened and after time cooling motor it is activated gen-set stop. The gen-set is active in automatic manner for
a new cycle.

IR

IG

KW GEN

KW MAINS

PARALLEL GEN- MAINS LOAD ON GEN RESYNCHRONIZATION LOAD ON MAINS

SECTIONIG OF NEUTRAL GEN-SET

During the gen-set running in parallel to mains, a contactor placed to sectioning of neutral gen-set is opened
to avoid heavy reactive currents while during the running in isola ( IR opened ) it is closed and a her possible
anomaly is signalled and it causes the opened of switch IG gen-set and gen-set alarm and stop state.

COMMANDS
§ Selector to key of activation supply activation board by battery.
§ Selector to key selection manner AUTOMATIC MANUAL.
§ Selector running programming central in AUTOMATIC LOCK and AUTOMATIC TEST.
§ Selector start command central PARALLEL-EMERGENCY.
§ Selector manual command IG-IR switchs, excluded parallel.
§ Start button enabled only in manual.
§ Stop button enabled only in manual.
§ RESET button or functions reset.
§ SILENT ALARM button.
§ Stop emergency button.

MANUAL RUNNING
It enables the running in manual emergency to mains, electric interlocks are activated to avoid the parallel. It
is possible to start the gen-set, to supply the load, to stop the gen-set and to supply the load by mains. On
request it is possible manual parallel controlled by coupler, to regulate the cosfì and the supplied power.
PARALLEL MAINS Pag 8 di13 Rev. 19/09/01
AUTOMATIC TEST
It actives all the automatic cycle of start and synchronization, without to close IG. In case of anomaly mains
the gen-set connects in automatic manner on load closing IG. It is used for the functional tests of gen-set
during maintenance phases.

LOCK
It enables the lock of gen-set; every start is prohibited, while the mains supplies the use. This position enables
to can work on unit in total safety having the certainty that the gen-set doesn’t start also if the mains will fail ( it
is used for maintanance phases ).

AUTOMATIC RUNNING
In addition to what described, during the running the gen-set is controlled by possible anomalies which are
displayed by led, over the 24 signals which are on PX a further module groups 8 signals of auxiliary services.
The table represents all the signals differentiating the respective functions and manner of intervention:
1. D = visualization on display with literal writing of anomaly type.
2. V-R-G = colour of led signal
3. A = acoustic alarm
4. SI = immediate stop, to start up of programmated anomaly with delayed stop cycle, it has acoustic
alarm, the opening of switch gen-set IG and the immediate stop of gen-set.
5. SR = delayed stop, to start up of program mated anomaly with immediate stop cycle, it has acoustic
alarm, the opening of switch gen-set IG and the stop of gen-set after cooling motor phase.

N° DESCRIPTION VISUALIZ. SIGNAL. ALL. STOP STOP

on DISPLAY LED ACUST. IMMED. DELAYED
STATE SIGNAL
1 Automatic V
2 Lock R
3 Automatic test G
4 Forced or parallel start G
5 Running in isola G
6 Running in parallel G
7 Present mains voltage present V
8 Present gen-set voltage V
9 Closed mains switch V
10 Closed gen-set switch V
11 Synchronization in act G
12 Connected automatic preheating ON V
13 Active fuel pump ON V
14 Connected battery charter ON V
15 Start R
16 Stop R
17 Present battery V
18
19
20

PARALLEL MAINS Pag 9 di13 Rev. 19/09/01

 N° DESCRIPTION VISUALIZ. SIGNAL. ALL. STOP STOP
ON DISPLAY LED ACUST. IMMED. DELAYED
M0TOR PROTECTIONS
21 Failed start D A
22 Failed stop D A
23 Low oil pressure prealarm D A
24 Lo west oil pressure stop D R A SI
25 Low water level prealarm D R A
26 High temperature water prealarm D A
27 Highest temperature water stop D R A SR
28 High oil temperature prealarm D A
29 Highest oil temperature stop D A SR
30 Battery charter gen-set R A
31 Fuel reserve prealarm D A
32 Lack fuel D R A SR
33 PS cumulative available alarm D R A SR
34 Battery overvoltage D A
35 Battery undervoltage D A
36
37
38
GEN-SET PROTECTION
39 Overvoltage (59) prealarm D A
40 Overvlotage (59) Stop D A SI
41 Undervoltage (27) prealarm D A
42 Undervoltage (27) stop D A SR
43 Overload (51) by switch release R A SR
44 Short-circuit (50) by switch release R A SR
45 Max frequency (81) stop D A SI
46 Min frequency (81) stop D A SR
47 Inverse power D A SR
48 Max active power KW prealarm D A
49 Max active power KW stop D A SR
50 Max reactive power KVAR prealarm D A
51 Max reactive power KVAR stop D A SR
52 Max current stop D A SR
53 Dissymmetry programmable voltages D A SR
54 Dissymmetry programmable currents D A SR
55
56
57
58
VARIOUS
59 Disconnected battery charger R A
60 Disconnected preheating R A
61 Disconnected fuel pump R A
62 Emergency R A
63 Contactor neutral in failure R A SR
64
65
OPTIONAL COGENERATION
66 Supplied startings V
67 By pass active download V
68 Active fan room ON V
69
70

PARALLEL MAINS Pag 10 di13 Rev. 19/09/01

During the inactivity the gen-set is controlled by possible anomalies to levels and to preheating system
emitting the acoustic alarm.

PARALLEL FUNCTIONS
During the synchronization a motorpotentiometer equalizes gen-set voltage to that of mains and only when
the discard is in the programmed value the parallel is enabled.

EMERGENCY STOP
If there is emergency stop it has:
§ Opening switch gen-set IG1.
§ Disconnection of all circuits motor.
§ Closing solenoid valves safety gas.
§ Immediate stop

AUXILIARIES SERVICES
AUXILIARES SERVICES
AUTOMATIC BATTERY CHARGER
10A automatic battery charger provides to perfect maintenance of charge of batteries, by electronic control of
voltage and current, which in manner automatic decreases charge current when the voltage hited the programmed
nominal value ( 13,5V for batt. 12V and 28V for batt. 24V ),limiting the current to needed value to compensation of
consumption various circuits and of autodownload of battery.

FEEDER COIL OF MINIMAL ON IR

Since all the services are supplied by batteries gen-set, to avoid that during the maintenance phases to gen-set
or to battery an interruption of battery circuit causes the opening of switch mains IR not supplying all the load, it is
foreseen a feeder for the coil minimal voltage situated on IR which guarantees the running independently by battery
gen-set.

PREHEATING MOTOR
Motor preheating is commanded by PX on motor temperature, with automatic exclusion to start same gen-set.
Supply unit for motor preheating is three-phase, protected by automatic switch and commanded by 20 A lth
contactor. The possible anomaly is signaled.

FUEL PUMP UNIT

In the module is foreseen the automatic command fuel pump unit, it is controlled by same level which signals the
reserve and lack fuel, it needs to provide for max level of safety for the compliances to MISA 31.
The command for three-phase pump is foreseen by 1 HP max. The possible anomaly is signaled.

PARALLEL MAINS Pag 11 di13 Rev. 19/09/01

 OPTIONAL
OPTIONALS
MANUAL PARALLEL
In manual running are excluded all the devices of automatic parallel which synchronizer and load dispatcher which
possible failure would prevent the running in parallel.
Are activated
· A couplerwhich enables the manual parallel only when the are the suitable conditions.
· Closing/opening parallel two buttons.
· A potentiometer speed-variator which enables the manual synchronization and after the parallel manual
modulation of supplied power.
· Two buttons to change voltage in phase of synchronization and the cosfì after the parallel.
During the automatic running the needed circuits and calibrations for manual running are excluded and its are
irrelevant.

COGENERATION (optional)
Its are foreseen: modulator valve command of motor water to exchanger water/water and the motor radiator;
by pass command on collector of download to exchanger air/water; startings delayed command and the
command for the electrovalve of safety on gas conduit.

ANTICONDENSATION UNIT
According to environment and climatic conditions its are foreseen presettings for anticondensate units installation for
the boards and the gen-set.

TELECONTROL
The PX is provided with RS232C serial exit for the total telecontrol, controlling in local room by PC orremoted by
telephonic line.

CONNECTOR(optional)
It is supplied a connector by 24 poles with 10ml multipolar cable.It includes connection wires to various commands
and controls of motor included the actuator and the pick up for electronic speed governor.

SUPPLY LIMIT
The supply is charged to only board, are excluded optionals, projects and external units in addition to
what described before

DOCUMENTATION
The supply is supplied by:
Wiring electric diagram.
Operative rules.
Running, use and maintenance manual
Operative rules

ATTENTION
The IR switch mains isn’t foreseen ih the supply, it have to be provided with:
- 220V ac. motor command
- 24V cc.minimal coil
- Auxiliary contact
- Released relay contact

PARALLEL MAINS Pag 12 di13 Rev. 19/09/01

 AUTOPRODUCTION BOARD FOR 1000KVA GEN-SET COMPLETE OF SWITCH OF
INTERFACE AND MT TRANSFORMER PROTECTION

INTERNAL VIEW

PARALLEL MAINS Pag 13 di13 Rev. 19/09/01