Professional Documents
Culture Documents
03
Date
June 2008
September 2008
Part of Page
Firth Release
Sixth Release
Information
New Section added for InteliLite AMF25 Panel Revision V2.6 Firmware
New Section added for InteliLite AMF25 Panel Revision V2.6 Firmware
TABLE OF CONTENTS
1.0
INTRODUCTION ....................................................................................................... 4
OVERVIEW .............................................................................................................. 4
2.1 Generator Control.................................................................................................................4
2.2 SAM2_CTL and SAM2_GEN Interconnections ........................................................................4
2.3 Automatic Transfer Switching ................................................................................................6
2.4 Generator Fuel Tank Monitoring ............................................................................................6
2.4.1 Duel Fuel Probe Address Programming and Fuel Tank Calibration ...........................................7
2.5 Minimum Set of Connections to Control/Monitor a Generator ....................................................7
2.0
INSTALLATION ......................................................................................................... 8
3.1 Mechanical Installation ..........................................................................................................8
3.2 Generator Door Switches ......................................................................................................8
3.3 SAM2_GEN Interconnecting Cable ........................................................................................8
3.4 SAM2_GEN Krone Block Cable Termination ...........................................................................9
3.5 Fuel Probe, Tank Lid Switch and Water in Diesel Probe Wiring ..............................................10
3.5.1 Dual Fuel Probe Wiring .......................................................................................................10
3.5.2 Duel Fuel Probe Address Programming ...............................................................................10
3.5.3 Duel Fuel Tank Lid Switch Wiring ........................................................................................10
3.5.4 Fuel Tank Diesel in Water Detection Probe Wiring ................................................................11
3.6 SAM2_GEN LED Indicators.................................................................................................11
3.7 Generator Start/Stop/Reset Control - Relay Contact Link Setting ............................................12
3.8 SAM2_GEN 230Vac and 12Vdc Power Cable Termination ....................................................13
3.9 Dual Generator Power Cable Distribution .............................................................................13
3.0
4.0
5.0
SAM2V3_gen_Manual V301
Page 2 of 67
SAM2V3_gen_Manual V301
Page 3 of 67
1.0 INTRODUCTION
The SAM2_GEN (SAM2 Generator controller) unit is designed to monitor and control the BTS remote site standby generator. The
SAM2_GEN does not replace the AMF generator controller; it has been designed to operate together with the AMF generator
controller to perform the following functions:
Generator Control: Automatic start-stop depending the state of the utility ac mains supply.
Generator Control: Automatic start-stop in EPCC mode as controlled by the main SAM2_CTL unit.
Alarm Monitoring: Generator alarm detection, i.e. generator fault, engine temperature/oil pressure.
State Monitoring: Generator state detection, i.e. generator run, mains/generator on load.
This document describes the operation, installation, commissioning and testing of the SAM2_GEN controller is association with the
SAM2_CTL main control unit.
2.0 OVERVIEW
The SAM2_GEN generator controller operates in conjunction with the SAM2_CTL main control unit to control the
starting/running/stopping functions and monitoring the alarm/status of the generator.
2.1
Generator Control
SAM2_CTL
Main Controller
Unit
Coms Status
SAM2_GEN
Controller
Unit
Generator #2
Generator #1
Monitored States
Rem Start 1
Rem Start 2
Rem Reset
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
2.2
The SAM2_CTL and SAM2_GEN units are interconnected using a multi-pair tie-cable; refer to table 1 below for a description of
each signal on transferred via the tie-cable.
SAM2 Controller
Multi-Pair Tie-Cable
SAM2 Generator
Controller
SAM2V3_gen_Manual V301
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The following table is a summary of the interconnections between the SAM2_CTL and SAM2_GEN units and the generators:
Signal
Krone Block 1
Mains on Load
Position
SAMCTL Unit
Description
KB1/1
GP I/P 16
Gen1 on Load
KB1/2
GP I/P 17
Gen1 Temperature
KB1/3
GP I/P 18
KB1/4
GP I/P 19
KB1/5
GP I/P 20
KB1/6
GP I/P 21
KB1/7
Relay 1
KB1/8
Relay 2
KB1/9
Relay 3
Fuel Probe
Communications
Krone Block 2
Gen1 Fault/Alarm
KB1/10
RS485/2
KB2/1
Gen Flt 1
Gen1 Door
KB2/2
Gen Door 1
Gen1 Running
Fuel Tank Lid Switch
KB2/3
KB2/4
Gen Run 1
Tank Lid
Gen Control
Communications
Gen2 Fault/Alarm
KB2/5
Gen Control
KB2/6
Gen Flt 2
Gen2 Door
KB2/7
Gen Door 2
Gen2 Running
Utility Mains Fail
KB2/8
KB2/9
Gen Run 2
Utility Mains
Gen Status
Communications
Krone Block 3
Gen2 on Load
KB2/10
Gen Status
KB3/1
GP I/P 11
Gen2 Temperature
KB3/2
GP I/P 12
KB3/3
GP I/P 13
KB3/4
GP I/P 14
KB3/5
GP I/P 15
KB3/7
Utility Meter 1
KB3
Spare I/Ps
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2.3
The diagram depicted in figure 2 shows a block diagram of how the automatic transfer switching takes place between the utility
230Vac mains supply and the 230Vac supply from either of the 2 generators.
SAM2 Controller
Genset Controller
GEN
MAINS
Generator #1
Generator #2
GCB
LOAD/BTS
GCB
MCB
MCB
ATS
ATS
2.4
The SAM2_CTL controller unit has the ability to measure the actual amount of diesel stored in the fuel tank, and to detect when the
fuel tank lid is open. The fuel probe is a pressure sensor and the SAM2_CTL unit converts the pressure reading to a fuel level
expressed in litres. The fuel tank lid switch is used to alert the SAM2_CTL unit that the fuel tank has been opened or closed. The
water detection probe is used to indicated that water is present in the diesel tank. The diagram in figure 3 shows how the fuel probe,
tank lid switch and water detection probe interface with the SAM2_CTL unit.
GEN 2 Tank Lid
SAM2_CTL
Main Controller
Unit
Fuel Tank #2
GEN 1 Tank Lid
Fuel Tank #1
Coms Control
Coms Status
Monitored States
SAM2_GEN
Controller
Unit
SAM2V3_gen_Manual V301
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2.4.1 Duel Fuel Probe Address Programming and Fuel Tank Calibration
When 2 fuel probes are used, both probes communicate with the SAM2_CTL unit via a single RS485 port, each fuel probe must be
programmed with a unique address using the ECT software, refer to the following screen shot and SAM2_ECT Software manual.
Note: Normal convention is genset #1 and thus fuel tank #1 is the one closest to the BTS/RBS.
Wire Probe #1 only, Refer to section 3 for fuel probe wiring i.e. Krone block 1 pair 10 (KB1/10/A+ and KB1/10B/-).
On the ECT Generator/Power screen type 1 for probe address.
Click Set Probe button.
Step 3:
With fuel tank 1 empty (Alternatively Probe 1 can be outside the tank, in the same position it would be inside the tank
i.e. horizontal), use the ECT "Generator/Power" screen Refresh Button to obtain the "Raw Fuel Level".
Enter this value into the field "Raw Fuel Empty Count" on the ECT "Generator/Power" screen.
Fill fuel tank, use the ECT "Generator/Power" screen Refresh Button to obtain the new "Raw Fuel Level".
Enter this value, into the field "Raw Fuel Full Count" on the ECT "Generator/Power" screen.
Update the SAM2unit using the "Set Config" button on the ECT "Generator/Power" screen.
Note: Click Refresh Button a number of times every 30 seconds to ensure the reading is stable.
Step 4:
Step 5:
Step 6:
Note: The fuel probe address can be verified using the Get Probe button when a single fuel probe is connected.
2.5
The solid lines shown in the diagram depicted in figure 4 below indicate the minimum set of connections that would effectively
control and monitor a generator. Not all generators have a low fuel indication nor do all generators have a remote fault/alarm reset
facility, these two connections are not absolutely necessary.
Generator
Page 7 of 67
3.0 INSTALLATION
3.1
Mechanical Installation
Physically mount the following items taking due care of cable entry and available space:
Fit the generator door switches and mounting plates; connect all the door switches of each generator in parallel using the
normally closed (NC) contact. Refer to table 3 below for the correct termination on the Krone blocks for the door switches.
Note: Normally Open (NO) refers to the state of the door switch contact when the door is closed, i.e. contact will
close when the door is open.
Fit the fuel probe ensuring that it is lying at the bottom of the tank. The fuel probe uses a single cable-pair to communicate with
the SAM2_CTU unit via a RS485 bus and is powered from 12Vdc via a separate cable pair; refer to table 2 below. Note that
the interconnecting cable clear plastic Breather pipe must not be sealed, obstructed or bent.
Fit the fuel tank lid switch, the switch is powered from 12Vdc via a separate cable-pair and has a single lead for its output
signal; refer to tables 1 above and table 2 below.
Fit the utility energy meter at a suitable cable entry point of the mains ac supply to the site. Refer to table 1 above for the single
cable pair used to interconnect the utility meter to the SAM2_CTL unit.
Fit the SAM2_GEN control unit in the primary standby generator (GEN1); refer to the following section for all the electrical
interconnections on the unit.
3.2
3.3
The diagram depicted in figure 5 below shows the Krone block layout for the SAM2_GEN cable termination. The following points are
important and should be noted:
Pair #1
Pair #10
Krone Block #3
Krone Block #2
Equipment
or Sensor
Side
Krone Block #1
Cable
Side
+12Vdc
SAM2V3_gen_Manual V301
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3.4
Refer to the following table to interconnect the SAM2_GEN unit to the SAM2_CTL unit using a 20/30-pair cable:
Krone Block Pair
Krone Block 1:
KB1 Pair #1: - 1/1/A
1/1/B
KB1 Pair #2: - 1/2/A
1/2/B
KB1 Pair #3: - 1/3/A
1/3/B
KB1 Pair #4: - 1/4/A
1/4/B
KB1 Pair #5: - 1/5/A
1/5/B
KB1 Pair #6: - 1/6/A
1/6/B
KB1 Pair #7: - 1/7/A
1/7/B
KB1 Pair #8: - 1/8/A
1/8/B
KB1 Pair #9: - 1/9/A
1/9/B
KB1 Pair #10: - 1/10/A
1/10/B
Krone Block 2:
KB2 Pair #1: - 2/1/A
2/1/B
KB2 Pair #2: - 2/2/A
2/2/B
KB2 Pair #3: - 2/3/A
2/3/B
KB2 Pair #4: - 2/4/A
2/4/B
KB2 Pair #5: - 2/5/A
2/5/B
KB2 Pair #6: - 2/6/A
2/6/B
KB2 Pair #7: - 2/7/A
2/7/B
KB2 Pair #8: - 2/8/A
2/8/B
KB2 Pair #9: - 2/9/A
2/9/B
KB2 Pair #10: - 2/10/A
2/10/B
Krone Block 3:
KB3 Pair #1: - 3/1/A
3/1/B
KB3 Pair #2: - 3/2/A
3/2/B
KB3 Pair #3: - 3/3/A
3/3/B
KB3 Pair #4: - 3/4/A
3/4/B
KB3 Pair #5: - 3/5/A
3/5/B
KB3 Pair #6: - 3/6/A
3/6/B
KB3 Pair #7: - 3/7/A
3/7/B
KB3 Pair #8: - 3/8/A
3/8/B
KB3 Pair #9: - 3/9/A
3/9/B
KB3 Pair #10: - 3/10/A
3/10/B
Pair
Polarity
Blue
Black
Orange
Black
Green
Black
Brown
Black
Grey
Black
Blue
Yellow
Orange
Yellow
Green
Yellow
Brown
Yellow
Grey
Yellow
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ NO/NC
- COM
+ NO/NC
- COM
+ NO/NC
- COM
+ RS485
- RS485
Blue
White
Orange
White
Green
White
Brown
White
Grey
White
Blue
Red
Orange
Red
Green
Red
Brown
Red
Grey
Red
+ GFLT1
- GFLT1
+ GDR1
- GDR1
+ GRUN1
- GRUN1
+ GTL
- GTL
+ GC Pulse
- GC Pulse
+ GFLT2
- GFLT2
+ GDR2
- GDR2
+ GRUN2
- GRUN2
+ UTIL
- UTIL
+ GS Pulse
- GS Pulse
Blue
White
Orange
White
Green
White
Brown
White
Grey
White
Blue
Red
Orange
Red
Green
Red
Brown
Red
Grey
Red
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ GP
- GP
+ GP
- GP
A
B
Alarm Description
Comment
Mains on Load
Ground (GND)
Generator 1 on Load
Ground (GND)
Generator 1 Engine Temperature
Ground (GND)
Generator 1 Oil Pressure
Ground (GND)
Generator 1 Emergency Stop
Ground (GND)
Generator 1 Low Fuel or alternatively Fuel Tank 1 Water in Diesel Alarm
Ground (GND)
Generator 1 Remote Start
Generator 2 Remote Start
Generator 1 & 2 Reset
Fuel Probe RS485 Coms Pair
Generator 1 Fault
Ground (GND)
Generator 1 Door
Ground (GND)
Generator 1 Running
Ground (GND)
Fuel Tank Lid
Ground (GND)
Generator Control Signal
Ground (GND)
Generator 2 Fault
Ground (GND)
Generator 2 Door
Ground (GND)
Generator 2 Running
Ground (GND)
Utility Mains Fail Alarm
Ground (GND)
Generator Status Signal
Ground (GND)
Generator 2 on Load
Ground (GND)
Generator 2 Engine Temperature
Ground (GND)
Generator 2 Oil Pressure
Ground (GND)
Generator 2 Emergency Stop
Ground (GND)
Generator 2 Low Fuel or alternatively Fuel Tank 2 Water in Diesel Alarm
Ground (GND)
Spare
Utility Meter Coms Pair
Spare
Spare
Spare
SAM2V3_gen_Manual V301
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3.5
Fuel Probe, Tank Lid Switch and Water in Diesel Probe Wiring
Use the following table as a reference to connect the fuel probe and tank lid switch to the SAM2_CTL unit:
Signal
Fuel Probe Coms:
RS485 A (Pos)
RS485 B (Neg)
Fuel Probe 12Vdc:
+12Vdc (Pos)
GND (Neg)
Tank Lid switch:
+12Vdc (Pos)
Tank Lid switch:
GND (Neg)
Tank Lid switch:
Output
SAM2_GEN Unit
KB1/10/A
KB1/10/B
Blue
Yellow
JP4 12V
JP4 GND
Black
White
JP4 12V
Brown
JP4 GND
KB2/4/A
Black
Blue
Description
RS458 Port on SAM2_CTL Cable pair used to
communicate with the fuel probe.
12Vdc Supply on SAM2-GEN Fused
provided on the SAM2_GEN unit to power
Note the fuse is an Auto-Reset type.
12Vdc Supply on SAM2-GEN Fused
provided on the SAM2_GEN unit to power
Note the fuse is an Auto-Reset type.
12Vdc supply
the fuel probe.
12Vdc supply
the fuel probe.
Notes:
The fuel probe cable has a clear plastic Breather pipe at the center of its core, this pipe must not be bent or sealed
as free airflow via this pipe is necessary for correct operation of the probe
The fuel probe cable has a screen and a red lead; both are not used and may be cut off.
Table 3: SAM2_CTL/GEN Fuel Probe and Tank Lid Switch Interconnection Summary
The RS485 communication ports of the 2 fuel probes are wired in parallel on one cable pair.
The SAM2_GEN unit makes provision for powering the 12Vdc supply input of 2 fuel probes via separate auto reset fuses.
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
Signal
Fuel Probe #1 Coms:
RS485 A (Pos)
RS485 B (Neg)
Fuel Probe #2 Coms:
RS485 A (Pos)
RS485 B (Neg)
12Vdc Fuel Probe #1:
+12Vdc (Pos)
GND (Neg)
12Vdc Fuel Probe #2:
+12Vdc (Pos)
GND (Neg)
SAM2_GEN Unit
KB1/10/A
KB1/10/B
Blue
Yellow
KB1/10/A
KB1/10/B
Blue
Yellow
JP4 12V
JP4 GND
Black
White
JP4 12V
JP4 GND
Black
White
Description
RS458 Port on SAM2_CTL Cable pair used to
communicate with the fuel probe.
Note: The RS485 communications ports of the 2 fuel
probes are connected in parallel on a single cable pair;
the RS485 port is polarity sensitive.
12Vdc Supply on SAM2-GEN Fused 12Vdc supply
output for fuel probe.
Note: The SAM2_GEN unit provides for 2 separate
fused 12Vdc supply pairs to power the 2 fuel probes;
the fuses are Auto-Reset type.
+12V (Brown)
+12Vdc
+12Vdc
Output (Blue)
Tank Lid
Switch #2
GND
GND (Black)
Output (Blue)
KB2/4/A
Tank Lid
Switch #1
GND
GND (Black)
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
Signal
Description
SAM2_GEN Unit
12Vdc Supply GND lead on SAM2-GEN unit.
Tank Lid Switch #2:
JP4 GND
GND (Neg)
12Vdc Supply on SAM2-GEN Fused 12Vdc supply
Tank Lid Switch #2:
output for the tank lid switches.
JP4 12V
+12Vdc (Pos)
Note: The SAM2_GEN unit caters for 2 separate fused
Tank Lid Switch #1:
12Vdc supply pairs to power the 2 fuel tank lid JP4 12V
+12Vdc (Pos)
switches; the fuses are Auto-Reset type.
Tank Lid Switch #2 Output - Used to indicate when the Tank lid switch #2
Tank Lid Switch #2:
fuel tank filling lid is opened.
blue lead connected
Output
Note: Connect the output lead (blue) of tank lid switch to tank lid switch #1
#1 to the GND lead (black) of tank lid switch #2.
black lead.
Tank Lid Switch #1 Output - Used to indicate when the
Tank Lid switch #1:
fuel tank filling lid is opened.
KB2/4/A
Output
SAM2V3_gen_Manual V301
Page 10 of 67
Blue
SAM2_GEN Unit
Description
JP4 12V
Brown
Black
Blue
JP4 12V
Brown
Black
Blue
The above wiring table assumes that the low fuel alarm input is not used (some generators have integral fuel tanks that are
equipped with mechanical fuel level detectors).
3.6
The diagram depicted in figure 6 below shows the LED Indicators available on the SAM2_GEN controller Unit.
LED1
LED2
3x Red LEDs
Utility 230Vac
Power
LED3
LED4
LED5
Utility 230Vac
Power Monitor
ON indicates L1, L2 and L3 phase voltage present and greater than 185Vac
LED OFF; No communication between SAM2_CTL and SAM2_GEN units, SAM2_GEN in control of generators.
LED Flashing; SAM2_GEN receiving communication from SAM2_CTL unit (via control cable pair KB2/5/A/B), but SAM2_CTL
is not receiving communication from SAM2_GEN unit (via status cable pair KB2/10/A/B).
LED ON; Full communication between SAM2_CTL and SAM2_GEN units, SAM2_CTL in control of generators.
LED3 Utility 230Vac Supply:
LED OFF; All 3 phases (L1, L2 and L3) voltage below 185Vac
LED ON; All 3 phases (L1, L2 and L3) voltage above 185Vac
LED4 and LED5 Generator Running Indication (LED4 generator 1 and LED5 generator 2):
LED Flashing; Generator running, but 230Vac output from generator not present.
LED ON; Generator running, and 230Vac output from generator is present.
Note: In bright ambient (sun) light it is difficult to distinguish whether the LEDs are illuminated, in such situations reduce
the amount of ambient light on the LEDs by casting a shadow on the LEDs.
SAM2V3_gen_Manual V301
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3.7
The 2 diagrams depicted in figure 7 below show the Links that determine whether a normally open (NO) or a normally closed (NC)
relay contact is used to start/stop the generators.
NO/NC Relay contact
selection for generator 1
Genset Reset
Generator 2
Generator 1
SAM2V3_gen_Manual V301
Page 12 of 67
3.8
The utility mains ac supply, generator ac supply and the 12VDc supply connections are shown in diagram below:
Mains 230Vac
Output Supply to BTS
L1
L2 L3
MCB
N
L1
L1
L2 L3
GCB
N
L2 L3
Utility 230Vac
Supply
L1
L2 L3
Battery 12Vdc
Supply
Generator
230Vac Supply
Refer to diagram in figure 8 above and make the following screw-terminal connections:
Mains ac supply; Neutral lead (N) and 3-phases (L1, L2 and L3), if the site is powered from a single phase then L1, L2 and L3
must be looped. Connect to the corresponding N, L1, L2 and L3 screw terminals on the AMF25 panel.
Generator ac output supply; 3-Phases (L1, L2 and L3), if the generator is 3-phase, then L1, L2 and L3 must be looped.
Connect to the corresponding L1, L2 and L3 screw terminals on the AMF25 panel.
12Vdc supply; Connect the +12V and GND to the generator AMF panel standby battery positive and negative terminals
respectively.
Emergency Stop button; Connect the output side (lead K107 on the Intelilite AMF25 control panel) of the emergency stop
button to screw-terminal I/P 1 for generator 1 and I/P2 for the second generator.
3.9
The diagram below shows the 230Vac distribution wiring for a dual generator scenario:
Utility 230Vac
Supply
L1
L2 L3
MCB
N
L1
Generator 2
230Vac Supply
L1
L2 L3
GCB
L2 L3
L1
L1
L2 L3
GCB1
L2 L3
L1
Generator 1
230Vac Supply
L1
L2 L3
GCB2
L2 L3
L1
L2 L3
Generator 230Vac
Output Supply
SAM2V3_gen_Manual V301
Page 13 of 67
Generator 2 O/P
230Vac Supply
230Vac Supply
L1 L2 L3
L1 L2 L3
GCB 2
GCB 1
L1 L2 L3
L1 L2 L3
L1, L2 and L3
N
230Vac Supply
230Vac Supply to
Input to BTS
SAM2_GEN Unit
30
D1
31
Generator 1 12V Battery
30
D2
31
Generator 2 12V Battery
If duel generators are used on site, the two 12V batteries can be connected via two diodes as shown above. Diodes D1 and D2
must have forward current rating of at lease 1A and a minimum reverse breakdown rating of 100V; diodes from the 1N4004 to
1N4007 series are suitable.
SAM2V3_gen_Manual V301
Page 14 of 67
SAM2_GEN
Krone Block
KB2/3/A - Orange
Gen1 Run
147
KB2/3/B - White
31
201
202
KB2/1/A - Blue
Gen1 Fault
KB2/1/B - White
203
Note: Connect
KB1/9/A (Brown)
to +12Vdc on JP4
KB1/9/B - Yellow
KB1/7/A - Orange
Gen1 Remote Start
KB1/7/B - Yellow
KB2/2/A - Orange
KB2/2/B - White
KB1/6/A - Blue
KB1/6/B - Yellow
Krone Block:
Cable Pair
Description
Generator Terminal
Blue
Krone Block 1:
KB1 Pair #6
KB1/6/A
KB1/6/B
Yellow
KB1 Pair #7
KB1/7/A
Orange
B13/3
KB1/7/B
Yellow
Ground (GND)
B13/4
KB1 Pair #9
KB1/9/A
Brown
Generator Reset
KB1/9/B
Yellow
Ground (GND)
KB1/10/A
Grey
KB1/10/B
Yellow
KB2/1/A
Blue
Generator1 Fault
KB2/1/B
White
KB2/2/A
Orange
KB2/2/B
White
KB2/3/A
Green
KB2/3/B
White
KB2/4/A
Brown
KB2/4/B
White
Krone Block 2:
KB2 Pair #1
KB2 Pair #2
KB2 Pair #3
KB2 Pair #4
B201/6
B201/4
Generator1 Door
Door Switch
NC Contact
Generator1 Running
B201/9
B201/7
Refer to section 2 above for Tank Lid
Swicth wiring (Single or Dual tanks)
SAM2V3_gen_Manual V301
Page 15 of 67
SAM2_GEN
Krone Block
KB2/8/A - Orange
Gen1 Run
147
KB2/8/B - Red
31
201
202
KB2/6/A - Blue
Gen1 Fault
KB2/6/B - Red
203
Note: Connect
KB1/9/A (Brown)
to +12Vdc on JP4
KB1/9/B - Yellow
KB1/8/A - Green
Gen1 Remote Start
KB1/8/B - Yellow
KB2/7/A - Orange
KB2/7/B - Red
KB3/5/A - Grey
KB3/5/B - White
Krone Block:
Cable Pair
Description
Generator Terminal
Krone Block 1:
KB1 Pair #8
KB1 Pair #9
KB1/8/A
Green
B13/3
KB1/8/B
Yellow
Ground (GND)
B13/4
KB1/9/A
Brown
Generator Reset
KB1/9/B
Yellow
Ground (GND)
Fuel Probe
JP4/12V
Power
JP4/GND
Krone Block 2:
KB2 Pair #6
KB2/6/A
Blue
KB2/6/B
Red
KB2 Pair #7
KB2/7/A
Orange
KB2/7/B
Red
KB2 Pair #8
KB2/8/A
Green
KB2/8/B
Red
Generator2 Fault
B201/6
B201/4
Generator2 Door
Door Switch
NC Contact
Generator2 Running
B201/9
B201/7
Tank Lid
JP4/12V
Power
JP4/GND
Krone Block 3:
KB3 Pair #5
KB3/5/A
Grey
KB5/5/B
White
SAM2V3_gen_Manual V301
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GND (31)
+12V (30)
12Vdc Supply
Note: Connect +12Vdc to KB1/9/A (JP4 +12V) to power the reset relay.
12Vdc Output
GND
+12V
GEN RESET
GEN RUN
GEN FAULT
GEN RUN
KB2/1/A/B
KB2/3/A/B
End of Section 4
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Binary Input 3: Configured as Remote Test, This input is used to start and stop the generator and is connected to
the SAM2 remote start output.
Binary Input 4: Configured as Test on Load, This input is used to ensure the generator goes on load when started. It
must be left open circuit.
Binary Input 5: Configured as Mains Fail Block, This input is used to disable the genset automatic start function for
a Mains Failure. The input simulates healthy mains. In the case of a running genset the GCB contactor is opened,
the genset goes to cooling procedure and stops.
Binary Input 6: Configured as Fault Reset Button, This input is used to reset a fault condition on the AMF25 panel
and is connected to the SAM2 remote reset output.
Binary Input 7: Configured as Remote AUTO, This input is used to switch the AMF25 panel to AUTO Mode in order
to stop the genset by initiating the cooling procedure. The input is used to ensure the MCB contactor closes when the
genset is not running and mains is present.
SAM2 sites already installed and programmed using the V1.3.2 or V2.4 revision InteliLite AMF25 firmware can be upgraded
by making the above wiring changes on the AMF25 panel and re-programming the AMF25 panel using the V2.6 firmware,
downloading the correct Inala V2.6 configuration template. Refer to the following picture:
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The diagram below shows the screw terminal blocks and relays where the wiring for generator alarm/status monitoring points are
terminated. Only 4 of the relays have contacts that are wired to the screw terminal blocks, thus the screw terminals and the relays
are used to terminate the wiring.
The six relays each have 2 sets of change over contacts, the back screw terminal on the relay base is the COM contact, the
centre screw terminal is the NO contact and the front screw terminal is the NC contact. Starting from the left hand side the six
relays have the following functions:
Relay
1
2
3
4
5
6
b)
Function
MCB
GCB
Low Fuel
Alarm
Service Time
Generator Run
The generator remote start and reset control lines are wired directly from the SAM2_GEN unit to the InteliLite AMF25 panel. Refer to
the InteliLite AMF25 panel-wiring table in section 5.3 below and the picture in section 5.0 above.
c)
The generator engine oil pressure and water temperature alarms are wired directly from the SAM2_GEN unit to the InteliLite AMF25
panel. Refer to the AMF25 panel-wiring table in section 5.3 below.
d)
The SAM2_GEN unit has 2 dedicated inputs to monitor the emergency stop button of single and dual generators. The emergency
stop button and ON/OFF key-switch are connected in series to provide 12Vdc power for the InteliLite AMF25 panel on the K109 wire
lead, the SAM2_GEN emergency stop input is wired directly to +12Vdc screw terminal (wire lead K109) on the InteliLite AMF25
control panel. Connect the emergency stop button of generator 1 to input I/P1 on the SAM2_GEN unit and if duel generators are
installed use input I/P2 for the second generator.
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Refer to the diagram below; BATT-1 is the large 12V battery used to start the generator engine and BATT-2 is the small battery used
to provide a 12V back-up supply for the InteliLite AMF25 panel while the generator engine is cranking and the voltage across BATT1 drops. The 2 batteries are inter-connected by diode D1 to ensure BATT-2 does not supply current to BATT-1 while the generator
engine is being cranked (started), D1 is an integral part of the generator wiring harness and does not need to be fitted during the
SAM2_GEN unit installation.
K105
D1
BATT-1
BATT-2
K117 (GND)
Use two Piggy-Back Male-Female spade terminals on BATT-2 to connect the 12Vdc supply input to the SAM2_GEN unit as
shown in the diagram above.
b)
Refer to the following diagram; the 3-Phase utility 230Vac mains supply is connected onto the 4-threaded terminals on the right
hand side and 3-Phase 230Vac output power from the generator is connected onto the 4-threaded terminals on the left hand side.
Generator Side
230Vac Wiring
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N L1 L2 L3
Generator ac
1 2 3 4 5 6 7
Binary Inputs
N L1 L2 L3
Utility Mains ac
Binary Outputs
3 4 5 6 7
Emergency Stop
K109
Refer to diagram above and make the following connections between the SAM2_GEN controller unit Krone blocks, the InteliLite
AMF25 panel and the alarm relay screw terminals:
Name
AMF25-Name
Krone Block
AMF25
Comments
Generator 1 Wiring:
GEN1 Run
----------KB2/3/A/B GN/WH X103/104
Connect to screw terminals X103 & X104 (Relay NO)
GEN1 Fault
Alarm
KB2/1/A/B BL/WH
X105/106
Connect to screw terminals X105 & X106 (Relay NO)
GEN1
Remote Test
KB1/7/A O/Yel
BIN I/P 3
Connect directly to BIN I/P 3 on AMF25 panel.
Remote Start
Notes: BIN I/P 3 must not be connected to any other leads, BIN I/P 4 and BIN I/P 5 must be Open Circuit
GEN1
FaultResButton
KB1/9/A/B BN/Yel
BIN I/P 6
Connect directly to BIN I/P 6 on AMF25 panel, and link
Remote Reset
Remote AUTO
BIN I/P 7
BIN I/P 6 to BIN I/P 7
Mains on Load
MCB Relay
KB1/1/A/B BL/BK
COM/NC
Connect across COM and NC on MCB relay
GEN1 on Load
GCB Relay
KB1/2/A/B O/BK
COM/NO
Connect across COM and NO on GCB relay
GEN1 Temp
Water Temp
KB1/3/A/B GN/BK
BIN O/P 6
Connect directly to BIN O/P 6 on AMF25 panel
GEN1 Oil
Oil Pressure
KB1/4/A/B BN/BK
BIN O/P 5
Connect directly to BIN O/P 5 on AMF25 panel
GEN1 Door
----------KB2/2/A/B O/WH
----------Wiring for GEN 1 door switches, refer to section 3.3
Emergency Stop + DC Power I/P
GR/BK
K109
GEN1 ES: Connect I/P 1 on SAM2_GEN Unit to K109
GEN1 Low Fuel
----------KB1/6/A/B BL/Yel
X107/108
Connect to screw terminals X107 & X108 (Relay NO)
Note: The GND (negative B) leg of all the cable pairs must be terminated on the Common Ground Point of the AMF25 panel
Generator 2 Wiring:
GEN2 Run
----------KB/2/8/A/B GN/RD
X103/104
Connect to screw terminals X103 & X104 (Relay NO)
GEN2 Fault
Alarm
KB2/6/A/B BL/RD
X105/106
Connect to screw terminals X105 & X106 (Relay NO)
GEN2
Remote Test
KB1/8/A GN/Yel
BIN I/P 3
Connect directly to BIN I/P 4 on AMF25 panel.
Remote Start
Notes: BIN I/P 3 must not be connected to any other leads, BIN I/P 4 and BIN I/P 5 must be Open Circuit
GEN2
FaultResButton
KB1/9/A/B BN/Yel
BIN I/P 6
Connect directly to BIN I/P 6 on AMF25 panel, and link
Remote Reset
Remote OUTO
BIN I/P 7
BIN I/P 6 to BIN I/P 7
GEN2 on Load
GCB Relay
KB3/1/A/B BL/WH
COM/NO
Connect across COM and NO on GCB relay
GEN2 Temp
Water Temp
KB3/2/A/B O/WH
BIN O/P 6
Connect directly to BIN O/P 6 on AMF25 panel
GEN2 Oil
Oil Pressure
KB3/3/A/B GN/WH BIN O/P 5
Connect directly to BIN O/P 5 on AMF25 panel
GEN2 Door
----------KB2/7/A/B O/RD
----------Wiring for GEN 2 door switches, refer to section 3.3
Emergency Stop + DC Power I/P
BN/WH
K109
GEN2 ES: Connect I/P 2 on SAM2_GEN Unit to K109
GEN2 Low Fuel
----------KB3/5/A/B GR/WH X107/108
Connect to screw terminals X107 & X108 (Relay NO)
Notes: The GND (negative B) leg of all the cable pairs must be terminated on the Common Ground Point of the AMF25 panel.
KB1/7/B, KB/1/8/B and KB/1/9/B must be grounded eg. Connect to the Common Ground Point of the AMF25 panel.
Generator Start/Stop/Reset Control Relay Contact Links:
Set links in Normally Open (NO) position
Note: Remove wire leads K131 and K133 from AMF25 screw terminals, insulate the bare terminal and cable tie (Do Not Cut)
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Reprogram the AMF25 control panel using the revision V2.6 firmware.
Load the SAM2 system specific configuration file on the InteliLite AMF25 Panel
Locate the InteliLite LiteEdit software application Installer executable program (e.g. the IL2.4_LE2.4.1.EXE) file saved in the
INTELILITE AMF25 Inala SAM2 Updates document folder on the PC desktop. Refer to the following 2 screenshots:
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b)
Install the InteliLite LiteEdit software application using the IL2.4_LE2.4.1.EXE Installer executable program located in the
InteliLite document folder. Refer to the following screenshots:
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Click Install.
Click Install
Select NO
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Select YES to create a shortcut to the LiteEdit software application program on the PC desktop.
Click Finish to complete the installation process for the LiteEdit software application program.
The installation process is complete and the LiteEdit software application is ready to be used, however the V2.6 revision firmware
must first be imported before the InteliLite AMF25 panel can be reprogrammed for operation together with the SAM2 system, refer to
the following section
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Click on the Browse button and navigate to the IL-2.6r1.iwe firmware file located in the Inala Default Templates document
folder. Select the file and click the Open button.
1
2
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Complete the firmware import process by clicking the Import button as indicated in the screenshot below:
The firmware importing process is now complete; the LiteEdit software application is ready to be used to reprogram the InteliLite
AMF control panel with revision V2.6 firmware and configuration file that has been specifically created for operation with the Inala
SAM2 system.
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The 12Vdc supply to the InteliLite AMF-25 panel must not be interrupted during the programming and configuration
procedure.
Ensure that the Laptop PC battery is in a fit state to power the PC during the entire programming and configuration
procedure.
Ensure that the serial port cable is not disconnected during the programming and configuration procedure.
A cross-over (Null-Modem) DB-9 female-to-female serial port cable is required for the programming and configuration
procedure.
Always save separate configuration files before reprogramming with revision V2.6 firmware and after making
configuration changes.
The InteliLite LiteEdit 2.4.1 version software application is required to communicate with AMF25 panels previously
programmed using the revision V2.4 firmware. LiteEdit revision V1.3 software does not communicate with AMF25
panels programmed with V2.4 or 2.6 firmware.
Note: The InteliLite AMF25 panel must be in the OFF MODE in order to download firmware and/or configuration, the following
steps are recommended:
Switch off the 12Vdc supply to the InteliLite AMF25 panel using either the On/Off switch or the Emergency button.
Unplug the 4-Way screw terminal connector from the Start and Fuel Solenoid relay outputs on the InteliLite AMF25 panel
Unplug the 7-Way Binary Inputs screw terminal connector from the InteliLite AMF25 panel
Switch on the 12Vdc supply to the InteliLite AMF25 panel (On/Off switch or restore the emergency button).
Switch the InteliLite AMF25 panel to the OFF MODE using the front panel keys.
Alternatively run the LiteEdit software and refer to the following screenshot to switch the InteliLite AMF25 panel to the OFF
MODE: Connect to the InteliLite AMF25 panel using the Open Direct menu icon. Select the Setpoints menu option and
in the Basic Settings group set the Mode IL option to OFF.
The InteliLite AMF25 panel should now be in the OFF Mode, follow the procedure described below to download the revision V2.6
firmware and to re-configure the InteliLite AMF25 panel.
Note: If the InteliLite AMF25 panel does not switch to the OFF mode using the procedures described above, verify that
the binary input configuration is not preventing it from switching to the OFF mode i.e. if a binary input is configured for
Remote Test and NC, the InteliLite AMF25 panel will remain in TEST mode as long as that binary input is open-circuit.
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To reprogram the InteliLite AMF25 panel and download configuration perform the following: Run the LiteEdit software and connect
using the Open Direct menu option. Click the Password icon, enter the password (0 - numeric zero) and click Ok.
2 Password Icon
Type 0
To download firmware: Select Controller menu option, click on Programming and Cloning followed by Programming
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Select the 2.6 InteliLite version AMF25 for the AMF25 panel and click Ok, click YES to switch to OFF mode. Note: If the
InteliLite AMF25 panel will not switch to the OFF Mode, refer to the beginning of section 5.8 where the procedure for switching the
InteliLite AMF25 panel is described.
Refer to the following screenshot: Click NO in order to retain the exiting Setpoint configuration on the AMD25 panel:
Click NO Button
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If the InteliLite AMF25 controller is in the OFF Mode, the firmware will start downloading and a progress bar will be visible.
When the Programming was Correct message will is displayed, click the Ok button,.
Click OK Button
The firmware download process is now complete; the next step is to download a new configuration file.
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To download the configuration file: Click the Folder icon, navigate to the INALA Template IL-AMF25 v26 20jun088
configuration file in the Inala Default document folder, select the file and click Open button.
If the existing configuration file has not been saved, click Yes, if the file was saved prior to reprogramming, click No
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In order to download the setpoint configuration and control function configuration to the InteliLite AMF25 panel, click Ok.
Click OK
NB! Click YES to overwrite the existing Setpoint configuration as indicated in the following screenshot:
Click YES
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If the InteliLite AMF25 controller is in the OFF Mode, the config file will start downloading, a progress bar will be visible as shown
in the screenshot below. When the configuration downloading process is complete, click the OK button.
Click OK
The Information Window displayed in the screenshot shown below indicates which Setpoints were not overwritten
Click OK
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Ensure the AMF25 panel ControllerMode setpoint is set for AUTO Mode, refer to the following screenshot:.
Switch the 12Vdc supply to InteliLite AMF25 panel off and on again in order to ensure that the newly downloaded
configuration is loaded from memory and in use
On the AMF25 front panel verify that the unit is in AUTO mode before the SAM2 Unit starts the genset.
Mode Control
Buttons
AUTO Mode
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Comments:
Analog Input 1: This input is normally reserved for the engine oil pressure sensor
Analog Input 2: This input is normally reserved for the engine water temperature sensor
Analog Input 3: This input is normally reserved for the fuel tank level sensor, this input is often not used.
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The analog sensor characteristics curves are modified by changing the existing entered Primary and Converted values.
Click the Add button to insert additional Primary value points.
Click the Remove button to delete unwanted Primary value points.
Exit and save the analog sensor characteristics by clicking the 2 OK buttons
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Run the LiteEdit application program, connect to the IteliLite AMF25 panel, click on the Setpoints icon to open Setpoints
window.
Now click on the Setpoints icon and select the Open Alternate Setpoint option. Navigate to the previously saved configuration
file that will be used for comparison.
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b)
Password Protection
Run the LiteEdit application program, connect to the IteliLite AMF25 panel, click on the Password icon and enter the password
(i.e. 0), click on the Modify icon and open the appropriate window, click on the Setpoints-Password button to open the
password protection widow.
1
Password
Protection
Disabled
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Appendix A: Wiring For FG Wilson Generator/Olympian - Power Wizard 1.0 AMF Panel
This section describes the installation details applicable to FG Wilson/Olympian generators equipped with PowerWizard 1 controller
Gen Fault:
Wire no 88 on the top terminal strip (Fig.1)
Gen Door:
From switch supplied.
Gen Run:Wire no 90 on the top terminal strip (Fig.1)
Gen on Load:
Not supported
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop: From switch on the side where +12Volt signal falls away when pushed, if switch is available.
Gen Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
Wire no 5&24 At the bottom terminal strip connection Points 1 and 2 refer to diagram 2 below.
Mains on load:
Not supported
Remote Reset:
Not supported
12Volt Supply:
+12V on terminal block wire 1+ position 1
Ground on terminal strip wire number 5 (diagram 1 below)
Note: Direct on battery is the best.
When making the connections the wires on positions 40 and 27 on the controller side (marked on the connector) and with the
numbers 7 on both wires should be cut off and joined together and connect these joined wires to ground number 5 on terminal strip.
Refer to diagram 3 below.
The controller should be programmed for the following configuration.
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Gen Fault
Wire no 88
Gen Running
Wire no 90
Remote Start
Wires no 5 / 24
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Gen Fault:
Gen Door:
Gen Run:
Gen on Load:
Gen Temp:
Gen Oil Press:
Emergency Stop:
Gen Low Fuel:
Remote Start:
Mains on load:
Remote Reset:
12Volt Supply:
Ensure that the controller is in AUTO Mode after completing the installation by pressing the yellow button.
End of Appendix B
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Gen Fault:
Gen Door:
Gen Run:
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Remember to switch the selector switch to the Automatic Running Mode after installation.
End of Appendix C
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Appendix D: Wiring For Diesel Electric Generator Controller with AMF25 Panel
This section describes the installation details applicable to Diesel Electric Services generator equipped with AMF25 control panel
Gen Fault:
Binary Output 7 on back of controller.
Gen Door:
From switch supplied.
Gen Run:
Position wires 9 and 10 on terminal strip. (Refer to Diagram 1)
Gen on Load:
Binary Output 3
Gen Temp:
Binary Output 6
Gen Oil Press:
Binary Output 5
Emergency Stop:
From switch on the side where +12Volt signal falls away when pushed.
Gen Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
Binary Input 3
Mains on load:
Binary Output 4
Remote Reset:
Binary Output 7 (Connect Binary Input 6 to Binary Input 7)
12Volt Supply:
Connect to J3B battery +12volt (Positive). (Refer to Diagram 2)
Connect to J2 battery 12Volt (Ground). (Refer to Diagram 2)
Binary Inputs 4 and 5 must be open circuit
Make sure to wire according to the AMF 25 for InteliLite, e.g. remove wires as mentioned in manual for InteliLite wiring.
Note: Programming is the same as for all other InteliLites AMF25 panels. (Gen Logic)
Diagram 1
Diagram 2
Gen Running
+12Volt Supply
- 12Volt Supply
End of Appendix D
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Appendix E: Wiring For Deep Sea Electronics DSE704 and DSE4120 Control Panels
This section describes the installation details applicable to Deep Sea Electronics DSE704 and DSE4120 generator control panels.
Gen Fault:
Not supported (Still to determine will advice.)
Gen Door:
From switch supplied.
Gen Run:
Position number 3 on back of controller.
Gen on Load:
Not supported
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop:
From switch on the side where +12Volt signal falls away when pushed, if switch is available.
Gen Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
Position number 12 on back of controller.
Mains on load:
Not supported
Remote Reset:
Not supported
12Volt Supply:
Direct on battery is the best.
Note: Both the jumpers inside the SAM generator controller and the main SAM controller need to be moved to N/C position and the
Remote Start should be wired as indicated in diagram 1 below. Also set the start pulse duration on the Main SAM controller under
the Generator/Power screen to 60 seconds.
Diagram 1: Wiring for SAM2 Normally Open (NO) Remote Start Relay Contact
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Remember to leave the controller in auto mode by pressing the auto button.
End of Appendix E
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Appendix F: Wiring For Lister Petter Generator with DSE5210 Control Panel
This section describes the installation details applicable to Lister Petter Generator equipped with the Deep Sea Electronics
DSE5210 AMF control panels.
Gen Fault:
Gen Door:
Gen Run:
Gen on Load:
Gen Temp:
Gen Oil Press:
Emergency Stop:
Gen Low Fuel:
Remote Start:
Mains on load:
Remote Reset:
12Volt Supply:
Remote Start
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Gen Running
Com and N/O
contact
Generator 230Vac
output supply
Remember to leave the controller in auto mode by pressing the auto button.
End of Appendix F
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Gen Fault:
Gen Door:
Gen Run:
Gen on Load:
Gen Temp:
Gen Oil Press:
Emergency Stop:
Gen Low Fuel:
Remote Start:
Mains on load:
Remote Reset:
12Volt Supply:
Remember to leave the generator in Auto mode by switching the switch to the right.
End of Appendix G
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Gen Fault:
Wires 41 & 43 NO - contact (Refer to diagram 2)
Gen Door:
From switch supplied.
Gen Run:
Wires 44 & 46 (SET Run/Low Oil Relay) NO - contact (Refer to diagram 2)
Gen on Load:
Wires PC1 & PC2 (Plant on load) (Refer to diagram 2)
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop:
Wire no 211 orange from controller (Refer to diagram 1)
Gen Low Fuel:
Not connected as Inala fuel probe is installed. Wires 51 & 52 NC - contact (Refer to diagram 2)
Remote Star:
Wires 10 & 200 (Remote Start/Stop) (Refer to diagram 2)
Mains on load:
Wires MC1 & MC2 (Mains On Load) (Refer to diagram 2)
Remote Reset:
Not supported
12Volt Supply:
Direct on battery is the best.
Diagram 1: Emergency Stop Signal Wiring
Emergency Stop:
Wire Lead 211
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Two parameters need to be changed on the controller to be able to control the generator from the SAM2, these two parameters is
parameter 43 and 49.
Parameter P.43 (Mains Control) should be set to 2 (Disabled).
Parameter P.49 (Remote Start) should be set to 0 (Remote starting).
To have access to advanced setup, place the unit in OFF mode keep OFF button pressed and pressed then push the
SELECT/RESET and GEN buttons and hold for 5 seconds. The setup is displayed with P.20 indicating the setting to be modified.
To go to the parameter to be changed use the GEN button to go up and the MAINS button to go down. When parameter is selected
use the STOP and START buttons to move the setting up or down till the required value is displayed. Press the OFF button to store
all changed values.
Remember to leave the controller in the Auto Mode when all wiring and settings have been done.
End of Appendix H
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Gen Fault:
From the Remote alarm Com and N/O contact on terminal strip (Refer to diagram 1)
Gen Door:
From switch supplied.
Gen Run:
From the Gen Running position on terminal strip. (Refer to diagram 1)
Gen on Load:
Not supported
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop:
From switch on the side where +12Volt signal falls away when pushed, if switch is available.
Gen Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
From position 10 on back of controller. (Refer to diagram 2)
Mains on load:
Not supported
Remote Reset:
Not supported
12Volt Supply:
From 12V DC battery supply on terminal strip. (Refer to diagram 1)
Diagram 1: Alarm Signal Wiring
Gen Fault
Gen Running
12V DC Supply
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Remote Start
Two parameters need to be changed on the controller to be able to control the generator from the SAM2, these two parameters is
parameter 43 and 49.
Parameter P.43 (Mains Control) should be set to 2 (Disabled).
Parameter P.49 (Remote Start) should be set to 0 (Remote starting).
To have access to advanced setup, place the unit in OFF mode keep OFF button pressed and pressed then push the
SELECT/RESET and GEN buttons and hold for 5 seconds. The setup is displayed with P.20 indicating the setting to be modified.
To go to the parameter to be changed use the GEN button to go up and the MAINS button to go down. When parameter is selected
use the STOP and START buttons to move the setting up or down till the required value is displayed. Press the OFF button to store
all changed values.
Remember to leave the controller in the Auto Mode when all wiring and settings have been done.
End of Appendix I
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Gen Fault:
Wires 29 and 31 N/O contact on terminal strip (Refer to diagram 2)
Gen Door:
From switch supplied.
Gen Run:
Wire number 205 on N/O contact side of Set Running Relay. (Refer to diagram 3)
Gen on Load:
Not supported
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop:
From switch on the side where +12Volt signal falls away when pushed. (Refer to diagram 1)
Gen Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
Wire number 200 and green wire on terminal strip. (Refer to diagram 2)
Mains on load:
Not supported
Remote Reset:
Not supported
Diagram 1: Alarm Signal Wiring
Emergency Stop
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Gen Alarm
Remote Start
Gen Running
After connections are made the VR controller of the generator needs to be set to operate in the Remote Start position.
1)
2)
3)
4)
5)
6)
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Gen Fault:
Gen Door:
Gen Run:
Gen on Load:
Gen Temp:
Gen Oil Press:
Emergency Stop:
Gen Low Fuel:
Remote Start:
Mains on load:
Remote Reset:
12Volt Supply:
Mains Lines:
The controller should be programmed for the Load Take Over Mode along with Auto Mode to enable the Remote Start/Stop signal
positions 9 and 10 on the X25 terminal strip.
Diagram 1: Generator Run Signal Relay Wiring
Gen Running
Com and N/O
contact
Generator 230Vac
output supply
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Diagram 2: Generator Remote Start Signal and Utility 230Vac Supply Wiring
Remote
Signal
Utility 230Vac
Mains Leads
Start
Remember to leave the controller in auto mode by pressing the auto button.
End of Appendix K
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Gen Fault:
Connect to position 4&6 on Relay pack. (Fig.1)
Gen Door:
From switch supplied.
Gen Run:
Connect to position 7&9 on relay pack. (Fig.1)
Gen on Load:
Not supported
Gen Temp:
Not supported
Gen Oil Press:
Not supported
Emergency Stop:
From switch on the side where +12Volt signal falls away when pushed or from connector B11. (Fig.1)
Low Fuel:
Not connected as Inala fuel probe is installed.
Remote Start:
Connect to connector B13 on panel. (Fig.1)
Mains on load:
Not supported
Remote Reset:
Refer to Section 4 above for connecting the SAM2 Remote Reset Signal.
12Volt Supply:
Direct on battery is the best (Across wire leads 30 and 31, refer to section 4 above).
To Program Controller for Remote Start if not already in Auto:
1)
2)
3)
4)
5)
6)
Gen Fault
Signal
Emergency
Stop Signal
Remote Start
Signal
End of Appendix L
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Gen Run
Signal
Appendix M: Wiring For Older Type SDMO Generator with Auto A50 Control Panel
This document describes the procedure for installing the Inala SAM2_GEN (SAM2 Generator controller) unit to monitor and control
the Older Type SDMO generator together with the SDMO Auto A50 control panel. It should be used in conjunction the following
document:
Electric Wiring Diagram: Auto A50 Control Panel (Client Reference: CTL-31614103601NE) Dated 27/Nov/2000.
The diagram depicted in diagram 1 below shows the wiring connection points on the SDMO Auto A50 Control Panel for the following
signals points
Generator Fault/Alarm
Connection Point
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Wiring connections
Make the following wiring connections between the SAM2_GEN control unit and SDMO Auto A50 Control Panel:
a)
Connect the 12Vdc supply output from the generator battery (wire leads marked 30 for +12V and 31 for GND) to the +12V and
GND screw terminals of the SAM2_GEN unit as shown in the diagram below.
Note: Connect the SAM2_GEN control unit 12Vdc supply directly to the generator battery terminals. Alternatively, if a separate 12V
battery supply is available (i.e. backup supply for the Siemens Logo, Electric fence or intrusion alarm system) it can be used to
power the SAM2_GEN control unit.
+12V (30)
BATTERY
GND (31)
b)
Refer to figure 1; Connect the live (L) and neutral (N) wires of the KPLC (mains) 230Vac supply from the input side (bottom) of
contactor 4KM6 to Mains screw terminals on the the SAM2_GEN control unit. Note: On single-phase sites loop L1 to L2 to L3.
c)
Refer to figure 1; Connect the live (L) and neutral (N) wires of the generator 230Vac supply from the output side (top) of contactor
5KM18 to the GEN screw terminals on the SAM2_GEN control unit. Note: On single-phase sites loop L1 to L2 to L3.
d)
The generator run signal must be connected to a normally open (NO) output, i.e. when the generator is at rest (not starting or
running), the run signal must be either open circuit or at a positive potential with reference to ground. When the generator has
started and is running the run signal must be connected to ground (GND).
Refer to the picture above and the Electric Wiring Diagram in the Auto A50 Control Panel document; Relay 5KA24 is connected
across the generator 230Vac supply output and operates when the generator is started and running. The common and NO contacts
of relay 5KA24 are used to provide a Generator Run signal output. Connect as follows:
Relay 5KA24 NO contact (LHS Screw terminal 11, wire 137,) to: Krone block 2, pair 3, leg A KB2/3/B
Relay 5KA24 Common contact (Centre Screw terminal 14) to: Krone block 2, pair 3, leg B (GND) KB2/3/B
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e)
Refer to the following picture and connect the generator remote start signal across pair 7 on Krone block one. Note the relay links on
the SAM2_GEN control unit must be in the NO position.
f)
Refer to the following picture and connect the generator fault/alarm signal from the screw terminal shown (3 and 4 from the top) to
Krone block 2, pair 1 across the A and B legs.
Note: The generator fault/alarm output is a NC contact, thus the SAM2_CTL unit must be configured for a NC input for the GEN1
RUN, refer to the Alarm Configuration screen of the SAM2_ECT software application.
g)
Refer to sheet 004 and sheet 009 of the SDMO Electric Wiring Diagram: Auto A50 Control Panel document.
On sheet 004 of the SDMO Auto A50 Control Panel document relay 4KA3 is connected across the live (L/R4) and neutral (N/N4) of
the KPLC (mains) 230Vac input lines. This relay detects when the KPLC (mains) supply fails and its contact closes to start the
generator (shown on sheet 009 and in figure 1 below).
The SAM2 remote start relay contact is connected across terminals XUC-10 and XUC-11, which are effectively in parallel with the
contact of relay 4KA3. Thus when either the SAM2 remote start relay contact or the SDMO Auto A50 4KA3 relay contact is closed
the generator will start.
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This will be a problem: The SAM2 unit will not start the generator when the site is in Hybrid power mode, but if KPLC mains fails at
this time the SDMO Auto A50 4KA3 relay contact will close and the generator will start. In order to prevent this problem Stripline
Link 9X15 must be removed (open).
In order to verify the operation described above perform the following test before the installation of the SAM2 generator controller:
1)
2)
3)
4)
Switch OFF the KPLC (mains) 230Vac supply, the generator should start, run and go On Load.
Switch ON the KPLC (mains) 230Vac supply, the generator should go Off Load, cool down and stop.
Remove the link across the Stripline Link 9X15.
Switch OFF the KPLC (mains) 230Vac supply, the generator should not start.
Diagram 2 : SDMO Auto A50 Control Panel Mains Fail Control Sheet 009
End of Appendix M
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End of Appendix N
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APPENDIX P: Acronyms
AMF
BTS
ECT
SAM
EPCC
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