Auto Mains Failure Be22 en
Auto Mains Failure Be22 en
Auto Mains Failure Be22 en
Name:_____________Company:_____________________Tel/Fax:___________________
__________________________________________________________________________
e-mail: [email protected]
mobile: ++39 335 7077148. Tel: ++39 0386-31445 (fax 31657).
Warranty
Bernini Design SRL (hereinafter "BD") warrants that Be22 shall be free from defect in material or
workmanship for a period of 3 years from the BD delivery date. BD shall, at its option, repair or replace
the product without charge. BD shall return the Be22 to the buyer with the Default parameters at no
extra charge. The buyer shall furnish sufficient information on any alleged defects in the product so as
to enable BD to determine their cause and existence. If the Be22 is not defective, or the product is
defective for reason other than covered by this warranty, the buyer will be charged accordingly. This
warranty shall not apply if the Be22 has not been used in accordance with the User Manual and other
operating instruction, particularly if any defects are caused by misuse, improper repair attempts,
negligence in use or handling. This purchase is non-refundable.
WARNING!! High voltage is present inside the Be22. To avoid electric-shock hazard, operating
personnel must not remove the protective cover. Do not disconnect the grounding connection. The Be22
can start the engine at anytime. Do not work on equipment which is controlled by the Be22. When
servicing the engine, disconnect the battery and battery charger. We recommend that warning signs be
placed on equipment indicating the above.
BE22 OEM's Manual V1.3x December 2007 page 2
Alphabetic index
1.0 Introduction.........................................................page 3
2.0 OPERATING MODE selection ...........................page 4
2.1 TEST operating mode.........................................page 4
2.2 AUTO operating mode .....................................page 4
2.3 MANUAL operating mode ..................................page 4
2.4 RESET operating mode ....................................page 4
2.5 START-STOP pushbuttons ................................page 5
2.6 CONTACTOR controls........................................page 5
3.0 DISPLAY features ..... .........................................page 5
4.0 DISPLAY messages .. .........................................page 6
5.0 LEDs for visual indication..................................page 7
5.1 Lamp and Display Test.......................................page 7
6.0 PROGRAMMING instructions ............................page 8
6.1 Programming ........ .........................................page 8
6.2 Default settings programming ........................page 8
6.3 Reading procedure .........................................page 8
7.0 GLOW PLUGS control (Preheat)........................page 8
8.0 MAINS simulation and ENGINE TEST ...............page 9
9.0 CHOKE control.......... .........................................page 9
10.0 HOUR METER reset .........................................page 9
11.0 PUMP set control .. .........................................page 9
11.A Electronic Governor........................................page 9
12.0 PARAMETER description................................page 10, 11, 12
13.0 ENGINE RUNNING setting [P15] .....................page 14
14.0 WIRING DIAGRAM .........................................page 15
15.0 Interface module, dimensions ........................page 16
16.0 CONNECTORS ....... .........................................page 16
17.0 FRONT PANEL ....... .........................................page 16
18.0 CPU module, dimensions................................page 16
19.0 CALIBRATION ......... .........................................page 17
20.0 GENERAL SPECIFICATION..............................page 18
21.0 SOFTWARE UPGRADE ....................................page 19
22.0 APPLICATION NOTES ......................................page 19
23.0 PANEL/GEN-SET BUILDER NOTES.................page 19
BE22 OEM's Manual V1.3x December 2007 page 4
1.0 INTRODUCTION
The BE22 features 3-Phase Automatic Mains Failure (A.M.F.) and Generating Set
(hereinafter ‘GEN-SET’) control and monitoring. The BE22 provides visual indication by
means of LEDs and Display Messages for the following: Fuel Level, Overload, Emergency,
Low Oil Pressure, High Temperature, Mains Simulation, Periodic Test, Starting Failure,
High/Low Battery voltage, Contactor status, Belt Break and Engine Running (see sections 4.0
and 5.0).
The following measurements and parameters are displayed on the front panel:
Mains/Generator Voltage, Battery Voltage, Generator Current, Generator Frequency/R.P.M.,
Charger Alternator voltage and Programmable Settings. The relay outputs feature START,
STOP, ALARM, FUEL SOLENOID, PREHEAT/CHOKE and MAINS/GENERATOR
CONTACTOR control. The front panel includes 6 pushbuttons, LEDs and a 4-digit DISPLAY
(section 17.0). The BE22 consists of two modules: CPU (panel mount) and INTERFACE (DIN
rail mount). The connection of the modules is via 25 cable shielded poles (1M length).
h/PROGRAM If the BE22 is in RESET operating mode, the display shows the
programmable parameters. The message [P.XX] (XX means a 2 digit number) appears on
the display indicating the name of the parameter.
By means of the [DISPLAY-UP] and [DISPLAY-DOWN] pushbuttons, it is possible to select a
parameter. After you push the [STOP] pushbutton, the display will show the setting of the
parameter (see section 12.0). If the BE22 is not in RESET operating mode, the Display will
show the [HOUR COUNT]. The BE22 allows a maximum count of [9999] h (see section 10.0
to clear the counter).
BE22 OEM's Manual V1.3x December 2007 page 6
CURRENT (*NOTE1) The display shows the Generator Current measurements (00.0-
99.9Aac and 100-1000Aac). The [P10] sets the size of the CTs, and the [P11] sets the
Overload.
VOLTAGE (*NOTE1) The display indicates the voltage of the MAINS or GEN-SET. If the fuel
solenoid is energised, the display shows the voltage of the generator ([GXXX]). Otherwise,
the display shows the voltage of the Mains ([UXXX]). The settings for Over/Under voltage are
programmed in the parameters P2/3 and P6/7 (section 12.0).
*NOTE1
In order to show the 3 phases of the voltage and current, the display scans the
measurements every 2 seconds, and dashes appear to indicate phase '2'([ - 400 ])
and '3'([ _400 ]).
BATTERY This menu indicates the Battery Voltage or Charger Alternator voltage. The
display shows the battery voltage if the yellow LED is illuminated. The Charger Alternator
voltage is displayed by pushing the [DISPLAY-DOWN] pushbutton (the yellow LED will blink).
Some alarms are displayed by means of [EXX] messages. ‘E’ indicates error (or alarm) and
‘XX’ indicates a number or a code. The message is removed by selecting the RESET
operating mode (except for [Err]). The BE22 will show one of the following:
[E 01] (OVER FREQUENCY) The source of the alarm is the frequency of the Generator
voltage. This protection is delayed by 2 seconds. The setting is the parameter [P9].
[E 02] (BELT BREAK)The alarm is enabled by means of the code [on] in [P23]. There is a
‘Belt Break’ alarm when the engine is running, but the output voltage of the Charger Alternator
is lower than the setting of P15. A 20-second delay prevents a false alarm. [E02] can be
inhibited by the code [OFF] in P23.
[E 05] (GEN-SET OVERLOAD) If the current of one phase is greater than [P11] for at least
6 seconds, the engine will shut down after a cooling down timing (P5).
[E 06] (UNDER FREQUENCY) [P8] sets the under frequency limit. This protection is
delayed by 6 seconds. The engine stops after a cooling down time.
BE22 OEM's Manual V1.3x December 2007 page 7
[Hi G] (OVER VOLTAGE) If the voltage of one phase rises above the [P8] setting for more
than 2 seconds, the Over Voltage alarm energises, and the engine shuts down. The alarm is
monitored in all operating modes.
[Err] (MEMORY ERROR) This message indicates an internal failure of the memory. To
restore the normal operating mode of the memory, disconnect the supply and re-apply the
supply after a minute. If the failure persists, follow the instructions of section 19.2.
[U-on] (MAINS SIMULATION). The input JD14 simulates the Mains presence (section 8.0)
[' ' ' '] (PRE-GLOW). The BE22 is driving the GLOW PLUGS cycle ([P13] setting)
[----] (V - METER out of range). The voltage (Mains or Generator) falls under 70Vac
[StOP] (STOP). The BE22 is driving the stop cycle ([P19] setting)
[rESt] (REST TIMING). The BE22 is waiting for a starting attempt ([P16] setting)
DURING THE STARTING ATTEMPTS (MANUAL OR AUTOMATIC), THE BE22 TURNS OFF THE LEDs
AND DISPLAYs IN ORDER TO SAVE ENERGY FOR THE INTERNAL CIRCUITS.
The following red LEDs (LED=solid state lamps) indicate alarms. To turn off the indicators,
select the RESET operating mode (see section 2.4).
LOW OIL PRESSURE [Red LED]. Indication of Low Oil Pressure alarm. The input is
connected to a normally closed contact Pressure Switch (input JD11). During the starting
sequence, the alarm is by-passed by means of the [P18] timing (section 12.0).
HIGH ENGINE TEMPERATURE [Red LED]. Indication of High Temperature alarm. This
input, terminal JD12, is connected to a normally open or closed temperature switch. The
contact selection is done by a code in [P24] (option [n.o.] or [n.c.]). The engine stops
immediately. During the starting sequence, the alarm is by-passed by means of the [P18]
timing (section 12.0)
STARTING FAILURE [Red LED]. This alarm is activated if the engine does not start after a
complete starting cycle (see settings of [P14] to [P17] in section 12.0).
BE22 OEM's Manual V1.3x December 2007 page 8
OVERLOAD [Red LED]. The OVERLOAD alarm energises if the input JD10 is connected to
the battery minus. The BE22 disables the contactor of the Generator, and stops the engine
after the programmed Cooling Down time ([P5], section 12.0).
BATTERY [Yellow LED]. The alarm settings are automatically fixed to 11.8/15.0V for a 12V
battery or 23.6/30.0V for a 24V battery. This alarm is ignored during the Pre-Glow timing and
starting cycle. A delay of 120 seconds prevents false alarms.
EMERGENCY [Red LEDs]. The EMERGENCY input (JD13) stops the engine immediately.
The polarity of the switch contact is programmed into [P25] (option [n.o.] or [n.c.]). The
EMERGENCY alarm is also activated by the [STOP] pushbutton in AUTO and TEST
operating modes.
ENGINE RUNNING [Green LED]. This LED illuminates when the voltage of the Charger
Alternator (terminals JD15 and JD16) is greater than the setting of the parameter [P15]
(section 13.0).
FUEL [Yellow LED]. This LED indicates Low Fuel in the tank. The engine stops if the
contact (terminal JD9) stays closed for more than 5 minutes continuously. The level switch
(terminal JD9) is bypassed for 15 seconds to avoid false alarms.
6.1 Programming
1) - Select the h/PROGRAM display mode by using the [DISPLAY-UP] pushbutton
2) - Select the RESET operating mode by using the [MODE-UP] pushbutton. If a STOP cycle
takes place, wait until the message [StOP] disappears.
3) - Push and hold the [DISPLAY-UP] and the [MODE-UP] pushbuttons simultaneously
4) - Wait until the [Pro-] message appears on the display (approximately 3 seconds)
5) - When the [Pro-] message is displayed, release the pushbuttons: the yellow LED
'h/PROGRAM' will blink indicating that the BE22 is ready for programming.
6) - Press the [DISPLAY-UP] (or [DISPLAY-DOWN]) pushbuttons to select the parameter
7) - Press the [STOP] and [DISPLAY-UP] (or [DISPLAY-DOWN]) pushbuttons simultaneously
to modify the parameter (the display will indicate the parameter).
BE22 OEM's Manual V1.3x December 2007 page 9
(* NOTE): the message [Err] indicates an error in the saving procedure. We recommend that
you repeat step 8). If the [Err] message remains on the display, try to cancel the memory as
described in section 19.2 ([-MEM]).
[P22] setting = [U-on] To enable the 'Mains simulation' mode, set the [P22] to [U-on]
(default setting). When the JD14 is grounded, the BE22 simulates the presence of the Mains.
The display will show the message [U-on] in the Voltage menu. This function is used if the
user requires remote ‘start’ and ‘stop’ by means of a switch (external switch, level switch or
timer switch).
BE22 OEM's Manual V1.3x December 2007 page 10
[P22] setting= [tESt] To enable the 'TEST MODE', set the [P22] to [tESt]. If the JD14 input
terminal is grounded (by means of an external switch) the engine starts and the BE22 will
transfer the load to the GEN-SET. During the starting cycle, the contactor of the Mains (KM)
remains closed.
As soon as the BE22 enters the start cycle, the Fuel solenoid will energize first. In this way,
the Electronic governor starts up.
After a 5 second delay, the BE22 will energize the output JA3 in order to start the engine.
BE22 OEM's Manual V1.3x December 2007 page 11
12.0 PARAMETERS DESCRIPTION Note: ['] means minute(s) and ["] means second(s)]
[P. 0] Mains Failure Delay Factory default: [5"] secs Range: 1-59 secs or 1-15 mins
Seconds or minutes of continuous Mains failure (see P2-P3) to initiate the automatic
engine start.
[P. 1] Mains Restore Delay Factory default: [5"] secs Range: 1-59 secs or 1-15 mins
Seconds or minutes of continuous presence of the Mains (see P2-P3) to initiate the stop
sequence.
[P. 2] Mains Under-Voltage Factory default: [320] Range: 80-500V (5V steps)
If the Mains voltage falls below the [setting], there is a Mains failure condition. An
hysteresis of 8Vac is introduced to prevent a false condition.
[P. 3] Mains Over-Voltage Factory default: [500] Range: 80-500V (5V Steps)
If the voltage rises above the [setting], there is a Mains failure condition.
[P. 4] Warm Up time Factory default: [5"] Range: 0-59 secs or 1-15 mins
This delay allows the engine to warm up. After the delay, the BE22 will enable the
contactor of the Generator.
[P. 5] Cooling Down time Factory default: [30"] Range: 0-59 secs or 1-15 mins
This delay cools the engine. During this time the engine runs off-load (the contactor is de-
energised).
[P. 6] Generator Under-Voltage Default: [320] Range: 80-500V (5V Step)
If the voltage rises above the [setting], the BE22 enables the contactor. If the voltage drops
under the [setting] for at least 6 secs or under [setting]-20% for 1 sec, the Under-Voltage
protection [Lo G] energises (see section 4.0).
[P. 7] Generator Over-Voltage Default: [500] Range: 80-500V (5V Steps)
If the Generator voltage rises above the [setting] for at least 2 seconds, the BE22 will
energise the Over Voltage protection [Hi G] (see section 4.0) in order to stop the engine
[P. 8] Generator Under-Frequency Default: [47] Range: 0 to 99Hz
The protection is delayed by 6 seconds. The BE22 opens the contactor and the display will
show the [E06] message (see section 4.0). The code [0] disables the under frequency)
[P. 9] Generator Over-Frequency Default: [53] Range: 45 to 99Hz
The protection is delayed by 2 seconds. The BE22 shuts down the engine and displays
[E01] (see section 4.0). The code [99] disables the over frequency alarm.
[P. 10] Current Transformer Size Default: [500] Range: 10/5 up to 1000/5
The settings are allowed only in steps of 10.
[P. 11] Generator Overload Setting Default: [0] Range: 0 to 1000 A
If the current rises above the setting by 6 seconds, the BE22 opens the contactor and
shows the message [E05].The settings are allowed in steps of 5A. The engine will stop
after the cooling down time.
[P. 12] Generator Failure Alarm Factory default: [on] Selection: [on] or [OFF]
The code [on] enables the Generator failure alarm. The alarm energises if the voltage (or
the frequency) is lower than the setting for more than 150 seconds. The BE22 shows the
[E04] message (see section 4.0) and the engine will shut down.
[P. 13] Pre-glow / Choke Control Factory default: [5"] Range: 1 to 99 secs
The BE22 energises the JA5 output for the programmed time.
The code [ 0] in the P21 disables the function. The channel P21 controls the way to
energise the output (Glow or Choke: see sections 7.0 and 9.0).
BE22 OEM's Manual V1.3x December 2007 page 12
[P. 14] Crank Timing Default: [5"] Range:1-20 seconds
This is the insertion time-out for the starter. The timer is cleared if the engine starts to run
[P.18] Engine Alarms By-Pass Default: [6"] secs Range: 0-99 secs
This delay allows the Oil Pressure and Temperature alarms, during the engine starting
cycle, to be ignored.
[P.19] Stop Solenoid Timing (Output JA4) Default: [15"] secs Range: 2-99 secs
The stop solenoid will remain energised for the programmed time.
[P.20] Alarm Output Timing (Output JA6) Default: [1'] Range: 0-59secs/1-15mins/[cont.]
The ALARM output turns off automatically after this timing. The code [cont.] requires the
RESET operating mode to turn off the ALARM output.
[P.21] JA5 Output Control Default: [0] (Inhibit) Options: [0], [1] or [2]
The following possibilities are available:
[ 0 ] Inhibits the JA5 output
[ 1 ] Choke Control Mode (see section 9.0)
[ 2 ] Glow Plugs Mode (see section 7.0, and the parameter P13)
[P.22] JD14 Input Control Mode Default:[U-on] Options: [U-on] or [tESt]
By means of the [U-on] mode, the JD14 simulates the Mains presence (section 8.0).
The [tESt] mode allows the TEST of the engine (section 8.0)
[P.23] Belt Break Alarm Default: [OFF] (inhibited) Options: [on] or [OFF]
The Belt Break (or Charger Alternator Failure) alarm is indicated by means of the message
[E02] (see section 4.0).
[P.24] Temperature Switch (Input JD12) Default: [n.o.] Options: [n.o.] or [n.c.]
[n.o.] Normally open contact: the engine shuts down if the contact closes.
[n.c.] Normally closed contact: the engine shuts down if the contact opens.
[P.25] Emergency Control (Input JD13) Default: [n.o.] Options: [n.o.] or [n.c.]
[n.o.] Normally open contact: the engine shuts down if the contact closes.
[n.c.] Normally closed contact: the engine shuts down if the contact opens.
[P.26] Automatic Periodic Test Cycle Default: [0] (inhibited) Range: 0-99 days
This is the interval time between the automatic periodic tests of the engine. The code [ 0]
disables the Automatic Periodic Test (see section 22.0).
BE22 OEM's Manual V1.3x December 2007 page 13
[P.27] Automatic Test Duration Default: [10'] mins Range: 1-99 minutes
This is the duration of the Automatic Periodic Test. The load is transferred to the GEN-SET
only if the Mains fails (see section 22.0).
[P.28] Phases Selection Default: [3Ph.] Options: [1 Ph.]/[ 3Ph.]
For single Phase mode, connect the BE22 as indicated below:
- Generator Current: terminals 19-20-21-22 to GND. Terminals 17 and 18 to the CT.
- Generator Votage: terminal 23 to Neutral, 25 and 27 to the Generator Phase.
- Mains Voltage: terminal 29 to Neutral, 31 and 33 to the Mains Phase.
[P.29] Alternator Poles Default: [ 4 ] Options: [ 2 ]/[ 4 ]
The setting allows the reading of R.P.M. according to the format of the alternator.
[P.31] Fail To Stop Options Default: [ Inh ] Options: [ Inh ]/[ E07 ]
The option [ OFF ] disables the FAIL to STOP alarm.
The Be22 terminates the crank when the engine is able to run without the aid of the starter
motor. When the engine is not running the D+/WL (input JD15-16) voltage is 0V. As soon as
the BE22 starts the engine (manual attempt or automatic cycle) a current will flow into the
D+/WL terminal.
At this moment, the engine is not running, but a voltage appears in the D+/WL terminal (0.8 to
2.5V). As soon as the engine starts running, the voltage of the D+/WL terminal increases up
to 3V-6V. When the engine runs, the voltage reaches the nominal 14 -15V to charge the
battery. The threshold to disconnect the starter motor is between 6V to 10V.
The default parameter of the [P15] is 8.0V. This value is recommended for engines using
12V batteries. For 24V batteries we recommend that you set the threshold to 16V.
For a safe setting, be sure that the green ‘ENGINE RUNNING’ LED on the front panel is off
during the cranking cycle.
NOTE
The Charger Alternator voltage can be displayed in the 'BATTERY' display mode: push the
[DISPLAY-DOWN] pushbutton and the BE22 removes the Battery voltage indication. It will
also display the Charger Alternator voltage (the yellow LED will blink). The accuracy of the
display is guaranteed within 5%, using a standard Charger Alternator. For other chargers,
(Flywheel Generator) the reading is not accurate. The [P15] setting, in this case, expresses
only a proportional factor.
The BE22 monitors the GEN-SET voltage to protect against unwanted insertion of the starter
motor. When the voltage reaches 80VAC the starter insertion is inhibited. This voltage does
not affect the status of the green ‘ENGINE RUNNING’ LED on the front panel. The insertion
of switches or breakers in series to the terminals JF23-25-27 is not recommended.
ATTENTION: THE ‘ENGINE RUNNING’ LED SHOULD ILLUMINATE WHEN THE ENGINE
RUNS. IF THE LED REMAINS OFF, VERIFY THE SETTING OF [P15] OR VERIFY THE
WIRING.
BE22 OEM's Manual V1.3x December 2007 page 14
19.0 CALIBRATION
To enter the Calibration, press and hold the [STOP] pushbutton during the power on of the
BE22. The message [CAL] will appear on the display (*). The BE22, by means of the
[DISPLAY-UP] and [DISPLAY-DOWN] pushbuttons, allows the following selections:
(*) NOTE: if the display shows the message [Err], push the [STOP] pushbutton and follow the
instructions described in section 19.2.
(**)NOTE: the message [Err] indicates a memory error. Simultaneously press the [STOP]
and [MODE-UP] pushbuttons in order to retry a memory writing cycle. If the [Err] message
remains on the display, follow the instructions described in the section 19.2. If the problem
persists, the BE22 is damaged and must be returned for repair.
BE22 OEM's Manual V1.3x December 2007 page 18
Supply Voltage 7Vdc to 33Vdc. Reverse polarity: permitted for unlimited time.
Supply Ripple: 15% up to 65 Hz, Over Voltage: 50V (60 secs) at 40 deg. C
V Battery Display error: 3% [**]. Protection: internal 300mA /60Vthermal fuse
Supply Current Consumption: 50 mA up to 150mA maximum
Supply to Reset the System: 6,0V for 5 seconds.
BE22 CPU dimensions: 224mm X 105mm X 42.5mm
Panel Cut-out: 190mm X 93mm, operation indoor
BE22 INTERFACE MODULE dimensions: 195mm X 126mm X 65mm.
Shipping (box dimensions): 255x230x80
Operating Temperature range: -25 deg C to +70 deg C. Humidity Range: 5% up to 95% non-
condensing
Total Weight: 1500 gr. (includes cable), Vibration: 40mm/sec
General Design: 89/336 EEC, 89/392 EEC, 73/23 EEC, 93/68 EEC, IEC 68-2-6, EN60950
Certification: CE
Programming the Automatic Periodic Testing for the first time (hereinafter ’A.P.T.’)
- enter the 'Program Mode' and set the P26 to 7 days (section 6.0)
- set the P27 to 20 (minutes)
- save the programming
- select the AUTO operating mode
The BE22 will start the engine after 7 days. The engine will run OFF-LOAD for 20 minutes. If
the Mains fails during the A.P.T., the BE22 will transfer the load to the GEN-SET.