IL-NT-PRAMAC AC03 Generator Engine Controller

1. Introduction

The IL-NT-PRAMAC AC03 Controller is a genuine ComAp ATS (Automatic Transfer Switch) display module specifically designed for comprehensive generator protection and control. This advanced module serves as a critical component in ensuring the reliable operation of industrial generators, providing extensive monitoring and control functionalities to optimize performance and safety.

The AC03 Controller is part of the PRAMAC series, known for its robustness and high-quality engineering in the field of power generation equipment. Its intuitive interface allows for easy navigation and monitoring of key parameters, making it simple for operators to keep track of the generator's status.

2. Key Features

• Comprehensive Generator Control: Manages generator startup, shutdown, and operational parameters.
• Automatic Transfer Switch (ATS) Functionality: Seamlessly switches power sources between mains and generator.
• Real-time Monitoring: Clear LCD display shows live operational data.
• Robust Design: Built to withstand harsh environmental conditions in industrial settings.
• User-Friendly Interface: Intuitive buttons for easy navigation and control.
• Integrated Protection: Features for generator protection and fault management.

3. Specifications

4. Package Contents

Upon opening the package, you should find the following items:

• 1 x IL-NT-PRAMAC AC03 Generator Engine Controller
• Mounting hardware (if applicable, not explicitly shown but typically included)
• Documentation (this user manual, or a quick start guide)

Please inspect all components for any signs of damage during transit. If anything is missing or damaged, contact your supplier immediately.

Figure 4.1: AC03 Controller and its packaging

Video 4.1: Unboxing and physical overview of the AC03 controller.

5. Setup and Installation

Important Safety Information: Installation should only be performed by qualified personnel. Ensure all power sources are disconnected before beginning installation. Use copper conductors only. Refer to the full installation instructions for specific torque values for terminal connections.

5.1 Mounting

• The AC03 controller is designed for use on a flat surface of a Type 1 enclosure.
• Ensure the mounting location allows for adequate ventilation and does not exceed the maximum ambient temperature of 70°C.

5.2 Wiring Connections

Refer to the diagram below for terminal identification and connection points. Ensure all connections are secure and correctly polarized.

Figure 5.1: Rear view of the AC03 controller showing wiring terminals.

Power Supply (9-30 VDC)

• Connect the DC power supply (9-30 VDC) to the designated POWER terminals. Observe polarity. The maximum current draw is 0.4A.

Voltage Sensing

• Mains Voltage: Connect the mains power lines (L1, L2, L3, N) to the MAINS VOLTAGE terminals. The controller supports 3x277A(480A)/VAC.
• Generator Voltage: Connect the generator output lines (L1, L2, L3, N) to the GENERATOR VOLTAGE terminals. The controller supports 3x277A(480A)/VAC.

Current Sensing

• Connect the current transformers (CTs) for generator current measurement to the GENERATOR CURRENT (0-5A) terminals.

Inputs and Outputs

• Binary Inputs (B1-B7): Connect external switches or sensors for various control functions.
• Analog Inputs (A11-A13): Connect analog sensors for parameters like fuel level, oil pressure, etc.
• RPM Input: Connect the engine RPM sensor to the RPM IN terminal.
• Binary Outputs (B01-B07): These outputs can be configured to control external devices such as contactors, alarms, or engine start/stop relays.

Communication

• CAN: Connect to a CAN bus for communication with other compatible devices.
• COM: General communication port.

6. Operation

The AC03 controller features a clear LCD display and a set of intuitive buttons for operation. The front panel includes indicators and a simplified diagram of the power system (mains and generator).

Figure 6.1: Front panel of the AC03 controller.

6.1 Front Panel Controls

• LCD Display: Shows real-time data, alarms, and menu options.
• MODE Buttons (Left/Right Arrows): Used to navigate through different display screens or menu options.
• PAGE Buttons (Up/Down Arrows): Used to scroll through parameters or adjust settings within a menu.
• START Button (Green): Initiates the generator start sequence.
• STOP Button (Red): Initiates the generator stop sequence.
• FUEL PUMP Button: Manually controls the fuel pump (functionality may vary based on configuration).
• FAULT RESET Button: Clears active fault alarms after the issue has been resolved.
• CR / CG Buttons: Typically used for Mains (CR) and Generator (CG) control, often related to breaker operation or status indication.

6.2 Basic Operation Sequence

1. Power On: Ensure the DC power supply (9-30 VDC) is connected and active. The LCD display should illuminate.
2. Monitoring: Use the MODE and PAGE buttons to view various generator and mains parameters (voltage, current, frequency, engine RPM, oil pressure, temperature, etc.).
3. Manual Start: Press the green START button to manually initiate the generator start sequence. The controller will follow its programmed startup routine.
4. Manual Stop: Press the red STOP button to manually shut down the generator.
5. Fault Handling: If a fault occurs, an alarm will be displayed on the LCD. Identify and resolve the fault condition, then press the FAULT RESET button to clear the alarm.
6. ATS Operation: In automatic mode, the controller will monitor the mains supply. If the mains fail, it will automatically start the generator and transfer the load. Upon mains return, it will transfer the load back and shut down the generator.

7. Maintenance

Regular maintenance ensures the longevity and reliable operation of your AC03 controller.

• Cleaning: Keep the controller's front panel clean and free from dust and debris. Use a soft, dry cloth. Do not use abrasive cleaners or solvents.
• Inspections: Periodically check all wiring connections for tightness and signs of corrosion or damage. Ensure the enclosure remains sealed to maintain IP54 protection.
• Software Updates: Check with ComAp or your supplier for any available firmware updates that may improve performance or add new features.
• Environmental Conditions: Ensure the operating environment remains within the specified temperature and humidity ranges to prevent damage.

8. Troubleshooting

This section provides solutions to common issues you might encounter with the AC03 controller.

For complex issues or persistent problems, it is recommended to consult a qualified technician or contact ComAp technical support.

9. User Tips

• Regular Testing: Periodically test your generator and ATS system to ensure it functions correctly during a power outage.
• Documentation: Keep this manual and any specific generator documentation readily accessible for quick reference.
• Clean Power: Ensure a stable and clean DC power supply to the controller to prevent erratic behavior.
• Environmental Control: While robust, protecting the controller from extreme dust, moisture, and direct sunlight will extend its lifespan.

10. Warranty and Support

For warranty information, technical support, or service inquiries, please contact your original point of purchase or refer to the official ComAp website for regional support contacts. Ensure you have your product model (AC03) and any serial numbers available when seeking support.