ComAp AC03 InteliLite NT PRAMAC Generator Controller User Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of the ComAp AC03 InteliLite NT PRAMAC Generator Controller. This compact gen-set controller is designed for both manual and remote start (MRS) applications, offering comprehensive monitoring and protection for your generator set. Please read this manual thoroughly before installation and operation to ensure safe and correct usage.

2. Product Overview

2.1 Key Features

• Compact design for gen-set operation.
• Supports Manual and Remote Start (MRS) applications.
• Full gen-set monitoring and protection.
• Connectivity for up to 8 engine gauges.
• True RMS voltage and current measurement.
• 3-phase measurement capabilities.
• 3 configurable analog inputs.
• Magnetic pickup input.
• Terminal D+ pre-excitation.
• 6 binary inputs and 6 binary outputs.
• Automatic Generator Circuit Breaker (GCB) control.
• Records operating hours and performance logs.
• Supports plug-in extension modules.
• Automatic SMS alarm functionality.
• Online control and monitoring via embedded web server (IB-Lite).
• Optional GSM/GPRS/Wireless Internet modem (IL-NT GPRS).
• User-changeable dual language support.

2.2 Components and Interface

Figure 1: Front panel of the ComAp AC03 InteliLite NT PRAMAC Generator Controller. This view shows the display screen, mode buttons, start/stop buttons, fuel pump, fault reset, page navigation, and arrow keys for user interaction.

Figure 2: Rear panel of the ComAp AC03 InteliLite NT PRAMAC Generator Controller, illustrating the various connection terminals for generator voltage, current, binary inputs/outputs, analog inputs, and communication modules. The serial number 1906143C is visible on the label.

Figure 3: The ComAp AC03 InteliLite NT PRAMAC Generator Controller packaging, along with the included InteliLite NT AC-03 Operator Guide and small accessory parts.

3. Setup and Installation

Proper installation is crucial for the reliable operation of the controller. It is recommended that installation be performed by qualified personnel.

3.1 Mounting

• Securely mount the controller in a suitable control panel or enclosure.
• Ensure adequate ventilation to prevent overheating.
• Protect the controller from direct sunlight, moisture, dust, and excessive vibrations.

3.2 Wiring Connections

Refer to the detailed wiring diagrams in the included Operator Guide for specific connection points. General connections include:

• Power Supply: Connect the controller to a stable DC power source (typically 8-36V DC).
• Generator Inputs: Connect generator voltage and current transformer (CT) inputs for accurate measurement.
• Analog Inputs: Wire up to 3 configurable analog inputs for sensors such as oil pressure, water temperature, or fuel level.
• Binary Inputs: Connect 6 binary inputs for signals like emergency stop, low fuel, high temperature, or external alarms.
• Binary Outputs: Connect 6 binary outputs to control devices such as fuel solenoids, starter motors, or alarm indicators.
• Magnetic Pickup: Connect for engine speed sensing.
• D+ Pre-excitation: Wire the D+ terminal for alternator excitation control.
• Grounding: Ensure proper grounding of the controller and the generator set to prevent electrical interference and ensure safety.

3.3 Initial Configuration

After wiring, the controller may require initial configuration using ComAp PC software tools to set parameters specific to your generator set, such as engine type, sensor ranges, and protection limits. Consult the Operator Guide for detailed software setup instructions.

4. Operating Instructions

The ComAp AC03 controller features an intuitive front panel for easy operation.

4.1 Front Panel Controls

• Display: The LCD screen shows operational data, alarms, and menu options.
• MODE Buttons: Used to navigate through different display screens and access menus.
• START Button (Green): Press to initiate the generator start sequence.
• STOP Button (Red): Press to stop the generator.
• FUEL PUMP Button: Manually operates the fuel pump for priming or testing.
• FAULT RESET Button: Resets active alarms after the fault condition has been cleared.
• PAGE Button: Cycles through various information pages on the display, showing different sets of parameters.
• Arrow Buttons (Up/Down/Left/Right): Used for navigation within menus and adjusting parameter values.

4.2 Starting the Generator

• Manual Start: Ensure all safety precautions are observed. Press the green START button. The controller will execute the pre-programmed start sequence.
• Remote Start (MRS): If configured for MRS, the generator will start automatically upon receiving a remote start signal or when pre-set conditions are met (e.g., mains failure).

4.3 Stopping the Generator

Press the red STOP button. The controller will execute the pre-programmed stop sequence.

4.4 Monitoring Operation

Use the PAGE and MODE buttons to view various operational parameters on the display, including:

• Generator voltage and current
• Frequency
• Engine speed (RPM)
• Oil pressure
• Engine temperature
• Fuel level
• Operating hours

5. Maintenance

Regular maintenance ensures the longevity and reliable performance of your controller.

• Cleaning: Keep the controller's front panel clean and free from dust and debris. Use a soft, dry cloth. Avoid abrasive cleaners, solvents, or excessive moisture.
• Connections: Periodically inspect all wiring connections for tightness and signs of corrosion. Loose connections can lead to intermittent operation or faults.
• Firmware Updates: Check the official ComAp website periodically for available firmware updates. Installing updates can provide new features, improvements, and bug fixes. Follow the manufacturer's instructions carefully for any update procedures.
• Environmental Check: Ensure the operating environment remains within specified temperature and humidity limits.

6. Troubleshooting

This section provides general guidance for common issues. For detailed troubleshooting, refer to the comprehensive Operator Guide.

• Controller Not Powering On:
  • Check the DC power supply connections and ensure the voltage is within the specified range.
  • Verify that any external fuses or circuit breakers for the power supply are intact.
• Generator Fails to Start:
  • Confirm adequate fuel level in the generator's tank.
  • Check the engine's starting battery voltage and connections.
  • Ensure the emergency stop button is not engaged.
  • Look for any active alarms on the controller's display and address the underlying fault before attempting to start again. Press FAULT RESET after clearing the fault.
• Active Alarms Displayed:
  • Note the specific alarm message or code on the display.
  • Consult the Operator Guide for detailed explanations of alarm codes and recommended corrective actions.
  • Once the fault condition is resolved, press the FAULT RESET button to clear the alarm.
• Communication Issues (for remote monitoring):
  • Verify network cable connections (if applicable).
  • Check the configuration settings for the communication module (e.g., IP address, gateway).
  • Ensure the remote monitoring server or software is operational.

7. Specifications

8. Warranty and Support

The ComAp AC03 InteliLite NT PRAMAC Generator Controller is covered by the manufacturer's standard warranty. For detailed warranty terms, technical support, or service inquiries, please refer to the documentation included with your product or visit the official ComAp website. Contact information and support resources can typically be found on the manufacturer's global website or through authorized distributors.