ELCOS CAM-335 Manual de usuario

GENSET CONTROL UNIT

CAM-335

Developed to equip automatic emergency panels.

It controls and operates genset, connecting the power user to the mains or generator.

USER’S MANUAL

Functions:

Complete with backlit graphic display with touch

screen to view:

Three voltmeters for the mains.

Three voltmeters for the generator.

Three mains/generator ammeters.

Mains/generator frequency meter.

Generator tachometer.

Mains/generator kW (active), kVAR (reactive)

and kVA (apparent) powers.

Battery voltmeter.

Fuel level gauge.

Water/oil thermometer.

Oil pressure gauge.

Total hour-meter.

Partial hour-meter.

Start-ups counter.

Automatic monitoring of faults with display messages.

Complete three-phase voltmetric control of mains and genset (undervoltage, overvoltage, phase asymmetry,

incorrect phase sequence, underfrequency and overfrequency).

Texts in 7 languages: Italian, English, French, German, Spanish, Portuguese and a programmable language.

CAN Bus Connection SAEJ1939.

RS232, RS485 serial ports and USB.

MOD Bus RTU Protocol.

4-maintenance management.

Management of rental hours.

Remote controls (start, stop, EJP).

Generator start and stop on power demand.

Ability to start generator when the battery charge is low.

Option of associating inputs and outputs with different functions.

Glow plug preheating management.

Management of refuelling of working tank from storage tank.

Clock for programming genset starting or stopping.

Automatic test.

Anomaly log.

Option of password protected programming.

Dimensions (LxHxW) 157x109x74mm

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 2 of 20

TABLE OF CONTENTS

CHRONOLOGY OF MANUAL REVISIONS.........................................................................2

INSTRUCTIONS IN BRIEF..................................................................................................3

INSTRUMENTS...................................................................................................................3

DISPLAY..............................................................................................................................4

OPERATION........................................................................................................................6

CONNECTION DIAGRAM.................................................................................................12

USER PROGRAMMING....................................................................................................14

FAULT LIST.......................................................................................................................17

TECHNICAL SPECIFICATIONS........................................................................................18

WARNING..........................................................................................................................19

INFORMATION FOR ORDERING.....................................................................................20

STANDARD ACCESSORIES ............................................................................................20

ACCESSORIES AVAILABLE ON REQUEST....................................................................20

DOCUMENTATION ON REQUEST ..................................................................................20

DECLARATION OF CONFORMITY....................... Provided in the manual as an attachment

CHRONOLOGY OF MANUAL REVISIONS

Date

Revision

Description

Page

27/07/2015

1.00

First release

05/09/2016

1.05

MAX mains voltage present delay =9999 sec.

12 technical prog.

10/10/2016

1.06

Fault: radiator stops without cooling

8 technical prog.

19/12/2016

1.09

Semi-automatic mode, reset of maintenance cycle, acceptance

of commands via SMS from any telephone number.

6, 16, 18 technical

prog.

23/05/2017

1.10

Exclusion of current transformers

Programming of maximum number of fault SMS

messages

Keyboard error input

Programmable mains contactor fault input

Programmable genset contactor fault input

5,12,18, 20

Technical prog.

1.13

Change automatic test

1, 7, 3, 13

Technical prog.

04/06/2020

1.14

Time synchronization of other control units.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 3 of 20

INSTRUCTIONS IN BRIEF

INSTRUMENTS

The control unit has a backlit 128 x 64 dot graphic display with touch screen. It is used to view the following

instruments:

Three line-to-line mains/generator voltages.

Three star mains/generator voltages.

Three mains/generator ammeters.

Mains/generator frequency meter.

Active (kW), reactive (kVAR) and apparent (kVA) power, for both mains and generator. The powers are

displayed for each phase and as a sum of the phases.

Mains/generator power factor indicator displayed for each phase.

Mains/generator energy counter (kWh).

Battery voltage.

D+ voltage (pre-excitation alternator).

Fuel tank level indicator.

Engine temperature expressed in °C or °F.

Oil pressure expressed in BAR or kPa.

Engine revolutions (RPM).

Total hour-meter.

Partial hour-meter.

Start-ups count.

Starting failure counter.

Maintenance expirations.

Rental hours expirations.

Calendar clock.

Automatic test.

All the instruments for the mains (V, A, Hz and kW) are also displayed simultaneously. Simply pressing the arrows

displays all electrical instruments for the generator and engine. In the event of an anomaly, the display presents the

message indicating the anomaly that has occurred.

Display with

touch screen

Press to start

in manual

mode

Press to stop

in manual

mode

Cumulative

alarm without

stop (yellow)

with stop

(red)

Power from

mains

present

Mains

inserted on

power user

Generator

inserted on

power user

Power from

generator

present

Control unit is

on:

manual

automatic

test

off

Press to select

function:

manual

automatic

test

off (failure reset)

programming

Engine running

Buttons to switch the

power user to mains

or generator (in

manual mode).

Press the arrows to browse display menus.

Acknowledging the general alarm.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 4 of 20

DISPLAY

The instruments displayed on the control unit are divided into groups. The groups are:

Mains

Generator

Engine instruments

CAN Bus instruments (if CAN Bus connection is enabled)

Counters

Maintenance (if maintenance hours have been set)

Rental (if rental hours have been set)

Fuel top-up management (if function is enabled)

Anomalies

Clock

Information about the control unit.

The two arrows are used to scroll through the instrument groups on the display or to select the sub-

menus under the settings.

The following are a few examples of instrument display menus.

The two arrows are used to move within the instrument groups or to scroll through the choices in the

settings menus.

Menu name

Line-to-line

voltages

Frequency

meter

Currents

Active power

Menu name

Fuel level

Temperature

Tachometer

Battery voltage

Pressure

D+ voltage

(input 66)

Icon identifying if

anomaly causes a

stop or does not

cause a stop .

Menu name

Anomaly

occurred

Menu name

Phase currents

Number of

active

anomalies

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 5 of 20

To display instruments individually, simply touch the display on the relevant instrument. For example:

touching the D+ icon with your finger opens the menu that

displays the individual instrument.

To move inside the groups of instruments, you can either touch the arrows or the display. Each press of the button

displays the next instrument in the group.

For example:

and doing so will allow you

to browse through all the instruments.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 6 of 20

OPERATION

FUNCTION SELECTION

The function selected using the key is indicated by its light which goes on.

MANUAL

Image displayed when switched to manual.

Press to start and to stop (a quick press is sufficient).

Pressing the button switches the load from the mains to the generator and vice versa.

In manual mode, the generator protection function can be programmed in two ways:

Display the fault recorded and stop the engine (this is the default setting).

Only display the fault recorded, without stopping the engine. Generator overspeed and emergency anomalies

are programmed to shut down the engine; they cannot be programmed without engine shutdown.

AUTOMATIC

Image displayed when switched to automatic.

When a mains anomaly occurs —detected by the internal voltage relay inside the control unit or when the

external call delay has elapsed —the control unit commands the mains contactor to open and the genset to start.

With the engine running and with correct generator voltage and frequency, once the G.S. VOLTAGE PRESENT

DELAY has elapsed, the generator contactor is closed. When operating, the genset is protected from any anomalies.

When the mains voltage is restored and the MAINS VOLTAGE PRESENT DELAY has elapsed, the control unit

commands the generator contactor to open and after the GENERATOR MAINS INTERLOCK time has elapsed, the

mains contactor closes.

The COOLING TIME enables and facilitates subsequent engine cooling before it shuts down.

To facilitate start-up, a special circuit determines a series of start-up attempts, the number, pause duration and start-

up duration of which can be programmed. If running of the entire series of start-up attempts is unable to start the

engine, when the cycle is completed, STARTING FAILURE is displayed and the stop cycle starts.

TEST

Image displayed when switched to test.

In testing, the engine start-up cycle is obtained as in automatic mode, with the exception that the user remains

powered from the mains. If, during the test, a mains anomaly occurs, the control unit remains in test mode but

commands the generator contactor to close.

OFF

Image displayed when switched to off. When set to OFF, the engine cannot be started in any

way and, if it is running, it stops without the engine cooling step.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 7 of 20

PROGRAMMABLE OUTPUTS

WARNING!

Outputs 6, 19 and 70 can be associated to many functions (see programming manual under the section

“PROGRAMMABLE OUTPUTS”). It is NOT possible to simultaneously associate more than one function to an

output. For example, if fuel filling is associated to output 70, it is not possible to manage the general alarm from this

terminal and vice-versa. By default, management of glow plugs is associated to output 6, the signal that simulates the

15/54 to output 19, and the general alarm to output 70.

GLOW PLUG PREHEATING

Activation of the glow plug output is adjustable —from a minimum of 0 seconds (command off) to a maximum of

60 seconds —for both automatic and manual mode. Once activation has been completed, the engine start-up

procedure begins. Glow plug post-heating can also be managed, i.e. maintaining output live for a set amount of time,

even after the engine has been started (see programming manual).

ENGINE TYPES

The control unit can manage start-up of both diesel and petrol engines. Diesel engines allow for the connection of

the CAN bus line to the control units with electronic injection. For choice of engines, see the programming manual.

AUTOMATIC TEST

The automatic test is enabled only with the control unit on automatic. During the test, the generator set starts up

and stays running for the AUTOMATIC TEST DURATION time (programmed at 3 minutes). If a mains anomaly

occurs, the generator contactor closes. The display shows AUTOMATIC TEST during the test cycle. You can also

choose whether to run a commutation or not during the test (default setting: no commutation). Press STOP to stop the

engine during the test. The test will not be run if there is an anomaly. The automatic test can be performed in two

ways:

WEEKLY: the test will be run weekly at the time and on the day set.

MEASURED: the test can be programmed to run at cycles ranging from 1 to 30 days. The default setting is 7 days.

To enable the test, just enter User Programming and include the function. Once any one of the test parameters has

been set, it starts for the first time when one minute after quitting the setting mode has elapsed. If at that time the

conditions for starting the test are not present (e.g. because the control unit is not on automatic), the test will be run

at the next deadline. The time count starts all over again when the control unit is reset.

ENGINE RUNNING DETECTION

Engine running is detected by revealing the residual generator frequency and voltage and by detecting the

voltage and frequency of the battery charger alternator (permanent or pre-excitation magnets). When an engine with

electronic management is connected to the control unit, detection of the running engine occurs when the RPM read by

the CAN Bus line exceed the RUNNING ENGINE THRESHOLD RPM. Once detected, the starter motor switches off

and the green LED lights up

STOPPING SYSTEMS

Stopping can be achieved in two ways:

With the electromagnet or solenoid valve energized when the engine is running and de-energized when the

engine is stopped (default setting).

With the electromagnet de-energized when engine is running and energized when it is stopped, remaining in

this condition for the entire STOPPING TIME after engine not running has been detected.

If, after 120 seconds from receipt of the stop command, the control still detects the engine running signal, the

STOPPING FAILURE trips.

EMERGENCY STOP

This is available in all operating modes. It is possible to install (hook mount) one or more buttons. Stopping is

immediate, without engine cooling; it activates the general alarm and EMERGENCY STOP is displayed.

Do not use the emergency button in combination with a stopping system that is not energized while

running.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 8 of 20

GENERAL ALARM

The general alarm can be obtained by installing a signal at the appropriate alarm terminal. It can be programmed

so that it is always on or remains on for a specific amount of time. It trips whenever the control unit detects an

anomaly. Pressing one of the arrows silences the alarm.

GENSET AND USER PROTECTIONS

Tripping of an anomaly is shown on the display and can cause the engine to cut out and activates the general

alarm. See the FAULT LIST table on page 17.

Normally the display shows the genset instruments; in the event of an anomaly, it displays the anomaly message

triggered. If the anomaly causes a stop, the red LED flashes and the icon lights up; if the anomaly does not cause

a stop, the yellow LED flashes and the icon lights up

If the anomalies are detected by the CAN Bus line connected to the engine’s electronic injection control unit, the

yellow and red LEDs light up and remain steady on.

Press the ARROW to review the instruments on the display and, at the same time, silence the general alarm, use one

of the 4 navigational arrows. After 20 seconds have elapsed since the last time the key was pressed, the display

reverts back to displaying the anomaly/anomalies that have occurred.

When OFF RESET lights up, the anomalies can be reset by pressing the key . If the OFF function is disabled,

press the key to reset the anomalies.

PREVENTIVE MAINTENANCE

When preventive maintenance operations are to be carried out, the flashing alarm light goes on and the

maintenance number that intervened is displayed along with the description set beforehand. If programmed, stopping

is also achieved with PROTECTION IN MANUAL bypassed and with the PROTECTION INHIBITION input active. The

procedure for resetting expired maintenance is to be performed only by genset manufacturer.

RENTAL FUNCTION

It is possible to programme the number of genset rental hours; after this time has elapsed, the control unit can

immediately block genset operation or can block it at the next start-up. If programmed, stopping is also achieved with

PROTECTION IN MANUAL bypassed and with the PROTECTION INHIBITION input active. Rental hours are counted

down when the engine is running.

STARTING GENSET WITH LOW BATTERY

When the battery is low, the genset can only be started up in automatic mode. When the voltage measured at the

battery terminals is below the minimum threshold, the engine will start and remain running until the maximum

threshold has been exceeded and the programmable delay time has elapsed.

START ON POWER REQUEST

The genset can only be started up on power request function when in automatic mode. When the power

absorbed by the power user is higher than the set threshold for the whole duration of the cut-in delay, the control unit

starts the generator set and switches the user to the generator. When the power absorbed by the power user is lower

than the set threshold for the whole duration of the cut-in delay, the control unit stops the generator set and switches

the user to the generator.

DAILY STARTING-STOPPING

The functions managed by the control unit’s internal clock are only active in automatic mode. Up to 10 genset

starts can be programmed, with relative switching of the power user to the generator at certain daily time slots.

It is also possible to program a genset lockout at a certain daily time slot.

CALL INPUT (TERMINAL 30)

Call input is active with control unit in automatic and test modes. When the contact closes to ground, operation is

the same as that of a mains failure.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 9 of 20

START INPUT (terminal 32)

The start input is active with control unit in automatic mode. When the contact closes to ground, REMOTE

START is shown on the display. When the REMOTE START DELAY time elapses, operation is the same as that of a

mains failure. When the start contact opens, operation is the same as when the mains power is restored. Other

functions can be associated to this input; see the programming manual.

STOP INPUT (TERMINAL 33)

The stop input is active with control unit in automatic mode. When the contact closes to ground, REMOTE STOP

is shown on the display. The control unit does not permit any start-up and, if the genset is running, it stops. Other

functions can be associated to this input; see the programming manual.

PROGRAMMABLE INPUTS (TERMINALS 41 and 42)

Inputs 41 and 42 are completely programmable (see the programming manual). The following settings are

possible:

Function, Text, Intervention delay, Stop, Cooling, Storage, Polarity, Activation.

MESSAGES AND CAN BUS INSTRUMENTS

Every message or instrument appearing on the display having to do with the injection control unit and read by the

CAN Bus line can be identified by the characters [ECU] shown in the lower right corner.

Anomaly messages are shown on the display as SPN, FMI and OC: SPN is a number identifying a particular

component of the diesel engine; FMI is a number identifying the failure or malfunction of the SPN component; OC

identifies the number of times this particular problem occurred in the engine.

If CAN Bus line connection between the two control units is interrupted, the message CAN Bus ANOMALY will

appear.

The instruments managed and displayed by the CAM-335 control unit are:

Instrument

Description

U.M.

Tachometer

Engine revolutions.

RPM

Oil pressure

Engine oil pressure.

BAR

kPa

Engine temperature

Engine water or oil temperature.

°C

°F

Fuel consumption

Amount of fuel consumed by the engine per unit of time.

l/h

Fuel temperature

Fuel temperature at injector inlet.

°C

°F

Turbo temperature

Temperature of turbo compressor oil.

°C

°F

Oil temperature

Temperature of engine oil.

°C

°F

Intercooler temperature

Temperature of fluid in the intercooler downstream the turbo

compressor.

°C

°F

Intake temperature

Temperature of pre-combustion air.

°C

°F

Coolant level

Coolant level.

Fuel pressure

Pressure of the fuel between the fuel pump and the injection

pump.

BAR

kPa

Coolant pressure

Pressure of coolant in the cooling system.

BAR

kPa

Engine torque

Engine output torque percentage.

Engine power

Power developed by the engine.

Fuel level

Indicates fuel level

Oil level

Level of oil in the engine.

Electronic engines currently managed are: John Deere, Perkins, Scania, Volvo, Deutz, FPT, VM, Cummins and MTU.

ENGINE HEATING

Function can be activated in SCANIA engines with CAN Bus connection. It warms up the engine at idling speed

after it starts. The function takes both engine temperature and set time into account. When the engine reaches the set

temperature or set time, the control unit speeds up the engine to rated speed. This default function is disabled. See

the programming manual for instructions on how to set the temperature threshold and time. Heating can also be

managed for mechanical engines by activating the function in a programmable output and connecting an

electromagnet to the engine.

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ELCOS –Parma –Italy –CAM-335 Valid for firmware revision 1.14 and above Page 10 of 20

EJP FUNCTION

To activate the EJP function, see the programming manual. It is only active in automatic mode. When the contact

connected to terminal 32 closes to ground, EJP STARTUP is shown on the display. After the EJP STARTING DELAY

has elapsed (set to 25 minutes), the start-up cycle begins. When the contact connected to terminal 33 closes to

ground, EJP SWITCHING CONSENT is shown on the display and operation is the same as that of a mains failure.

When the two contacts open, operation is the same as when mains power is restored.

VOLTMETRIC CONNECTIONS

The control unit can be configured to manage THREE-PHASE, TWO-PHASE and SINGLE-PHASE voltages. This

selection is valid both for the mains and for the generator; therefore, it is possible to manage, for example, three-

phase voltage from the mains and two-phase from the generator. When the mains power is three-phase, the phases

must be connected to terminals 91, 92 and 93 and the neutral to terminal 90. With two-phase connection, terminals

91 and 92 must be connected and the neutral must not be connected. Instead, with the single-phase connection, the

phase must be connected to terminal 92 and the neutral to terminal 90. Likewise, when the generator power is three-

phase, the phases must be connected to terminals 96, 97 and 98 and the neutral to terminal 95. With two-phase

connection, terminals 96 and 97 must be connected and the neutral must not be connected. Instead, with the single-

phase connection, the phase must be connected to terminal 97 and the neutral to terminal 95.

MAINS/GENERATOR VOLTMETRIC RELAYS

The voltmetric relays are located inside the control unit and serve to control the mains and genset voltages and

frequencies. The parameters considered are: power failure, undervoltage, overvoltage, asymmetrical voltages,

incorrect phase sequence, under-frequency and overfrequency.

Mains voltmetric relay: when each parameter has been accepted individually, after the mains voltage present

delay has elapsed (programmed to 100 seconds), if the genset is running, it stops and the mains contactor is

energized.

Generator voltmetric relay: when each parameter has been accepted individually, after the generator voltage

present delay has elapsed (programmed to 7 seconds), the generator contactor closes. It takes just one

parameter outside the normal range to de-energize the generator contactor.

FUEL FILLING MANAGEMENT

When the automatic fuel filling function is enabled, a dedicated menu is displayed. With filling, the fuel is

transferred from a storage tank to the genset tank. Either automatic mode, manual mode or filling lockout can be

selected using the display touch screen. The filling function is managed independently, meaning it does not depend

on the control unit’s operation mode. It is possible to enable filling either when the genset is powered or when the

user is powered. A contact float controls the maximum safety level. Another float with variable resistance (terminal

37) manages activation and deactivation of the output for pump and/or solenoid valve piloting. If the function is

enabled by default, the pump relay piloting output is associated to terminal 70, while the maximum level float input is

associated to terminal 41.

To change the filling management operation mode, simply press “AUT”, “MAN” or “OFF” on the display. The mode is

saved in the control unit even if the battery gets disconnected.

Automatic filling: when the level of fuel drops below the “minimum level”, the output is

enabled and MINIMUM FUEL LEVEL appears on the display. When the “maximum level” is

exceeded, the output is disabled and MAXIMUM FUEL LEVEL appears on the display.

Manual filling: pressing the START button on the display enables the filling output; taking the

finger off the button disables the output.

Filling OFF: turns filling off; the output, if enabled, is disabled.

Request the connection diagram, which can also be downloaded from the website www.elcos.it.

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