_

GB

USE AND MAINTENANCE

HANDBOOK FOR ELECTRIC
BOARD

G3
MADE FOR :

MO1/G3SHORT 12/’08
This handbook should be kept in a safe place to allow rapid consultation during the whole life cycle
of the electric board. This handbook and the conformity statement are an integrating part of the
generating set. Read use and maintenance handbooks before using the generating set.

MARGEN srl
Plant 1 and Headquarters: Plant 2:
Via Dino Ferrari ,50 Via Bucciardi,33
41053 MARANELLO (MO) ITALY 41042 FIORANO
Modenese (MO) ITALY
Tel. +39 0536 94.36.15 FAX +39 0536 94.35.81
e-mail: info@margen.it www.margen.it

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Handbook G3_SHORT
Version 0.1 del 20/04/2006
REDUCED VERSION FOR THE COMPLETE VERSION MAKE REFERENCE TO ANNEX CD
G3 CPU has a backlighted alphanumeric LCD with 2 lines of 16 characters on its front side. This display
allows surfing the menu freely except for configuration that is strictly reserved to Margen staff and therefore
protected through a password. To surf this menu you have to use the 8 eight keys under the display.

Enter/ESC Configuration: allows entering protected configuration menu and exit

Scroll down menu/decrease: allows scrolling down menu pages and decreasing figures from
configuration menu.

Scroll UP menu/increase: allows scrolling up menu pages and increasing figures from configuration
menu.

enter/esc SUB Menu: allows entering visualisation sub menus, confirming visualisation and exiting.

Back to main menu/alarm reset: you can go back to main page from any menu page, in manual mode
you can reset alarms.

function key/manual starting: in manual mode it allows manual generating set starting, it has different
functions according to different options.

function key/manual stop: in manual mode it allows manual group stopping, it has different functions
according to different options.

function key/generating set commutation: in manual mode it allows group commutation (with net
open), it has different functions according to different options.

Led: LED on “Enter/Esc configuration” key blinks with 0.5 s ON/OFF frequency to show that the program is
in execution. If the LED is off or steady on there is a system or program malfunctioning.
For a complete description of the menu see attachment “G3CPU Menu”

Use of panel keys

All G3Panel keys have a red led that shows state or functioning of the function linked to it. During the first
functioning cycle the system is always preset in LOCK mode for security reasons, therefore key LED must be
on. System presetting also includes TEST, AUTO and MANUAL keys.

LOCK: after blocking all generating set functions, if generating set is on you will have immediate lock
by pressing this key. All manual functions are cut out too (except starting from local: see chapter G3 CPU),
buzzer and alarms are cut out in LOCK mode until different setting.

TEST: it makes the unit start immediately but if there is net tension no control on commutation is
possible. If net tension fails during the test there would be commutation net / unit as in automatic mode; in
order to arrest generating set select AUTO (but only if there is net tension) or manual mode by switching
suitable keys. All protections are active.

AUTO: it activates Standby mode, i.e. generating set is waiting for the control of net tension
missing. All automatic functions are on including periodical test; in case net tension fails the generating set

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starts automatically. As soon as nominal parameters are reached, generating set net contact maker closes.
When net tension is back again and after a programmable time there will be opposite commutation
generating set / net, after a cooling time (which is also programmable) generating set stops. All protections
are active.

MANUAL: In this position the system becomes semi-automatic, i.e. generating set starting and
arrest are voluntary and controlled by the operator, all alarms and protections are on. In manual mode button
controls for starting, arrest and net / power unit commutation are on. In manual mode, when the machine is

stopped and the key START is pressed and no lock alarms are on, the generating set starts. You just
need to press this key for a second to start a complete starting cycle with preset duration. You can interrupt

this cycle any time by pressing the key STOP . In manual mode you must be particularly careful with the

key MS (net contact maker) : if you press this key when the light is on you release load on the net
(provided you have not disabled the software upon request thus making it impossible to use the key MS); in

the same way, only if it is open (led off) it is possible to close that of the GS pressing the key when the
machine is working. The light in the key GS confirms that load on GS has been closed. Commutation keys
work in set-reset mode: every time you press them you close and open the control alternatively. Also in
manual mode controls are interlocked, so it is not possible to have a contemporary lock. With manual control
of Margen motorised commutators you have to press the key of the generating set contact maker only once
then press the net contact maker to go back from GS or net manually, or act manually on commutator from
GS to net position.

NOTE: Control system for net commutation is operated through NC logics in order to safeguard the load, as
soon as there is net tension you can have net remote control switch; this means that also in case the CPU is
replaced or Battery tension is disconnected the working of the machine is still granted. The same happens
when you want to open net load, i.e. you have to keep pertinent control fuse open (see diagram).

ACK: the key ACK or implied alarm lights up every time there is a new alarm and it shows that
active acoustic alarm has been activated (led with steady light). To silence the acoustic alarm, press ACK
key. If the function automatic alarm silencing is on, the acoustic alarm will be automatically silenced after pre
set time but the led of the key ACK will be blinking (the last alarm has not been recognised yet). NB at first
starting up and in LOCK mode both led and siren are OFF.
RESET: Alarm reset key lights up each time there is a new alarm and shows that there are alarm pages in
the alarm section. Once alarms have been solved the reset key has the function of resetting all solved

alarms. To see what alarms are still on press the key , alarm pages will be displayed alternatively
every 2 seconds.

FUEL PUMP MAN/OFF: if there is a fuel pump as a system for tank filling you can use this key to
control the pump manually. Press this key for a second, its LED will light up to show that the pump is in
manual mode, if the led blinks it means that the control contact maker is fed and presumably that the pump
is filling the tank. When the pump is in Manual mode only the alarm of overfilling can stop the pump
automatically, to stop it manually press the key MAN/OFF for 2 seconds, when the LED turns off it means
that the pump has stopped.
FUEL PUMP AUTO: if you press the fuel pump key AUTO this will start working automatically (LED with
steady light); this means that you can or cannot control the fuel pump according to the position of the floats.
When the pump is working, pump LED AUTO blinks; you can stop the pump any time by pressing the key
MAN/OFF at least for 2 seconds.

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Starting up

Connections
Once you have completed all power and auxiliary connections (as explained in engine installation handbook)
you can apply voltage to electric board.
Presence of electric network: usually referred to as L1R, L2R, L3R, NR (Neutral wire) except different
directions in electric diagram of connections. The reference of presence of electric network has to be taken
from a point in the system where, once there is no tension, you want to control unit starting up; usually the
power of such line does not exceed one kW.
Privileged service line: usually L1P, L2P, L3P, NP (Neutral wire) except different directions in electric
diagram of connections. Privileged line usually has to be taken in common point usually fed through the net,
while it is fed through GS during emergency functioning. The power of this line varies from GS to GS. Keep
to directions given in the electric diagram of connections for line dimension. All input lines to Margen electric
board must be limited to 10kA short circuit current.
Always open all fuses and circuit breakers or sectioning devices before giving power to the lines or
connecting batteries. Use an instrument to measure input AC tension to the lines of Presence of net and of
auxiliary services to privileged line. Check that neutral wire position is correct and that tension corresponds
to the nominal one reported in electric diagrams; always make sure that PE earth wire is connected before
feeding the panel. Electric wiring installation must be performed workmanlike.
Further controls: Check that there is a special liquid in cooling circuit and that taps that might be in water
heating device are open. In case of remote board you have to connect all wires given for connection
between electric board and machine. It is forbidden to modify, even partially, all wires supplied by Margen or
to use other non prescribed wires because this may cause guarantee invalidation in case of malfunctioning.

Installation and connections among units/Wires Specifications

For connections between G3PLC and G3Panel use given wires or, in case of remaking on site, you have to
respect some rules given each time by UT Margen according to installation distance. For serial connection
diagram you have to use Belden wire with 4-screened conductors specially designed for RS422/RS485
communication.

4
3
G3CPU
2
1
J17
J2 _

CONNECTION IN RS422
CONN. 9 POLES FEMALE CONN. 9 POLES FEMALE

In addition to this there are 24Vdc feeding connection for terminal and two wires for emergency button; (this
is a standard specification, for specific cases always refer to attached electric wire diagram).
These wires must not be laid next to wires with high current or/and distorting currents or power
wires in general or with middle tension. It is advisable to follow independent paths or near other
signal wires always keeping to regulation in force in the country where installation is carried out.

Panel Installation
Remote controlled G3Panel can be installed without any particular precaution (as far as communication is
concerned) up to a distance of 100 m (as wire length). For longer distances special precautions are
necessary and they will be discussed together with UT Margen.
Anyway we advise that installation should be made in places with little dust, with temperatures between 0
and 55°C, humidity below 80%, not exposed to drippi ng water and not in open air, and lift from the ground at
a height that allows correct display reading at right angle at eyes height (about 1.70-1.80 m). Panel cannot
be installed in a place with explosion risks (except in case of particular installation that must be always
checked before). As for wiring from and to the device follow regulation in force in the country where it is

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installed. Make sure that there is earth connection before you put device under tension. Electric wiring must
be performed workmanlike.

Starting up
Starting up a generating set is always a very critical operation especially with the first starting up.
Therefore in case your contract foresees starting up by Margen staff, the installer should wait before
feeding the board either through battery or Motive power in order to avoid possible problems that
could partially jeopardize manufacturer’s guarantee. If it is the installer himself that carries out the
first starting up, he has to read following paragraphs carefully to accomplish a faultless test. In
addition we wish to remind you that each power unit is tested in our factory and that system
presetting is tested according to customer’s and system requirements; the customer shall assume
full responsibility for any further change in configuration parameters made by the customer or by
third parties on customer’s behalf. Margen owns equipments that can check what parameters have
been changed after factory test and how.

Preliminary fundamental parameters before starting up

1. read all generating set installation handbook thoroughly, finish all building, hydraulic and electric
works (for ex.: exhaust and suction air conveyance, exhaust gas system, tank installation and
hydraulic connections from and to GS, completion of auxiliary and power electric connection, etc.
…). Once you have completed connections of this book, you can feed pre-heating circuit considering
all possible protection organs from electric diagram including circulator.
2. The poles of the batteries can be connected only after charge reaction has ended. Match the
symbols in the poles with the symbols printed on batteries carefully.
3. Measure actual tension in the ends of the terminal board and check that it matches the one written
on electric diagram for polarity and absolute value (usually higher than 24Vdc).
4. Close the fuses with battery tension one by one and feed all equipments (except that of G3Panel if it
has not been connected yet). Insert the switch of the battery charger/chargers and check that LEDs
above them are lighted.
5. Wait until engine temperature has reached at least 30° C before any start.
6. Check that machine switch is open, check that power connections before the switch (if this is not
installed on the edge of the machine) are correct and that there are no terminals in short circuit;
ATTENTION!: if the generating set has not been used for more than 6 months and it has been stored in a
particularly wet place you have to carry out an isolation test before starting it up! An isolation fault could
destroy alternator at the starting up. Test rules are in alternator handbook, as for the electric panel you have
to open all fuses and disconnect all equipments that are directly connected after the alternator, open GS
cutout switch; do not exceed 1kV test tension. If the results of the test do not comply with data reported in
alternator handbook do not start the machine up and contact Margen assistance.
Check levels of cooling liquid and lubricating oil again. Check the presence of suitable and clean fuel in the
tank and that feeding pipes are filled and deaerated up to engine injection pump (see engine handbook for
this). If fuel tank has a security solenoid valve on delivery circuit to the engine you have to open it to fill the
pipes; disconnect the wire that controls unit starting up, set up Manual mode and press Start for a second.
After this the valve is open for 60 seconds to deaerate the circuit. After 60 seconds the solenoid valve shuts
again. If for any reason you want to shut the valve before this time you have to press STOP. Connect the
wire of starting up control again. Go to G3 panel if it is near the GS, otherwise it is advisable to carry out the
first starting up directly with manual procedure from G3CPU (for details see G3CPU Menu).

Manual starting up from G3CPU: press the key until you visualize “Manual Functions”, press
ENTER, on the display you will see the list of the options you can activate with the keys F1, F2, F3. At this
point you cannot change system set up on the display but you can only activate or control manual mode. If
you press F1 you will start the GS up, if you press F2 you lock the GS. If you press F3 when the GS is
working and the net is not present you can control GS commutation. To exclude GS commutation press F3
again.

Equipment set up from G3CPU: press the key until you visualize “Functioning mode” press
ENTER. On the display you will see the list of options you can activate with keys F1, F2, F3. If there is no
communication with the terminal you can modify set up: if you press F1 you set up EXCLUDED (LOCK), if
you press F2 you set up AUTOMATIC (AUTO), if you press F3 you set up TEST. To check correct selection
press the key ENTER again to exit menu and the key RESET to go to main visualization. For further
information see the handbook see G3CPU Menu.

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 Before starting the GS up, read the remaining paragraphs of this handbook carefully in order to learn
the meaning of some terminologies and procedures that have not been put in this section to make
reading easier.
Check that all lock alarms have been solved then press RESET.
Set up Manual mode and check that the led of the key Manual is on.
Press START for a second. If the system does not start try again at least 2/3 times (that is to say 2/3
complete starting cycles). Check if there are any alarms and check again if there is fuel in the feeding circuit.
Try to start it up again. If for any reason and after you have tried several times you still cannot start the
system up, contact Margen assistance. If the system has started to work correctly press the key STOP to
stop the machine. Check the level of liquids again. Then go to G3 panel. We suggest opening the page of
generator/engine parameters or INFO page, start the GS again and check electrical and physical
parameters.
Put the board in AUTO mode and simulate net absence, check the correct starting up of the GS and check
that consent to commutation arrive at commutation system correctly; reset net tension to correct values and
wait for exchange GS-net. The GS will keep on working for the time necessary to cool down then it will
automatically turn off. Put G3Panel in Test mode. The GS will start immediately but if the net is present it will
not make any commutation to the unit. Simulate absence of net and check that there is a commutation net
GS. Give net presence again and wait for inverse commutation GS-net as in automatic mode; to stop the GS
you have to put the presetter in AUTO mode again. When the net is present the GS will stop after cooling.
Switch to LOCK mode then repeat simulation of net absence. The GS should not start even if you press
Start and Stop G3Panel.
If the system has electro pump control to load fuel, you have to check that it is functioning: press FUEL
PUMP MAN/OFF. Blinking LED shows that the contact maker is feeding the pump. Check that the pump
turns in the direction of the arrow on the pump itself. If not, invert two phases after excluding tension. Press
the key for 2 seconds to stop it. Put pump control in AUTO mode and wait until fuel reaches preset maximum
stop level. In the menu “Machine parameters” you can visualize reached fuel level.
If it is possible you should carry out a load test as the last test: close the GS switch (if it is not motorised),
then simulate net absence in AUTO mode as done before, increase load gradually and check electric and
physical parameters to see if they remain normal and correct. Check above all engine temperature that
should not normally exceed 90°C at full load, while pressure depends on the type of engine but usually it
should not go under 2 bar.
Contacts available to the customer for remote controls are usually cleared contacts (with no tension) with 6A,
400V so it is necessary to avoid exceeding absorption or tension values as indicated in the diagram; input
contacts to the board should normally be cleared (with no tension) but they have to bear board tension as
indicated in the diagram.

Safety measures
For safety measures we mean all necessary precautions to safeguard machine operators (electric board and
power unit).
If the presetter is set up in LOCK mode (excluded) you have all guarantees that the machine will not start.
However if somebody could change this setting from a remote control, the operator would be in potential
danger. Therefore we advise pressing local emergency button, too. In this case you would never have an
unexpected GS starting up even with a remote change in presetter set up.

Problem solving

In this section you can find some problems that may occur and how to solve them:
Problem Possible Cause Solution Notes
G3CPU has no feeding 1) there is no tension 1) check general feeding fuse
2) connector J2 not and CPU fuse
inserted properly 2) check and insert connector J2
3) G3CPU is damaged 3) call assistance
G3CPU keyboard led is 1) controller failure 1) switch CPU off and on again
steady on or off 2) no feeding opening and closing its fuse
2) check feeding
No control from connector 1) emergency pressed 1) remove emergency alarm
J4 outputs 2) no output common 2) check presence of common
3) lock alarms active +24Vdc
3) reset lock alarms

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Terminal keyboard does 1) No communication with 1) check that there is no alarm of
not function G3CPU. no communication with G3CPU
2) Manual mode from check wires.
G3CPU 2) quit manual mode from
G3CPU
Generating set starts 1) there is at least one 1) check input tension to J 24
when net is present net phase missing connector CPU
2) net presence has been 2) check that net input is
activated from an external deactivated in configuration.
contact
Red led is on in this 1) some alarms are still 1) press indicated key to check
on which alarms are still on
2) no communication with 2) check that communication is
key
G3CPU present by pressing the key
repeatedly.
Terminal display is off but 1) automatic switching off 1) press a key to switch display
LEDs are on has been activated to on again
preserve the lamp 2) if you press the keys but the
2) lamp is burnt-out lamp still does not switch on
replace it as it is damaged.
Pre-heating system is on 1) 24vdc feeding is 1) if 24Vdc is missing there is no
but the engine is cool missing control to pre-heating control
2) pre-heating device is system.
damaged Check that tension gets to pre-
heating device.
Following message is 1) it is a lock alarm of the Contact Margen for the solution
displayed ”Severe Lock operating system of this problem
contact MARGEN”
Alarm message “no COM 1) no feeding for the 1) check instrument feeding
with multimeter” device 2) check connection of com
2) connector of module on the instrument and
COM module position of DIP switch
disconnected 3) communication parameters
3) error in serial should be the same as shown on
configuration diagrams.

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