Cam-402 Prog en
Cam-402 Prog en
CAM‐402
Developed to equip automatic emergency panels.
It controls and operates genset, connecting the power user to the mains or generator.
USER’S MANUAL
Functions:
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 6 languages: Italian, English, French, German, Spanish and Portuguese.
RS485 serial port.
MOD Bus RTU Protocol.
4‐maintenance management.
Remote controls (start, stop, EJP).
Ability to start generator when the battery charge is low.
Glow plug preheating management.
Clock for programming genset starting or stopping.
Programmable weekly self‐test.
Anomaly log (including data from the last 50 anomalies that caused cut‐outs).
Dimensions (LxHxW) 252x175x60mm
TABLE OF CONTENTS
INSTRUCTIONS IN BRIEF ................................................................................................................................................................................................... 3
INSTRUMENTS ................................................................................................................................................................................................................. 3
OPERATION ...................................................................................................................................................................................................................... 4
FUNCTION SELECTION 4
MANUAL 4
AUTOMATIC 4
TEST 4
OFF 4
GLOW PLUG PREHEATING 4
ENGINE TYPES 4
WEEKLY TEST 5
ENGINE RUNNING DETECTION 5
STOPPING SYSTEMS 5
EMERGENCY STOP 5
GENERAL ALARM 5
GENSET AND USER PROTECTIONS 5
PREVENTIVE MAINTENANCE 5
STARTING GENSET WITH LOW BATTERY 6
DAILY STARTING‐STOPPING 6
CALL INPUT (TERMINAL 30) 6
STOP INPUT (TERMINAL 33) 6
PROGRAMMABLE INPUT (TERMINAL 41) 6
EJP FUNCTION 6
VOLTMETRIC CONNECTIONS 6
MAINS/GENERATOR VOLTMETRIC RELAYS 6
IMMINENT START WARNING 6
SERIAL PORT 7
CLOCK/CALENDAR 7
CONNECTION DIAGRAM .................................................................................................................................................................................................. 8
USER PROGRAMMING ................................................................................................................................................................................................... 10
FAULT LIST ..................................................................................................................................................................................................................... 12
TECHNICAL SPECIFICATIONS .......................................................................................................................................................................................... 13
WARNING ...................................................................................................................................................................................................................... 14
INFORMATION FOR ORDERING ...................................................................................................................................................................................... 16
STANDARD ACCESSORIES ............................................................................................................................................................................................... 16
DOCUMENTATION ON REQUEST.................................................................................................................................................................................... 16
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INSTRUCTIONS IN BRIEF
ARROW button
Press quickly to display instruments.
Press and keep pressed to check LED test.
Display
Acknowledging the general alarm.
ALARM LED
Cumulative alarm. POWER
Flashing ‐ alarm signal only USER_GENERATOR LED
Lit steadily ‐ stopped Generator inserted on
power user
ENGINE LED
POWER USER_MAINS LED Engine running
Mains inserted on power
user
GENSET LED
MAINS LED Power from generator
Power from mains present
present
INSTRUMENTS
The control unit has a backlit alphanumeric display. It is used to view the following instruments:
Three line‐to‐line mains/generator voltages.
Three mains/generator ammeters.
Mains/generator frequency meter.
Apparent mains/generator power, kVA. The powers are displayed as a sum of the phases.
Battery voltage.
D+ voltage (pre‐excitation alternator).
Fuel tank level indicator.
Engine revolutions (RPM).
Total hour‐meter.
Partial hour‐meter.
Start‐ups count.
Starting failure counter.
Maintenance expirations.
Calendar clock.
Simply pressing the arrow displays all electrical instruments for the mains, generator and engine. In the event of an anomaly, the
display presents the message indicating the anomaly that has occurred.
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OPERATION
FUNCTION SELECTION
FUNCTION button.
The function selected using the button is indicated by the corresponding light turning on.
MANUAL
MAN LED.
LED goes on when switched to manual.
Press START to start the unit and STOP to stop it (a quick press is sufficient).
Press MAINS/GENERATOR to switch 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
AUT LED.
LED goes on 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
TEST LED.
This LED goes on 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
OFF LED.
This LED goes on 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.
ENGINE TYPES
The control unit can manage start‐up of both diesel and petrol engines. To facilitate start‐up, a special circuit runs a series
of start‐ups: for diesel engines: 4 start‐ups of 5 seconds each with 5‐second pauses between them; for petrol engines: 15 pulsed
start‐ups of 3 seconds each with 5‐second pauses between them.
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WEEKLY TEST
The weekly test is enabled only with the control unit in automatic mode. During the test, the genset starts up and remains
running for the WEEKLY TEST DURATION (programmed time: 3 minutes). If a mains anomaly occurs, the generator contactor
closes. This test is automatically repeated every week at precisely the programmed day and time. The display shows
AUTOMATIC TEST during the test cycle. The test can be programmed to run at cycles ranging from 1 to 30 days. The default
setting is 7 days (weekly test). 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. 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 has elapsed after exiting the setting mode. 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.
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.
Petrol engines are shut down by switching off the ignition system.
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.
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 the
ARROW silences the alarm.
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. If programmed, stopping is also achieved with PROTECTION IN MANUAL bypassed. The
procedure for resetting expired maintenance is to be performed only by genset manufacturer.
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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.
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.
EJP FUNCTION
To activate the EJP function, see the programming manual. It is only active in automatic mode. When the contact
connected to terminal 30 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; for example, it is possible to manage 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.
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SERIAL PORT
The control unit has an RS485 serial port. This port can be used in slave mode so that an external device can poll the
control unit using the MOD Bus RTU protocol.
CLOCK/CALENDAR
This makes it possible to program daily genset operation or blocking and to save the time/date of the anomalies in the
Anomaly log. When power is cut off, the calendar clock must be reset.
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CONNECTION DIAGRAM
Once the connections have been made and powered, the control unit is set to OFF. See programming to change this status.
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USER PROGRAMMING
To access user programming, press the FUNCTION key and keep it pressed until “USER PROGRAMMING” appears on the display.
Release the button. Press the ARROW to scroll through the programming menus. The listings on the menu are given below:
For example:
SCELTA ITALIANO
LINGUA
After several seconds, the parameter to be changed will appear, for example:
ENGLISH
Press the START or STOP buttons to select the desired language. Example:
PROGRAMMATO
Press and hold the ARROW for 5 seconds to confirm the choice. The following appears: Release the button.
The chosen parameter is now programmed in the control unit. The settings are stored in a non‐volatile memory, and are
therefore maintained even if the power is switched off. The value can be modified at any time by repeating the procedure as
described above.
Press the ARROW to proceed with programming of other parameters.
If the parameter to be set has several variables, for example a threshold and a time, the display will show the following screens
DAILY FROM 00:00 FROM 00:00
START‐UP TO 00:00 TO 00:00
in sequence, for example: , after 3 seconds , after 3 seconds . Press START or
STOP to change the variable indicated by the arrow. Press and hold the ARROW for 5 seconds to confirm the choice. The
PROGRAMMED
following will appear: .
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DATE: 01‐08‐2016
TIME: 14:36
To set the clock/calendar, press and hold MAINS/GENERATOR until the number to be changed flashes; then
press START or STOP to change the number and press MAINS/GENERATOR to move the cursor.
To exit programming, do not press any key for 60 seconds or press the FUNCTIONS key.
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FAULT LIST
The complete list of anomalies managed by the control unit is given below.
Fault code Description Occurs when:
111 MAINTENANCE 1 Maintenance 1 expired.
112 MAINTENANCE 2 Maintenance 2 expired.
113 MAINTENANCE 3 Maintenance 3 expired.
114 PROGRAMMED MAINTENANCE Programmed maintenance expired.
120 BATTERY UNDERVOLTAGE The battery voltage is lower than the set threshold.
121 BATTERY OVERVOLTAGE The battery voltage is higher than the set threshold.
125 THERMOSTAT OVERTEMPERATURE The engine thermostat has cut in.
129 FUEL RESERVE The fuel level is lower than the reserve threshold.
130 NO FUEL The fuel level is lower than the set threshold.
132 LOW OIL PRESSURE The engine oil pressure switch has cut in.
133 STOPPING FAILURE Detects that engine is running even if the stopping system has been activated.
136 CHARGING ALTERNATOR The output “D+” or “W” on the charging alternator does not work.
The control unit has attempted to start the generator, but the engine is not
137 STARTING FAILURE
running.
139 OVERSPEED The RPMs detected by the control unit have exceeded the set threshold.
140 FUEL FLOAT INTERRUPTED The electrical circuit for the fuel float is interrupted.
141 OIL PRESSURE SWITCH ANOMALY The oil pressure switch contact is open with the engine switched off.
220 G.S. UNDERVOLTAGE The genset voltage is lower than the set threshold.
222 G.S. OVERVOLTAGE The genset voltage is higher than the set threshold.
223 G.S. UNDERFREQUENCY The genset Hz value is lower than the set threshold.
224 G.S. OVERFREQUENCY The genset Hz value is higher than the set threshold.
225 G.S. OVERLOAD PREALARM The current absorbed by the genset has exceeded the pre‐alarm threshold.
226 G.S. OVERLOAD The current absorbed by the genset has exceeded the alarm threshold.
227 G.S. NOT DELIVERING Although running, the genset does not deliver voltage.
230 GENERATOR PHASE SEQUENCE The sequence of the three genset phases is not correct.
231 GENERATOR ASYMMETRY The voltages between the three genset phases are not similar.
323 MAINS PHASE SEQUENCE The sequence of the three mains phases is not correct.
325 MAINS OVERLOAD The current absorbed by the mains has exceeded the alarm threshold.
419 EMERGENCY STOP The emergency button has been pressed.
421 AVAILABLE ANOMALY 41 The anomaly associated with programmable input 41 has occurred.
443 INCORRECT FUEL FLOAT TABLE The float table has been programmed with errors.
447 EEPROM ERROR Failed access to the static memory.
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TECHNICAL SPECIFICATIONS
Power supply
Suitable for batteries 12Vdc 24Vdc
Operating range 8 ÷ 48Vdc
Absorption with engine not running 110mA@12Vdc 60mA@24Vdc
Voltage dip on battery power supply From 10Vdc to 0Vdc for 250ms
Digital inputs
Type of input Negative
Maximum current supplied 0.55mA
Voltage threshold for low signal ≤ 0.2Vdc
Voltage threshold for high signal ≥ 2Vdc
Terminal input 65
AC voltage 5.5 ÷ 65Vac
Measurement range 50 ‐ 1500Hz
Mains and generator voltmetric inputs
Dielectric strength voltage between battery voltage circuits and 3750Vac 50Hz 1sec
mains/generator voltage circuits
Mains voltage terminal 600Vac
Rated insulation voltage Genset voltage terminal 600Vac
Battery voltage terminal 48Vac
Measurement range 80 ÷ 570Vac (three‐phase) 45 ÷ 340Vac (single‐phase)
Accuracy ±1%
Frequency meter
Measurement range 45 ‐ 85Hz
Accuracy ±0.1Hz
Amperometric input
Measurement range 20mA ÷ 6Aac
Amperometric transformer ratio /5
Maximum displayable current 4800Aac
Accuracy ±1%
Digital outputs
Type of output Positive (battery voltage)
Terminal 6, 15, 19, 70. 0.25 A
Maximum load
Terminal 17 1.5 A
Contactors command outputs
Type of output Dry contact
Maximum applicable voltage 275Vac
Maximum load 3 A (AC1)
Power displayed (kVA)
Accuracy ±2%
Engine instruments
Fuel level 0 ÷ 360 Ohm 0 ÷ 100%
Accuracy ±2%
Lines of communication
Baud‐rate 1200 ÷ 115200 bps
RS485 (Not opto isolated)
Parity None/even
Environmental conditions
Operating temperature ‐20 ÷ 60°C
Storage temperature ‐20 ÷ 60°C
Relative humidity ≤ 80%
Protection class
Back IP 00
Front IP 64
Container
Weight 450g
Dimensions (LxHxW) 243x170x62mm
Perforations 227x155mm
Material PC/ABS
Terminals
Screw M3
Nominal wire size 2.5mm2
Installation
Wall‐mount, 4 nuts M4
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WARNING
Performs only genset control and command functions. It controls the mains and generator contactors for user power supply. It is designed
solely to be built into an electrical panel and connected to the other components (contactors, fuses, thermal magnetic switches, etc.) the
installer has arranged to complete the system.
The control unit can only be accessed by specifically assigned, duly trained personnel. Maintenance operations cannot be
performed unless the system is disconnected from the mains and the battery. As an additional protection measure, we
recommend grounding the system phases.
Notwithstanding the above, only specifically assigned, duly trained personnel can perform the following operations with the system powered:
visual inspection of control unit connections and markings;
taking voltage and/or current measurements;
function programming.
These works must always be performed using equipment that ensures appropriate electrical protection.
Electromagnetic compatibility
This control unit works correctly only if it is installed in systems that comply with regulations governing CE marking; in fact,
it complies with the immunity requirements given in EN61326‐1, but this does not rule out the possibility that
malfunctions could occur in extreme cases that may arise in particular situations.
The installer is responsible for checking that the level of perturbation does not exceed that specified in standards.
IN THE ABSENCE OF OUR WRITTEN DECLARATION ATTESTING TO THE CONTRARY, THIS UNIT IS NOT SUITABLE FOR USE AS A CRITICAL COMPONENT IN
EQUIPMENT OR SYSTEMS VITAL TO THE LIFE OF PEOPLE AND OTHER LIVING THINGS.
YOUR ELECTRICIAN MAY TELEPHONE OUR TECHNICAL SERVICE WITH ANY QUESTIONS REGARDING THIS CONTROL UNIT
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NOTES
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INFORMATION FOR ORDERING
Type Item Code
CAM‐402 00242319
STANDARD ACCESSORIES
Type Item Code
KIT MU CAM‐402 40804488
DOCUMENTATION ON REQUEST
Can be downloaded from the website www.elcos.it
Diagram
number
Petrol engine diagram 00000740
Connection diagram with contact float 00000736
CONFORMITY
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