ALTERNATOR

CONTROLLER

7AVR0100
AC/DC CONVERTER 57V 9KW

- USER’S GUIDE -
 - INTRODUCTION -
The system consists of a permanent magnets generator and a DC/DC converter to be
applied to a generating set (with a gasoline engine)
As the application is in the telecom field, the stability and the quality of the generated
voltage must grant the correct working and safety of electronics devices connected .
Optimizing the engine performances adapting the speed in function of the output load,
the fuel consumption and noise are reduced.
The system is designed in accordance with the most important EC standards.

- FEATURES -
INPUT VOLTAGE FROM PMG 48-145Veff THREE PHASES
OUTPUT VOLTAGE 44-57 Vdc +/-1%
MAX CURRENT 190 Adc
MAX HEATSINK TEMPERATURE 100 °C
OPERATING TEMPERATURE -15°C / 50°C
ENGINE SPEED REGULATION DC MOTOR ACTUATOR
ENGINE SPEED RANGE 1350-2900RPM
AUX VOLTAGE 10Vrms / 30Vrms
PARAMETERS PROGRAMMABLE
BATTERY CHARGE FUNCTION
PROTECTION IP40
SERIAL COMMUNICATION - RS232 PORT (modbus protocol)
- RS485 PORT (modbus protocol)

SAFETY: • OUTPUT SHORT CIRCUIT PROTECTION

• OUTPUT REVERSE VOLTAGE PROTECTION (BATTERY)
• LOW VOLTAGE AND OVERVOLTAGE PROTECTION

DATE : 18/04/2012 REV. 3.0 Pag.1/15

 - INSTALLATION –

- LOCATE THE CONVERTER IN A PLACE PROTECTED AGAINST

MECHANICAL SHOCK , WATER AND DIRTY.

- MOUNT THE CONVERTER ON THE FIX BODY OF THE CANOPY TO AVOID

THE EFFECTS OF THE GENSET VIBRATIONS

- FIX IT IN THE VERTICAL POSITION WITH THE FAN IN THE LEFT SIDE NEAR
THE FRESH AIR ENTRY TO OBTAIN THE BEST POWER DISSIPATION

- CHECK THE MAX SPEED OF THE ENGINE AND VOLTAGE GENERATED BY

THE PMG TO AVOID DAMAGE OF THE CONVERTER BEFORE TO CONNECT
IT

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- BLOCK DIAGRAM OF THE SYSTEM –

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 - WIRING DIAGRAM –

NOTE: TO CONNECT ALARM AND START-STOP RELAY, REFER TO

“RELAY CONNECTION” PARAGRAPH.

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7PROGLCD HANDHELD PROGRAMMER (OPTIONAL)
NOTE: HANDHELD PROGRAMMER WORKS ONLY IF PINS 1 AND 3 OF J5 ARE IN SHORT
CIRCUIT AND NO DEVICES ARE CONNECTED ON J12.
LCD 16X2:
Displays parameters, alarms and measures (description and value).
UP Key:
Rolls up parameters and increases values.

MODE Key:
Confirms a selection and the change of value.

DOWN Key:
Rolls down parameters and decreases values.

At power-on, handheld programmer displays the “Tester Mode” page. In this pages , you’ll find running
information of the device.
To start the programming function push the button “MODE” .
Will appear the first parameter; pushing the “UP” button the number of the parameter will be increased and
with the “DOWN” button the number will be decreased. When a parameter is selected , push the button
“MODE” to enter in the change menu, change the value with the buttons “UP” and “DOWN”, then confirm
the parameter with the button “MODE”. To return to the TESTER menu push together the buttons
“MODE “and “UP”, or wait few seconds.

TESTER MODE

HOURMETER Counter of hours with power on

HH.MM
NSM Total output voltage and current
Sys V______ I________
TOTAL ENERGY Cumulative output energy
### KWh
POWER Output average power
#.# KW
ALARM Active alarms
NO ALARM
ENGINE SPEED Speed of the engine
#### rpm
INPUT VOLTAGE Input DC voltage to the converter
### V
BATTERY CURRENT Battery charging current
##.# A
SW RELEASE Software release
7AVR100_X.Y
TEMPERATURE Temperature inside the box and battery temperature
## °C ## °C
NSM Output voltage and current on power board1
Sys1 V______ I________
NSM Output voltage and current on power board2
Sys2 V______ I________

DATE : 18/04/2012 REV. 3.0 Pag.5/15

DG CONTROLLER TESTER PAGES (see serial communication users guide for
more information).
N. of bytes: 22
Tester pages address: 0x00
After receiving a tester pages reading request, the system answers sending tester pages in
the order set in "DATA BYTE ORDER" column.
DATA TYPE DATA BYTE ORDER
OUTPUT VOLTAGE [Vdc] decimal 2bytes BYTES 1(LSB),2 (MSB)
OUTPUT CURRENT [Adc] decimal 2bytes BYTES 3(LSB),4 (MSB)
TOTAL ENERGY [kWh] decimal 2bytes BYTES 5(LSB),6 (MSB)
POWER [kW] decimal 2bytes BYTES 7(LSB),8 (MSB)
HOURMETER HOURS [h] 2bytes BYTES 9(LSB),10 (MSB)
HOURMETER MINUTES [min] 2bytes BYTES 11(LSB),12 (MSB)
ENGINE SPEED [rpm] 2bytes BYTES 13(LSB),14 (MSB)
INPUT VOLTAGE [Vdc] 2bytes BYTES 15(LSB),16 (MSB)
BATTERY CURRENT [Adc] decimal 2bytes BYTES 17(LSB),18 (MSB)
TEMPERATURE [°C] 2bytes BYTES 19(LSB),20 (MSB)
SW RELEASE 1 byte BYTE 21
ALARM 1 byte Bit 5 to 0 of BYTE 22
1=stop,
START/STOP ENGINE 0=start 1 bit Bit 6 of BYTE 22
1=standby,
STANDBY/RUNNING 0=running 1 bit MSbit of BYTE 22

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PARAMETERS (settable through handheld programmer or DG controller):

NAME DESCRIPTION MIN MAX DEFAULT RS485 address

OUTPUT VOLTAGE VOLTAGE OUTPUT SETTING 44 V 57 V 57V 1
DECIMAL VALUE
OUTPUT CURRENT CURRENT LIMIT 0 Amp 240 Amp 156Amp 3
DECIMAL VALUE
MIN SPEED ENGINE MIN SPEED 850 rpm 2500 rpm 1350rpm 5
MAX SPEED ENGINE MAX SPEED 2500 rpm 3000 rpm 2900rpm 7
BATT. LOW CHARGING CURRENT STOP 0 Amp 50Amp 10Amp 9
CURRENT
BATT. MAX MAX BATTERY CHARGING 5 Amp 200 Amp 20Amp 11
CURRENT CURRENT DECIMAL VALUE
BATT.LOW VOLTAGE LOW BATTERY VOLTAGE 35 V 54 V 49V 13
SETTING DECIMAL VALUE
BATT.MAX VOLTAGE BATTERY CHARGE STOP 44 V 57 V 57 V 15
VOLTAGE DECIMAL VALUE
ACTUATOR SPEED+ DC VOLTAGE DURING 0% 100% 12% 17
ACCELERATION
ACTUATOR SPEED- DC VOLTAGE DURING 0% 100% 30% 19
DECELERATION
RESET TO DEFAULT RESET TO DEFAULT 0 3 0 21
PARAMETERS
HOURMETER_RES HOURMETER AND 0 1 0 23
TOTAL ENERGY RESET
NO RPM ALARM LOW-RPM ALARM DISABLED 0 1 0 25
AND SYSTEM RUNNING
WITH 0RPM
RESET_ALARM IF SET TO 1, AFTER 2 0 1 0 27
SECONDS RESETS ALARMS
PASSWORD PASSWORD 0 10000 0 NOT
SETTABLE BY
DG controller
COEFF_IOUT Regulation coefficient of Iout 1 200 97 NOT
reading SETTABLE BY
DG controller
MULTIPL.COEFF / / / / NOT USED
COEFF. LEM Regulation coefficient of Ibatt 1 800 94 NOT
reading SETTABLE BY
DG controller
COEFF. VOUT Regulation coefficient of Vout 1 200 99 NOT
reading (after power relè) SETTABLE BY
DG controller
COEFF. PWM1 Regulation coefficient of Output 0 300 78 NOT
Voltage level SETTABLE BY
DG controller
COEFF. OUT1 Regulation coefficient of Vout 1 200 99 NOT
reading (before power relè) SETTABLE BY
DG controller
RAMP DELTA / 5 120 15 NOT
SETTABLE BY
DG controller

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FIXED SPEED If =1, actuator goes to max 0 10000 0 51
motor speed for 1 minute, then
come back to normal operation
ACTUATOR SETTING MANUAL SPEED 0 4 0 49
REGULATION
BOOST VOLTAGE OUTPUT VOLTAGE IN BOOST 44 V 57 V 55,2V 29
MODE DECIMAL VALUE
DOD BATTERY DOD 0% 200% 5% 31
COB BATTERY COB 0% 200% 100% 33
BOOST ENABLE BOOST VOLTAGE FUNCTION 0 1 0 35
ENABLE
PMG-GRID GRID SELECTOR 0 1 0 (=PMG) 37
MIN.SATURATION V. MINIMUM SATURATION 44 V 57 V 51 V 39
VOLTAGE DECIMAL VALUE
MAX.SATURATION V. MAXIMUM SATURATION 44 V 57 V 56,5 V 41
VOLTAGE DECIMAL VALUE
VOLT/DEGREE VOLT PER DEGREE 2 mV 6 mV 3 mV 43
BATTERY REF. TEMP BATTERY TEMPERATURE 20 °C 40°C 25 °C 45
REFERENCE
TEMP.COMP.ENABLE TEMP. COMPENSATION 0 1 0 (=DISABLED) 47
ENABLE

NOTE1: reset procedure:

• To recharge default values of parameters set “RESET TO DEFAULT=1” and then switch-off
the system.
• Setting “RESET TO DEFAULT=3” => COOLING_DOWN function will start: output relay will
open and actuator will move to min.speed position until parameter come back to “0”.

NOTE2: password setting:

• With handheld programmer set “PASSWORD” =61 to access password protected parameters.

NOTE3: regulation of output voltage, output current and battery current reading:
• With NO load and NO batteries connected to the converter, set the correct OUTPUT VOLTAGE
reading. First of all, connect a multimeter at output of converter, then set parameters
“COEFF.VOUT” and “COEFF. OUT1” until the voltage red on programmer reaches the voltage
measured by multimeter. Then set “COEFF.PWM1” parameter until it reaches the value set in
“OUTPUT VOLTAGE” parameter.

• With a fixed load (20A for example) and NO batteries, set the correct OUTPUT CURRENT and
BATTERY CURRENT reading. Connect a current probe and LEM on output load, then set
parameters “COEFF.IOUT” and “COEFF. LEM” until the current red on programmer reaches the
current measured by the probe.

DATE : 18/04/2012 REV. 3.0 Pag.8/15

ALARMS
Handheld programmer can display the failures or alarms: in the following table there is the list, the meaning of this
alarms, and how to solve the problem.
The alarms are visualised immediately on the LCD and after a delay the converter is disabled and “alarm relay
activated”(if an alarm disappear within the delay the converter runs normally).

DISPLAY ALARM DELAY/ RESET WHAT TO DO

ACTIVE
ALARM A1 INPUT VDC>300V 2” SWITCH OFF THE SYSTEM CHECK PMG VOLTAGE
OVERVOLTAGE STANDBY/ AND ENGINE SPEED
switch off engine RUNNING
ALARM A2 INPUT VDC<50V 12” SWITCH OFF THE SYSTEM CHECK PMG VOLTAGE
UNDERVOLTAGE RUNNING
ALARM A3 SPEED > ( RPM 2” SWITCH OFF THE SYSTEM CHECK ENGINE SPEED
HIGH RPM MAX+300RPM) STANDBY/
switch off engine soon RUNNING
ALARM A4 SPEED < 850RPM 12” SWITCH OFF THE SYSTEM CHECK ENGINE SPEED
LOW RPM (if speed<700rpm, the RUNNING
engine is not running and
no alarm acts)
ALARM A5 V_OUT<5V I_OUT >50A 2” DISCONNECT THE CHECK OUTPUT
SHORT CIRCUIT STANDBY/ OUTPUT,SWITCH OFF THE CONNECTIONS
switch off engine soon RUNNING SYSTEM AND RESTART
THE SYSTEM KEEPING
LOAD DISCONNECTED
ALARM A6 V_OUT < -10V 2” SWITCH OFF THE SYSTEM CHECK BATTERY
REVERSE BATTERY STANDBY/ AND REVERSE THE POLARITY
RUNNING BATTERY
ALARM A7 HEATSINK_TEMP.>100°C 2” SWITCH OFF THE SYSTEM CHECK THE FAN OR
TEMP. FAULT OR DIODE_TEMP.>100°C STANDBY/ DIRTY ON THE BOX
switch off engine soon RUNNING
ALARM A8 ENGINE SPEED DO NOT 32” DISCONNECT THE LOAD CHECK THE ACTUATOR
ACT.TIMEOUT REACH THE DESIRED RUNNING
VALUE
ALARM A9 OUTPUT DC 0” SWITCH OFF THE SYSTEM CHECK THE LOAD AND
FAULT OVERVOLTAGE (>68V) OR RUNNING 12V BATTERY
LOW LOGIC SUPPLY
A10 OUTPUT RELAY WRONG 0” SWITCH OFF THE SYSTEM, CHECK THE OUTPUT
RELAY FAULT STATE RUNNING CHECK THE RELAY AND
OUTPUT SHORT CIRCUIT
A11 (INPUT VOLTAGE >50Vdc) 3’ SWITCH OFF THE SYSTEM CHECK RPM READING
AUX FAULT & (RPM READING<700rpm) STANDBY WIRINGS
A12 OUTPUT CURRENT >250A 30” SWITCH OFF THE SYSTEM CHECK THE OUTPUT AND
POWER FAULT or OUTPUT VOLTAGE > RUNNING THE READINGS ON
switch off engine soon output voltage parameter TESTER PAGES
+3V
A13 BATTERY CURRENT > 15” SWITCH OFF THE SYSTEM CHECK THE LEM AND
LEM FAULT (BATT_MAX_CURRENT + RUNNING BATTERY CURRENT
10A) READING ON TESTER
PAGE
A14 DIFFERENCE BETWEEN 12’’ SWITCH OFF THE SYSTEM CHECK OUTPUT WIRINGS
CURR.UNBALANCE CURRENT IN 2 LOGIC RUNNING BETWEEN PCB1 AND
BOARDS HIGHER THAN PCB2, VERIFY O/P RELAY
12A STATE OF BOTH PCB
A15 NOT USED / / /
DG-GRID
A16 Vout/Vin>0.7 and Iout> 60A 1’ and10’’ SWITCH OFF THE SYSTEM CHECK THE ENGINE OR
PMG OVERLOAD RUNNING STEP

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 NOTE: IF ALARM A5 OR A10, SWITCH-OFF THE SYSTEM AND RESTART IT
WITHOUT THE BATTERY 48V.
IN CASE OF BATTERY CHANGE CHECK NO ALARM THEN CONNECT IT AND
SWITCH-ON THE ENGINE.
NOTE: ALARMS A1, A3, A5, A7, A12 ARE DANGEROUS => WHEN THEY ACT,
IMMEDIATELY SWITCH OFF THE ENGINE.

DATE : 18/04/2012 REV. 3.0 Pag.10/15

ACTUATOR SETTING MODE
Actuator setting parameter can be used to move actuator manually:

- If ACTUATOR SETTING = 1 (settable by handheld programmer):

Actuator is moved only by handheld programmer (not by RS232 port). With
UP_KEY or DOWN_KEY actuator moves forward/backward;
- If ACTUATOR SETTING = 2 (settable by handheld programmer or RS232 port):
Actuator keeps moving forward;
- If ACTUATOR SETTING = 3 (settable by handheld programmer or RS232 port):
Actuator keeps moving backward;
- If ACTUATOR SETTING = 4 (settable by handheld programmer or RS232 port):
Actuator ia stopped;
- If ACTUATOR SETTING = 0 (settable by handheld programmer or RS232 port):
Exit from Actuator setting Mode;

SPEED REGULATION WITH DC MOTOR ACTUATOR

The position of the actuator (connected with the engine butterfly valve) is settled in
function of the output power requested from the converter : in the range of power 0KW to
9 KW the position changes in 7 STEPS between the programmed values MIN_SPEED
and MAX_SPEED.

TIME-OUT : each time the next step position speed isn’t reached within 60 seconds the
actuator is powered-off to avoid overload and alarm A8 is visualized.

Steps are set as follows:

POWER [W] RPM

0 1350
2200 1350
2200 1560
3200 1560
3200 1770
4500 1770
4500 1980
5200 1980
5200 2190
5800 2190
5800 2400
6500 2400
6500 2650
7800 2650
7800 2900
9000 2900
NOTE:
• At start-up, the warm-up time is fixed to 25”.

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 INSTALLATION DC ACTUATOR :

- THE ACTUATOR MUST BE MOUNTED ON THE ENGINE IN A SAFETY

PLACE AND TEMPERATURES BELOW 60°C
- MECHANICAL STOPS MUST BE PUT IN THE POSITIONS OF MINIMUM AND
MAXIMUM SPEED DESIRED TO AVOID DAMAGE OF THE CONVERTER IN
CASE OF WRONG REGULATION OR FAILURE
- CHECK THE DIRECTION AND RANGE OF THE ACTUATOR BY MEAN OF
AN EXTERNAL SUPPLY 12VDC BEFORE TO CONNECT IT TO THE
CONVERTER
- CONNECT THE ACTUATOR ACCORDING TO THE WIRING DIAGRAM :
POSITIVE (+12) MEANS ACCELERATION OF THE ENGINE
- ACTUATOR RED WIRE POSITIVE = MOVEMENT OUT (IF A REVERSED
MOVEMENT IS NEEDED CHANGE RED AND BLACK WIRES OF THE
ACTUATOR)

KEEP THE WIRES BETWEEN THE ACTUATOR AND THE CONVERTER AS

SHORT AS POSSIBLE.

MANTAINACE PROGRAM DEPENDENT ON THE AMBIENT OF

INSTALLATION :
- CHECK THE FUNCTION OF THE FAN
- CHECK THE GRIDS OF THE BOX (IF DIRTY GET THEM-OFF AND CLEAN BY MEAN OF
COMPRESSED AIR FLOW)

OUTPUT TERMINALS (+48V) AND (-48V) ARE ISOLATED FROM OTHER

POWER SUPPLIES, SO ONE OF THEM CAN BE CONNECTED TO GROUND.

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FIXED SPEED FUNCTION

If “FIXED_SPEED” parameter is set to 1, fixed speed function is enabled.

Actuator moves to max. speed position, no ramps on output voltage can act for 1 minute,
then it decreases motor speed to reach the correct step.

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RELAY CONNECTION

On the logic PCB there are two relays: alarm relay and start-stop relay.

1. ALARM RELAY:

Each time an alarm acts (after the delay indicated on “Alarms” paragraph) this relay
switches.

2. START-STOP RELAY:

If output current is lower than OUT_MIN_CURRENT parameter then start-stop relay

is in STOP condition;

If output voltage is lower than BATT_LOW_VOLTAGE parameter (default=49V) then

start-stop relay is in START condition:

These relay are usually connected to engine key circuit as follows:

If start-stop relay is not used, connection becomes as follows:

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 - INDEX -

INTRODUCTION Page 1

FEATURES Page 1

INSTALLATION Page 2

BLOCK DIAGRAM Page 3

WIRING DIAGRAM Page 4

7PROGLCD HAND HELD PROGRAMMER Page 5

TESTER MODE Page 5

PARAMETERS Page 7

ALARMS Page 9

ENGINE AUTOMATIC SPEED REGULATION WITH DC ACTUATOR Page 11

INSTALLATION DC ACTUATOR Page 11

FIXED SPEED FUNCTION Page 13

RELAY CONNECTION Page 14

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