CONTROL UNIT FOR GENERATING SET

TYPE CAM-684
Made for the preparation of automatic emergency intervention switchboards.
This controls and commands the genset unit. It commands the mains and generator contactors to
supply the user. It is equipped with display to show
the INSTRUMENTS:
- three mains voltmeters
- three generator voltmeters
- delta voltages phase/phase
- star voltages
- three mains/generator ammeters
- frequency meter
- wattmeter total and per phase
- varmeter “
- voltammeter “
- kilowatt-hour
- cosphimeter per phase
- partial hour-meter
- total hour-meter
- starting counter
- starting failure counter
- tachometer
- battery voltmeter
- battery charger current
(with battery charger type CBS)
- fuel level gauge
- water oil thermometer
- oil pressure gauge
• Automatic supervision of faults with messages on the display
• Texts in 6 languages: Italian, English, French, German, Spanish and Portuguese
• Information on 4 programmable preventive maintenance operations with display of the hours
remaining before the maintenance work is due
• Remote controls (starting, stop and test)
• EJP function
• Preheating glow plugs management
• Management of refuelling of working tank from storage tank
• Clock to program starting or stopping the generating set
• Generator start/stop on request for power
• Possibility of starting the generating set in case of low battery-charge
• Programmable weekly selftest.
• Available inputs for fully programmable anomalies (times, polarities, stopping possibility and message
about the anomaly)
• Three-phase voltmetric control, voltage failure, undervoltage, overvoltage, asymmetryc voltage and
not correct phase sequence of the mains and of the generator.
• Anomaly historical log (including data from the last 50 occurred anomalies)
• Displaying of the most serious faults with both led and messages on the display
• Possibility of password protected programming.
MODES OF COMMUNICATION OF CAM-684
• CAN Bus Connection (SAE J1939)
• Serial ports RS232 and RS485
• Connection with a remote panel (Type PRE-685) to display the instruments and errors managed
by the CAM-684
• GSM Modem (to be mounted externally), possibility of displaying the control unit instruments with a
mobile phone, operating the starting and stopping and notifying with an SMS message when the
generating set is in alarm state
• MODBus protocol through port RS232, RS485 and the serial port via USB
• Remote operation with personal computer (on request):
- reading of the instruments shown on the display of the control unit
- anomaly historical record
- displaying of anomalies and operating status of the generating set.
- start stop controls

ELCOS- Parma- Italy - CAM -684 - MAN - EN Valid for firmware revisions higher than or equal to 1.24 1
 SUM M ARY
S u m m a r y – T e c h n ic a l d a ta - H is to r y o f r e v is io n s Page 2
B r ie f in s tr u c t io n s – In s tr u m e n ts – M o d e s o f c o m m u n ic a tio n 3
o f th e c o n tr o l u n it “
O p e r a tio n : F u n c tio n s s e le c tio n – M a n u a l – A u to m a tic – 4
T e s t – O ff – G lo w p lu g s p r e h e a t in g – S ta r tin g – S ta r tin g “
F a ilu r e
O p e r a tio n : D e te c t io n o f r u n n in g e n g in e – S t o p – G e n e r a to r 5
s e t p r o te c t io n d e v ic e s – G e n e r a l a la r m – P r e v e n tiv e
m a in te n a n c e – E m e r g e n c y s to p – S to p p in g f a ilu r e – “
G e n e r a to r s e t s ta r tin g w ith lo w c h a r g e o f th e b a tt e r y -
S ta r t in g o n r e q u e s t f o r p o w e r – C lo c k
W ir in g d ia g r a m 6 -7
“
M e s s a g e s a n d in s tr u m e n ts – A n o m a ly m e s s a g e s – C A N 8
B u s in s tr u m e n ts – C u m u la tiv e a la r m s “
S ta r t u p , s to p a n d t e s t c a ll r e m o te c o n tr o ls a n d E J P 9
fu n c tio n s – M a in s g e n e r a t o r v o ltm e tr ic r e la y s “
U s e r p r o g r a m m in g 10
“
N o tic e s 11
“
B a tt e r y c h a r g e r – O r d e r in g d a ta – A c c e s s o r ie s s u p p lie d - 12
D e c la r a t io n C E “
TECHNICAL DATA
Supply by battery 12 Vdc 24 Vdc
Supply voltage 8 y 32V
Selfconsumption with stopped engine and pressed 350 mA 12V 180 mA 24V
emergency button
Suitable for three-phase generators having the following 80 y 430Vac r10%; frequency 50 y 60Hz
voltage range:
Dielectric withstand voltage between battery powered 3750 Vac 50Hz 1 sec
circuits and mains/group powered circuits

Voltage sag in power line from battery

Rated insulation voltage:

• Terminal board at mains voltage 600V
• Terminal board at genset voltage 600V
• Terminal board at battery voltage 32V
Capacity of contact for control of the genset contactor 250V 3A (AC1)
Max load on the outputs 15 (starting) 0,25A,
17 (stop) 1,5A, 19 (key) 0,25A,
6 (glow plugs) 0,25A
70 (general alarm) 0,25A
Degree of rear protection IP 20
Degree of front protection IP 64
Temperature range - 20 ÷ + 60°C
W eight 1120g
Dimensions w ith term inals disconnected (LxH xP)mm 290x200x62
Hole mm 274x185
Tachometer 5 digits
Instruments accuracy: oil pressure gauge, water ±2%
thermometer, fuel level
Mains/generator voltmeter Max 570V accuracy ±1%
field of measurement 50 y 570Vac
Rated current of the ammeters 5 A ac
Ammeter Max 4800A, accuracy ±1%
field of measurement 0,02 (20mA) y 6A
Frequency meter: 0-85 Hz, accuracy ±0,1 Hz
frequency field 45 y 85Hz
Precision of the wattmeter, varmeter, voltamm eter, kilowatt- ±2%
hour and cosphimeter
Tachometer Max 4000 RPM accuracy ± 10 RPM
Serial output parameters 9600 baud, 8 bit data, 1 bit stop; even parity
Rechargeable batteries (excluded from supply) 1,2V Type AAA

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 CONTACTOR CONTROL
FUEL
PUMP

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 REMOTE CONTROLS START, STOP, TEST AND EJP FUNCTIONS
ENABLED WITH CONTROL UNIT IN AUTOMATIC AND IN TEST MODE
CALL

On closing the call contact operation is as with mains fault.

ENABLED WITH CONTROL UNIT IN AUTOMATIC

STARTING

When the start up contact (see page 6) is closed REMOTE STARTING is shown on the
display. After the REMOTE STARTUP DELAY time (programmed to 1 sec.) has elapsed,
the start up begins, the general alarm is activated intermittently (for 8 seconds), then the
general alarm is deactivated and after a pause of 3 seconds the start up cycle begins and
operation is as with mains fault.
When the startup contact is opened operation is as with mains return.

TEST
When the test contact is closed (see page 8) REMOTE TEST is shown on the display.
The general alarm is activated intermittently (for 8 seconds). When the general alarm is
deactivated, after a pause of 3 seconds the start up cycle begins. If there is a mains fault
during the test, the control unit remains in test mode and, as in automatic, commands the
closing of the generator contactor that will reopen when the mains returns. When the test
contact is opened operation is as with mains return.
If the automatic test is in progress the engine continues to run until the end of the
automatic test.
STOP
When the stop contact is closed, REMOTE STOP is shown on the display. The control unit
does not allow any startup operation, and if the generator set is running, it is stopped.
The intervention of the remote control is shown on the display.

EJP FUNCTION
Choose EJP function (see TECHNICAL PROGRAMMING manual on page 18).
When the START UP contact, connected to terminal 31, closes, EJP STARTUP is seen on
the display. After the EJP STARTUP DELAY time (programmed to 25 min.) has elapsed ,
the start up procedure begins. When the switching contact (terminal 32) closes, EJP
SWITCHING CONSENT is seen on the display and the operation is as when there is a
mains fault.
When the two EJP contacts are opened functioning is as when the mains power returns.

VOLTMETRIC MAINS AND GENERATOR RELAYS

INSIDE THE CONTROL UNIT
These check the mains and generator set voltage. They intervene in the event of: voltage
failure, undervoltage, overvoltage, asymmetrical voltage and incorrect phase sequence
MAINS RELAY
When voltage has been detected on the three phases, with a value within the preset limits,
after the MAINS ACCEPTANCE delay (programmed to 100 sec.) the generator set stops
(for the starting and stopping procedures see automatic operation on page 4).

GENERATOR RELAY
When a voltage value is detected on the three phases of the operating generator set within
the expected range, the generator contactor closes after the delay (setpoint equal to 7
seconds) for “GENERATOR TO POWER USERS CONNECTION”.
When the voltage value detected is inferior or superior to the normally expected range, the
generator contactor is de-energised.
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 NOTICES
Used only to check and command a genset unit. It commands the mains and generator contactors to supply the user. It
has been designed to be installed only inside on an electrical panel as a single unit and so that it can be connected to
other components (contactors, fuses, thermo-magnetic switches, etc.) which the installer will have available to complete
the plant.

Warning: Components carrying dangerous voltage levels

Only assigned and suitably trained personnel are allowed access to the control unit. No
maintenance operations are permitted unless the plant is disconnected from the mains and the
battery. As an additional safety measure, the plant phases should be short-circuited and earthed.
Not withstanding the above, only assigned and trained personnel can perform the following
operations with the plant on:
- make a visual inspection of the control unit, the connections and their markings;
- measure the voltage and/or current values;
- programming of the functions.
These interventions, however, must be performed using equipment which ensures appropriate levels of
electrical protection.

Warning:
Adhere closely to the following advice

- When making connections always follow the instructions and the Wiring Diagram on pages 6-7.
- Any interventions on the unit must be performed with the motor stationary and terminal 50 of the starting motor
disconnected.
- Check that the consumption of the connected equipment are compatible with the described technical characteristics.
- Install in such a way that there is always adequate heat disposal.
- Always install under other equipment which produces or spreads heat.
- Handle and connect without mechanically stressing the electronic board.
- Make sure that no copper conductor cuttings or other waste material fall inside the control panel.
- Never disconnect the terminals of the battery with running engine.
- Never use a battery charger for the emergency start-up; the control unit could be damaged.
- In order to safeguard people and equipment, before connecting an external battery charger, disconnect the electrical
system terminals from the battery poles.

THIS CONTROL UNIT IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING CONDITIONS:
- Where the environmental temperature is outside the limits indicated in the technical data.
- Where the air pressure and temperature variations are so rapid as to produce exceptional condensation.
- Where there are high levels of pollution caused by dust, smoke, vapour, salts and corrosive or radioactive particles.
- Where there are high levels or heat from radiation caused by the sun, ovens or the like.
- Where attacks from mould or small animals are possible.
- Where there is the risk of fire or explosions.
- Where the control panel can receive strong vibrations or knocks.
- Where the control panel is protected by barriers or casing with protection level less than IP40.

ELECTROMAGNETIC COMPATIBILITY
This control unit functions correctly only if inserted in plants which conform with the CE marking standards; it meets the
exemption requirements of the standard EN61326-1 but it cannot be excluded that malfunctions could occur in extreme
cases due to particular situations.
The installer has the task of checking that the disturbance levels are within the requirements of the standards.

CONDUCTION AND MAINTENANCE

The following maintenance operations should be performed every week:
- check that the indicators function;
- check the condition of the batteries;
- check that the conductors are tight, check the condition of the terminals.

UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS CONTROL UNIT IS NOT
SUITABLE FOR USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE FOR KEEPING
PERSONS OR OTHER LIVING BEINGS ALIVE.

YOUR ELECTRICAL TECHNICIAN CAN ASK ANY QUESTIONS ABOUT

THIS CONTROL UNIT BY TELEPHONING OUR TECHNICIAN

ELCOS- Parma- Italy - CAM -684 - MAN - EN Valid for firmware revisions higher than or equal to 1.24 11
 BATTERY CHARGER
We recommend fitting the plant with battery chargers
compliant with DIN41773 standards .
BATTERY CHARGER OPERATION
THREE CHARGING LEVELS
- RAPID WITH CURRENT CONTROL
- INTERMEDIATE
- MAINTENANCE
}
WITH VOLTAGE CONTROL

WHEN THE BATTERY CHARGER IS CONNECTED TO THE CAM-684 CONTROL UNIT,

THE DISPLAY SHOWS THE FOLLOWING:
x CHARGING CURRENT
x BATTERY VOLTAGE
ANOMALIES
• DETACHMENT OF BATTERY CABLES (with engine stopped)
• SHORT CIRCUITING OF BATTERY CABLES

ORDERING DATA
Type Code
CAM-684 00242283
ACCESSORIES SUPPLIED
Type Code
KIT MU CAM-684 40804469
ACCESSORIES ON REQUEST
Type Code
THE REMOTE PANEL Type PRE-685 00242282
(Displays the instruments and errors
managed by the CAM-684)

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