Procom ECON-A-4C, ECON-A-A, ECON-A-S, ECON-A-M Operating Instructions Manual
OPERATING INSTRUCTIONS
ECON-A-4C/A/S/M
INDEX
1.0 Introduction
2.0 Salient features, Protection & Supervision
3.0 Display/ Front Panel
4.0 Switches Description
5.0 LED Annunciations Description
6.0 Lamp Test
7.0 Digital Input
8.0 Analog Input
9.0 Digital Output
10.0 Modes of Operation
10.1 AMF Mode (ECON-A & ECON -A-4C)
10.1.1 Auto Mode
10.1.2 Semi Auto Mode
10.1.3 Manual Mode
10.2 Auto Stop Mode ( ECON-A & ECON - A-4C or ECON-S)
10.3 Manual Controller ( All models)
11.0 Setting Procedure
12.0 Parameter Mode
12.1 System Parameter
12.2 Generator Parameter
12.3 AMF Parameter
12.4 Protection Parameter
12.5 RS 485 parameters
12.6 Reset Service Alarm
12.7 Adjust Clock
12.8 Reset Password
13.0 Model Selection Chart
14.0 Load Management
15.0 Event Recording
16.0 Faults
16.1 Internal Faults
16.2 External Faults
16.3 Fault Reset
17.0 Communication
18.0 MODBUS Specifications.
19.0 Terminal description
20.0 Specifications
21.0 Dimension
Operating Instructions
Page - 1
• 1.0 Introduction
Microprocessor based controller for DG Set which can be configured as both
automatic or manual controller.
ECON comes in various models to cater for varieties of requirements:
• ECON-A-4C
• ECON-A
• ECON-S
• ECON-M
• ECON-A-4C: It is a AMF controller with 4 channel of analog measurement
and can be site configured as ECON-A or ECON-S or ECON-M.
• ECON-A: It is a AMF controller with 3 Analog channels and is site
configurable to ECON-S or ECON-M
• ECON-S: It is a manual controller with Shunt trip contact for MCCB. This is to
avoid shutting down the engine on load in manual operation. After the shunt
trip is initiated the generator stops after re-cooling time. ECON-M is sub set of
this model
• ECON-M: This is a pure manual controller for manual operation only.
All these models can be ordered with optional features such as RS485
communication,3 Extra digital inputs of Canopy fan current protection. This
manual has to be read along with the controller selected and all the features
may not be available in all the models.
• Display: 128*64 pixel graphial backlit LCD for ease of readout and symbolic
representation.
• Cyclic Timer based Engine Operation. Maximum engine on time as well as
rest time are programmable
• Fan Current monitoring for canopy fan (Optional)
• Menu driven MM1 for easy in field configuration without PC or any
customized equipment.
• Load Management . Load Dependent start/stop of 2nd DG in case of two DG
application.
• Periodic Automatic Start of engine if not used for a predefined time to charge
the battery as well as maintenance.
• ECON reminds user for timely service by indicating service due alarm.
• True RMS measurement of all measured parameters with 1% accuracy of
measured value.
• Plug in connectors for error free replacement.
• Programmable DG on delay, DG continuous on time, DG Rest Time, warm-up
time along with 33 other times.
• Automatic real time based DG Start and Stop(Manual Control Configuration.).
• Dimensions 167 х 129 х 41.8 mm.
Operating Instructions
Page - 2
• 2.0 Salient Features, Protection and Supervision
• Mains Measurements
◦ 1 Phase/ 3 Phase Voltage
◦ 1 Phase/ 3 Phase Current
◦ Frequency
◦ PF, KW, KVA,
• Generator Measurements
◦ 1 Phase / 3 Phase Voltage
◦ 1 Phase / 3 Phase Current
◦ Frequency
◦ PF, KW, KVA, KWH .
◦ Battery Voltage
◦ Water Temperature
◦ Oil Pressure
◦ Fuel Level
◦ RPM
◦ Run Hour
◦ Service Due Hour
• Protection / Supervision Mains
◦ Under/Over Voltage
◦ Under/Over Frequency
◦ Phase Sequence
◦ Voltage Unbalance
◦ Overload
• Protection / Supervision DG
◦ Under/Over Voltage
◦ Under/Over Frequency
◦ Current Unbalance
◦ Over Speed
◦ RWL
◦ LLOP
◦ HWT
◦ LFL
◦ Charging Alternator/V-belt
◦ Emergency off
◦ Service Due
◦ Fail To Start
◦ Fail To Stop
• Digital Input : 10 digital [3 fixed, 4 programmable, 3 programmable (optional)]
• Output: 9 digital
Operating Instructions
Page - 3
◦ AMF Operation: 9 outputs (five fixed and three programmable) and one for
charging Alternator
• Fault Data Recording: Last 64 fault with date and time stamping
• Event Recording: Last 64 event with date and time stamping
• Start Stop Recording: Last 100 records with date and time stamping
• Password Protection: Three digit password protection for system settings.
• Real Time Clock (RTC)
• Communication: RS232, USB, Fully Isolated RS485(Optional)
• Provision for switching ON or OFF the measurement for individual sensors.
• Option of warning or tripping when open sensor is detected
• Programmable crank cut off method based on either voltage built up, or oil
pressure build up & voltage built up
• 3.0 Display / Front Panel
• 128x64 pixels Graphical LCD Display for ease of readout. Parameters are
displayed in English along with symbolic representation. Normally the display
auto scrolls and displays a parameter for 10 seconds, but any time the Next key
( ) can be pressed to select the next parameter window.
• 4.0 Switches Description
ECON has 7 switches provided on its front panel. The table below describes
the operation of these.
Start
Switch
MCB
Switch
Reset
Switch
Mode
Indication
LEDs
Next
Switch
GCB
Switch
Stop
Switch
Mode
selection
switch
Mains & DG
Contactor
Indicator
Operating Instructions
Page - 4
Switch
Symbol
Switch
Function
Description
Next
Normal operation mode: In this mode, it is
used to change the parameters being
displayed on LCD.
Programming Mode: Next key is used to
select the next parameter to be programmed.
Increment
/Start
This key has dual function
Programming Mode: It is used to increment
the value of the parameters under
programming.
Manual mode: it is used to issue the crank/
start command to DG
Decrement
/Stop
This key has dual function
Programming mode: It is used to decrement
the value of the parameter under
programming.
Manual mode: It is used to issue the stop
command to DG
Reset
Reset key resets the Hooter and Fault signals.
The first press shall reset the hooter and next
shall reset the faults. A long press of 1 Sec
shall reset both.
Programming
/History
Fault Mode
Entry
If both the keys are pressed simultaneously
the unit will enter in Programming Mode
History Fault/Service Hours
MCB
In Manual Mode this toggles the mains
contactor, On/Off
GCB
In Manual Mode this toggles the generator
contactor, On/Off
MODE
Toggle between Auto, Manual & Test Mode
• 5.0 LED Annunciations Description: ECON has nine annunciations on its
front panel. These either announce the faults or indicate status of the
system.
Nomenclature
Symbol
Description
Auto
Led lights up when ECON is in Auto mode
Manual Mode
Led lights up when ECON is in manual mode
Operating Instructions
Page - 5
Nomenclature
Symbol
Description
Semi Auto
Led lights up when ECON is in Semi Auto
Mains Voltage
This symbol lights up continuously if Main is
healthy else starts blinking.
MCB
LED turns on in case the mains breaker is
switched on or else turned off
GCB
LED turns on in case the DG breaker is switched
on or else turned off
DG Voltage
This indication glows continuously when the
generator is running.
Warning
This LED blinks in case of a warning.
Fault
This LED blinks in case of a fault
• 6.0 Lamp Test:
If the ECON is switched on while the reset switch is pressed, all the LEDs
start blinking till reset switch is kept pressed.. This state shall persist till the
switch is kept pressed and on release of the switch ECON shall start
functioning normally
• 7.0 Digital Input:
ECON has 10 digital input as below
• Fixed Inputs
◦ Remote Start,
◦ Remote Stop / Semi Auto
◦ Emergency
• Programmable 4 inputs each can be programmed as one of the
following inputs.
◦ RWL Switch ◦ LLOP Switch
◦ Fuel Switch ◦ HWT Switch
◦ Oil Level Switch ◦ Canopy Temperature Switch
◦ Oil Temperature Switch
• Optional programmable 3 inputs each can be programmed as one of the
following inputs.
◦ Earth Fault ◦ Oil Level Switch
◦ Canopy Temperature Switch ◦ Oil Temperature Switch
Operating Instructions
Page - 6
Operating Instructions
Page - 7
• 8.0 Analog Input: ECON has 4 Analog Input
◦ Low Lube Oil Pressure Sensor
◦ High Water Temperature Sensor
◦ Low Fuel Level Sensor
◦ OIL Temperature (ECON-A-4C only )
• 9.0 Digital Output: ECON has 9 digital outputs :
• Programmable output
Three digital outputs can independently be configured for the any functions
from the list below.
◦ Unit Healthy ◦ Load Warning
◦ Fuel Pump ◦ Heater/Choke
◦ Pull Solenoid ◦ None
• Fixed output: The remaining 6 digital outputs are fixed:
◦ Charging Alt( Battery Voltage) ◦ Crank
◦ Solenoid ◦ Hooter
◦ Mains Contactor ◦ Generator Contactor
• 10.0 Modes of Operation
10.1 AMF Mode (ECON-A & ECON -A-4C)
• 10.1.1 Auto Mode
ECON monitors the Mains supply, if Mains supply varies beyond set limit of
under/over voltage or under/over frequency or voltage unbalance for more
than their individual programmed supervision time, ECON releases the MCB
contactor (to protect the contactor from failure because of low input voltage)
and attempts to starts the generator after the following conditions are meet:
1. If engine start delay is enabled than the engine will wait for the programmed
delay before cranking the engine
2. In case the mains voltage returns to normal before cranking the engine the
engine shall not be cranked.
Heater/Fuel Pump contact are switched on depending upon their settings.
Heater/choke/glow plug is first switched followed by fuel pump. Next ECON
cranks the engine. Crank command is withdrawn once the engine start which
is detected, either by LLOP pressure or by build-up of generator voltage, as
per the setting by the user. Max duration of crank command is user settable.
In case of non-start of the engine ECON re-cranks it till it starts or user
programmed crank attempts are exhausted. If generator fails to start after the
maximum programmed crank attempts, Fail to Start LED starts blinking,
indicating start failure and the hooter is switched on.
After successful start of the generator, it is allowed to warm up for a user
programmed time before the load is transferred to generator.
While the generator is running ECON monitors it for external fault (Digital
Inputs: Emergency, V-Belt, RWL,, LLOP Switch etc) and internal faults
(Measured Values faults: LLOP, HWT, Fuel, Over Load, voltage and
frequency).
On persistence of any fault for more than the programmed supervision
delay,for that fault, generator is stopped, corresponding fault is announced &
hooter is switched on. On restoration of healthy mains supply, continuously,
for the programme duration the load is transferred to the mains and generator
is stopped after expiry of re-cooling time. In case mains again become
unhealthy during the re-cooling period the load is switched to generator.
After successful stopping of the generator either normally or on fault the Fuel
Pump Contact is removed. In case of fail to stop, the Fuel Pump Contact is
not removed to avoid air locking.
Cyclic Operation: ECON can be programmed to automatically shut down
the engine, for a predefined duration, after a predefined duration of
operation, even if the mains is unhealthy. In case the mains continue to be
unhealthy this cyclic operation will continue till the mains is restored.
• 10.1.2 Semi Auto Mode
Semi Auto Mode is sub set of Auto mode. This mode can be selected by
pulling the pin 28(Semi/Auto) low and selecting auto mode from the front
panel. The Auto LED will blink indicating that the unit is in Semi-Auto Mode.
In this mode the unit does not automatically starts the engine after the mains
has failed and mains supervision timer has expired but waits for an external
start signal pin 29(Remote Start/Stop). Once the start signal is given the unit
now functions like auto mode with 3 crank attempts. The unit can be stopped
by pulling low Pin 29(Remote Stop). Both Remote start and remote stop are
one touch and hence should not be continuously activated. These pins shall
only function during semi auto mode.
• 10.1.3 Manual Mode
ECON-A, in this mode is under the manual control of the operator for starting
and stopping of the generator. Engine has to be started manually by manually
pressing “Start” switch. The “Start” switch shall not operate if GCB contact is
closed, to provide protection to generator. Once the generator is started the
load can be switched to generator by pressing “GCB” switch or to mains by
pressing MCB switch. At any given time, either of GCB or MCB can be
operational. Attempt to switch on GCB while MCB is on will be ignored and
vice versa. Both MCB and GCB key have dual function of either switching
ON or OFF the respective contactor. A press shall toggle the state.
Continuously pressing these keys shall keep toggling the status. To stop the
generator, switch off the GCB contactor and press “STOP” key. Any attempt
to stop the generator, while the GCB contact is engaged, shall be ignored.
While the generator is running ECON-A protects the generator by monitoring
all internal and external faults.
Operating Instructions
Page - 8
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