TABLE OF CONTENTS
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
The diagram shown on figure 1 depicts the system reference model:
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
If the SAM2_GEN unit is faulty, the SAM2_CTL unit is able to start/stop/reset the generators depending on the state of the utility ac
mains supply, i.e. utility mains failure. Under these circumstances hybrid power mode (EPCC) is possible because the SAM2_CTL
monitors the state of the BTS battery as well as the cabin environmental conditions.
If the SAM2_CTL unit is faulty, the SAM2_GEN unit is able to start/stop the generator depending only on the state of the utility ac
mains supply, i.e. utility mains failure. Under these circumstances hybrid power mode (EPCC) will not be activated because the
SAM2_GEN does not monitor the state of the BTS battery or the cabin environmental conditions.
The SAM2_CTL and SAM2_GEN units communicate using a simple protocol transferred via the control and status cable pairs as
indicated in figure 1 above. On power-up the SAM2_CTL unit sends a message to the SAM2_GEN unit, the SAM2_GEN unit
acknowledges to indicate that the message was received correctly. The SAM2_CTL unit now sends a new message to indicate
communication in both directions has been established and that both units are functional, the SAM2_CTL unit is in control. The 2
units communicate periodically to ensure both are functional, if communication is lost, the SAM2_CTL unit will re-initiate the start-up
communication handshaking procedure.
2.2 SAM2_CTL and SAM2_GEN Interconnections
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
Note: In order to monitor the state of the emergency stop button on the generators, the SAM2_GEN unit detects the 12Vdc
potential normally present on the output side of emergency stop button switch contacts. The SAM2_GEN unit has 2
dedicated inputs to monitor the emergency stop button of single or dual generators. 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.
The digital output signals of the 2 emergency stop buttons are on Krone block-1/pair-5 for generator 1, Krone block-3/pair-4
for generator 2 and interconnect between the SAM2_GEN and The SAM2_CTL units via the multi-pair cable.
SAM2 Controller
Genset Controller
MAINS GEN
Generator #2 Generator #1
GCB
GCB LOAD/BTS
MCB
MCB
ATS
ATS
Utility 230Vac Supply
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
Coms Control
SAM2_GEN Tank1: Water in Diesel
Coms Status Controller
Unit Tank2: Water in Diesel
Monitored States
Tank1: 2x12Vdc Supply
Note: Normal convention is genset #1 and thus fuel tank #1 is the one closest to the BTS/RBS.
Step 2: 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: Calibrate the Fuel Probe as follows or refer to the SAM2_ECT manual.
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 6: Enable Duel Fuel Tanks, and click Set Config button.
Note: The fuel probe address can be verified using the Get Probe button when a single fuel probe is connected.
2.5 Minimum Set of Connections to Control/Monitor a Generator
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.
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 Generator Door Switches
Connect all the door switches of each generator in parallel using the normally closed (NC) contact. Refer to table 1 above 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.
3.3 SAM2_GEN Interconnecting Cable
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:
A B Krone Block #2
Equipment
or Sensor
Side
Krone Block #1
Cable
Side
+12Vdc
JP4: Fused 12Vdc
Supply for
Fuel probe &
Tank lid Switch
GND
Figure 5: Krone Block Cable Termination Layout
If only one generator is installed at the site, a single 20-pair cable is sufficient to interconnect all the possible control and monitored
states between the SAM2_CTL and SAM2_GEN units.
When 2 generators are used in a standby mode at the site, a 20-pair cable is sufficient to interconnect only the minimum signal
necessary to control 2 generators. If all the possible control and monitored states are to be used for the 2 generators a 30-pair cable
is required to interconnect the SAM2_CTL and SAM2_GEN units and an additional 10-pair cable is required to interconnect the 2
generators.
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
GND GND
GND (Black) GND (Black)
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
Signal Description SAM2_GEN Unit Cable Lead Colour
Tank Lid Switch #2: 12Vdc Supply GND lead on SAM2-GEN unit.
GND (Neg) JP4 GND Black
Tank Lid Switch #2: 12Vdc Supply on SAM2-GEN Fused 12Vdc supply
+12Vdc (Pos) output for the tank lid switches. JP4 12V Brown
Tank Lid Switch #1: Note: The SAM2_GEN unit caters for 2 separate fused
+12Vdc (Pos) 12Vdc supply pairs to power the 2 fuel tank lid JP4 12V Brown
switches; the fuses are Auto-Reset type.
Tank Lid Switch #2: Tank Lid Switch #2 Output - Used to indicate when the Tank lid switch #2 Switch #2 Blue
Output fuel tank filling lid is opened. blue lead connected to
Note: Connect the output lead (blue) of tank lid switch to tank lid switch #1 Switch #1Black
#1 to the GND lead (black) of tank lid switch #2. black lead.
Tank Lid switch #1: Tank Lid Switch #1 Output - Used to indicate when the
Output fuel tank filling lid is opened. KB2/4/A Blue
Note: Normal convention is genset #1 and thus fuel tank #1 are closest to the BTS/RBS.
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 SAM2_GEN LED Indicators
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 LED3
Power
LED4
LED5
LED4 and LED5 Generator Running Indication (LED4 generator 1 and LED5 generator 2):
LED OFF; Generator not running
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.
Genset Reset
Generator 2
Generator 1
Note: The SAM2_CTL Krone block cable termination unit relay NO/NC link setting must match those on SAM2_GEN unit.
Mains 230Vac
Output Supply to BTS
N L1 L2 L3 N L1 L2 L3
MCB GCB
N L1 L2 L3 N L1 L2 L3
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.
N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3
N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3
Generator 230Vac
230Vac Supply Output Output Supply
230Vac Supply Output
from Generator 2
from Generator 1 to BTS
N L1 L2 L3 N L1 L2 L3
GCB 1 GCB 2
N L1 L2 L3 N L1 L2 L3
L1, L2 and L3
N
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.
SAM2_GEN
Krone Block
KB2/3/A - Orange
Gen1 Run
147
KB2/3/B - White
31
KB2/1/A - Blue
201 Gen1 Fault
202
KB2/1/B - White
203 Wire in Series with Key-Switch
NEXYS Control Panel
Remote Reset
Note: Connect
KB1/9/A (Brown)
to +12Vdc on JP4
NEXYS Contro Panel
Note: KB1/9/B - Yellow
Cut wire Lead 203 for Remote Rest fromSAM2 Unit
Remote Reset
KB1/7/A - Orange
Gen1 Remote Start
KB1/7/B - Yellow
KB2/2/A - Orange
Gen1 Door Switch
KB2/2/B - White
KB1/6/A - Blue
Fuel Tank Level Switch or Water in Diesel Sensor
KB1/6/B - Yellow
SAM2_GEN
Krone Block
KB2/8/A - Orange
Gen1 Run
147
KB2/8/B - Red
31
KB2/6/A - Blue
201 Gen1 Fault
202
KB2/6/B - Red
203 Wire in Series with Key-Switch
NEXYS Control Panel
Remote Reset
Note: Connect
KB1/9/A (Brown)
to +12Vdc on JP4
NEXYS Contro Panel
Note: KB1/9/B - Yellow
Cut wire Lead 203 for Remote Rest fromSAM2 Unit
Remote Reset
KB1/8/A - Green
Gen1 Remote Start
KB1/8/B - Yellow
KB2/7/A - Orange
Gen1 Door Switch
KB2/7/B - Red
KB3/5/A - Grey
Fuel Tank Level Switch or Water in Diesel Sensor
KB3/5/B - White
12Vdc Output
Remote GEN Reset KB1/9/B
GND +12V
Notes:
This solution requires the InteliLite AMF20/AMF25 panel firmware to be reprogrammed using the InteliLite V2.6 firmware.
The Inala V2.6 Template for InteliLite AMF20/AMF25 SetPoint configuration and Binary input/output configuration
must also be downloaded.
The Inala SAM2 system switches the AMF panel to TEST Mode to start and run the generator. When the generator is not
running it should always be left in AUTO Mode. The following binary inputs on the AMF25 panel are used to control the
generator Start/Stop and Reset functions (refer also to the picture below):
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:
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 Function Wiring Directly on Relay Base or Screw Terminals SAM2 Alarm/Indication Description
1 MCB Wire directly across LHS COM & NC relay contact set Mains on Load Indication Input
2 GCB Wire directly across LHS COM & NO relay contact set Generator on Load Indication Input
3 Low Fuel Wire to screw terminals X107/108, relay COM & NO contact Generator Low Fuel Alarm Input
4 Alarm Wire to screw terminals X105/106, relay COM & NO contact Generator Common Fault Alarm Input
5 Service Time Wire to screw terminals X101/102, relay COM & NO contact Not Used
6 Generator Run Wire to screw terminals X103/104, relay COM & NO contact Generator Running Indication Input
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.
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.
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.
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 BATT-
1 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.
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.
Connect the 4 screw terminals of the MAINS input on the SAM2_GEN unit to the corresponding 3-Phase utility 230Vac mains
supply input terminals (N-Black, L1_Red, L2_White and L3_Blue). Connect the 3 screw terminals of the GEN input on the
SAM2_GEN unit to the corresponding 3-Phase 230Vac output power terminals (L1_Red, L2_White and L3_Blue) of the generator.
First refer to figure 2 in section 2 above. Connect the 4 screw terminals of the MAINS input on the SAM2_GEN unit to the
corresponding 3-Phase utility 230Vac mains supply input terminals (N-Black, L1_Red, L2_White and L3_Blue) in the generator at
the Point of Entry of the utility 230Vac supply. Connect the 3 screw terminals of the GEN input on the SAM2_GEN unit to the
corresponding 3-Phase utility 230Vac output power terminals (L1_Red, L2_White and L3_Blue) of the generator that is feeding the
load (BTS cabin or RBS shelter).
N L1 L2 L3 N L1 L2 L3 1 2 3 4 5 6 7
Generator ac Utility Mains ac Binary Inputs
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:
Note: Remove wire leads K131 and K133 from AMF25 screw terminals, insulate the bare terminal and cable tie (Do Not Cut)
5.4 Generator Start/Stop/Reset Control - Relay Contact Link Setting
The generator start/stop control relay contact links on both the SAM2_Gen unit and the SAM2_CTL Krone block cable termination
board must be set in the normally open (NO) positions for generators with an InteliLite AMF25 control panel.
A SAM2 system application specific configuration file must be downloaded after the unit has been reprogrammed using the V2.6
firmware. This will ensure all the relevant setpoints parameters and I/O configuration are loaded for optimal inter-operation between
the AMF25 panel and the SAM2 system.
The following steps should be followed to reprogram the AMF25 panel and load the correct configuration file.
Install the LiteEdit software application on your PC.
Save the existing configuration file for future reference.
Reprogram the AMF25 control panel using the revision V2.6 firmware.
Load the SAM2 system specific configuration file on the InteliLite AMF25 Panel
Verify that the AMF25 panel is configured and operational.
Save the new configuration file for future reference.
5.6 Installing the LiteEdit Application Software
The LiteEdit software application must be installed on a PC in order to reprogram and configure the AMF25 control panel, follow the
steps listed below:
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:
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:
Click Install
Select NO
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
Run the LiteEdit software application, select the Options menu tab and click on the Import Firmware option:
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.
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.
A SAM2 system application specific configuration file must be downloaded. This will ensure all the relevant setpoints parameters
and I/O configuration are loaded for optimal inter-operation between the AMF25 panel and the SAM2 system.
a) The 12Vdc supply to the InteliLite AMF-25 panel must not be interrupted during the programming and configuration
procedure.
b) Ensure that the Laptop PC battery is in a fit state to power the PC during the entire programming and configuration
procedure.
c) Ensure that the serial port cable is not disconnected during the programming and configuration procedure.
d) A cross-over (Null-Modem) DB-9 female-to-female serial port cable is required for the programming and configuration
procedure.
e) Always save separate configuration files before reprogramming with revision V2.6 firmware and after making
configuration changes.
f) 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.
Type 0
To download firmware: Select Controller menu option, click on Programming and Cloning followed by Programming
Refer to the following screenshot: Click NO in order to retain the exiting Setpoint configuration on the AMD25 panel:
Click NO Button
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.
If the existing configuration file has not been saved, click Yes, if the file was saved prior to reprogramming, click No
Click OK
NB! Click YES to overwrite the existing Setpoint configuration as indicated in the following screenshot:
Click YES
Click OK
The Information Window displayed in the screenshot shown below indicates which Setpoints were not overwritten
Click OK
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
Run a second instance of LiteEdit software and open the original configuration file that was saved before the InteliLite AMF-25 panel
was programmed using the revision V2.6 firmware.
Double click on the Analog Input of the original configuration to verify whether the sensors used on the engine are binary or
analog.
Note: If any of the sensors used on the engine are an analog type, the characteristic curve parameters need to be verified,
refer to the following section for this procedure.
The configuration of all 3 analog inputs must be verified and changed where necessary.
Configure the 3 analog inputs by copying the information obtained from the original configuration file, the screen shot below is
included as a reference example.
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.
If necessary modify the curve primary characteristics to match those of the curve used in the original configuration file. Note points
can be added or removed.
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
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.
i) Basic Settings:
Gen-Set-Name, InteliLite may be replaced with the Site Name
Verify the Nominal Power is correct, i.e. 13 or 16kW?
Verify the Nominal Current is correct, i.e. 20 or 25A?
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 2 3
Password
Protection
Disabled
i) Basic Settings: Mode iL, this provides maintenance personnel the ability to change operating modes from the front panel keys.
ii) Engine Protection: NextServiceTime, this provides maintenance personnel the ability to change reset the next service
interval time back to 250 hours.
End of Section 5
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.
Gen Fault
Wire no 88
Remote Start
Wires no 5 / 24
Ensure that the controller is in AUTO Mode after completing the installation by pressing the yellow button in the middle.
End of Appendix A
Ensure that the controller is in AUTO Mode after completing the installation by pressing the yellow button.
End of Appendix B
Gen Fault: Connect to number 12 on the back of CGM01 controller, refer to diagram 2 below.
Gen Door: From switch supplied.
Gen Run: Connect (1) Common contact to A-leg of Generator Running contact on generator controller. Connect (2) N/O
contact to B-leg of Generator Running contact on generator controller (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: Refer to diagram 1 below; Connect the coil (3) to the A-leg of the Remote Start contact on generator controller.
Connect the B-leg of the Remote Start contact on generator controller to a battery Negative or the (B-) terminal.
Connect the coil (4) to the battery Positive (B+) Connect (5) Com contact to a battery Negative (B). Connect (6)
N/C contact to the (BLC) terminal.
Mains on load: Not supported
Remote Reset: Not supported
12Volt Supply: Direct on battery is the best.
Remember to switch the selector switch to the Automatic Running Mode after installation.
End of Appendix C
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
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
Remember to leave the controller in auto mode by pressing the auto button.
End of Appendix E
Remote Start
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
Remember to leave the generator in Auto mode by switching the switch to the right.
End of Appendix G
Emergency Stop:
Wire Lead 211
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.
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
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)
Gen Running
12V DC Supply
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.
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
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
Emergency Stop
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.
End of Appendix J
Mains Lines: Connect Neutral to terminal 1 on X25 terminal strip. (Refer to diagram 2)
Connect L1 to terminal 2 on X25 terminal strip. (Refer to diagram 2)
Connect L2 to terminal 4 on X25 terminal strip. (Refer to diagram 2)
Connect L3 to terminal 5 on X25 terminal strip. (Refer to diagram 2)
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.
Gen Running
Com and N/O
contact
Generator 230Vac
output supply
Remote Start
Utility 230Vac Signal
Mains Leads
Remember to leave the controller in auto mode by pressing the auto button.
End of Appendix K
Gen Fault
Signal
Emergency
Stop Signal
Remote Start
Signal Gen Run
Signal
End of Appendix L
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
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)
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.
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.
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
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.
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.
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.
In order to verify the operation described above perform the following test before the installation of the SAM2 generator controller:
1) Switch OFF the KPLC (mains) 230Vac supply, the generator should start, run and go On Load.
2) Switch ON the KPLC (mains) 230Vac supply, the generator should go Off Load, cool down and stop.
3) Remove the link across the Stripline Link 9X15.
4) Switch OFF the KPLC (mains) 230Vac supply, the generator should not start.
Diagram 2 : SDMO Auto A50 Control Panel Mains Fail Control Sheet 009
SAM2 Remote
Start relay
contact across
XUC10/XUC11
End of Appendix M
End of Appendix N
b) If the GEN Run signal activates (closing contact across KB2/3/A and KB2/3/B) within the 20 second interval indicating a running
genset, the start relay contact remains closed. AMF25 panel should continue to indicate that it is in "Test" mode.
c) The SAM2 unit now monitors the state of the AC Phase fail input, if this input clears within 90 seconds the generator is assumed
to have started, is running and generating 230Vac on all 3 phases.
d) If the Gen Run signal does not activate or the AC Phase alarm does not clear, the start signal is turned off for 30 seconds and the
cycle repeats.
e) The start attempt cycle is repeated 4 times, if the genset does not start after the 4th attempt, the "Gen Start Fail" alarm is
activated and the SAM2 stops attempting to start the genset.
f) The are a number of conditions that will reset the "Fail to Start Counter" in order for the SAM2 unit again attempt to start the
genset, Remote reset on the ECT software is one way to clear the "Fail to Start Counter". If activated the "Gen Start Fail" alarm will
only clear when the genset starts and runs for more than 90 seconds.
Note: The SAM2 unit is configured for 60 second genset start delay, this delay is operational when the Utility 230Vac power fails,
when the genset is started remotely from the ECT software there is no delay.
Note: The SAM2 Unit has an "Override Time-Out" period that is configurable from the ECT software on the Generato/Power screen.
This is normally set to 5 minutes. If a genset is started remotely from the ECT software it will run for the configured Override time-out
period, i.e. 5 minutes and then stop.
b) Almost immediately after the remote start relay contact is opened the remote reset relay contact across KB1/9/A and
KB1/9/B closes for 10 seconds. This action both resets the AMF panel fault condition and stops the genset by switching the AMF25
panel into "Off" mode for 10 seconds. When the remote reset relay contact across KB1/9/A and KB1/9/B opens the AMF25 panel
switches back to (and is locked in) manual mode. Thus the maintenance personell can start and stop the genset manually.
Note: The SAM2 unit is configured for 60 second genset stop delay, this delay is operational when the Utility 230Vac power clears,
when the genset is stopped remotely from the ECT software there is no delay.
Note: The SAM2 Unit has an "Override Time-Out" period that is configurable from the ECT software on the Generato/Power screen.
This is normally set to 5 minutes. If a running genset is stopped remotely from the ECT software it will stop for the configured
Override time-out period, i.e. 5 minutes and then re-start again automatically.
Note: When the genset is reset remotely from the ECT software there is no delay, the genset stops immediately and the alarm is
reset.
Note: If a genset is started manually when it should not be running (i.e. site is in epcc mode or the Utility 230Vac power alarm is not
active), then the SAM2 unit will allow the genset to run for the override time-out period (5 minutes) and then stop it using the reset
signal.
Note: The start/stop/reset action described above has be tested in the lab on a testbox and in the field on various types of AMF
panels and is functioning reliably.
A simple way of testing the Start/Stop/Reset functions is via the ECT software:
1) If the genset is not running (i.e. site is in epcc mode or the Utility 230Vac power alarm is not active), click the Gen start button on
the ECT software, the genset should start and run for the override time-out period (5 minutes).
2) If the genset is not running (i.e. site is in epcc mode or the Utility 230Vac power alarm is not active), then AMF25 panel should be
in "MAN" mode, press the start button on the AMF25 panel, the genset should start and run for the override time-out period (5
minutes).
3) If the genset is running (i.e. site is not in epcc mode and the Utility 230Vac power alarm is active), click the Gen stop button on
the ECT software, the genset should stop for the override time-out period (5 minutes) and then restart automatically.
4) If the genset is running (i.e. site is not in epcc mode and the Utility 230Vac power alarm is active), click the Gen reset button on
the ECT software, the genset should stop immediately and restart automatically after about 60 seconds (genset start delay).
End of Appendix O
End of Document