AMF CONTROLLER
The AMF controller governs all functions of a standby generator. It automatically manages the connection assignment of the LOAD to MAINS or GENERATOR. In other words, it is an intelligent form of automatic mains failure relay. The AMF controller is the core of an AMF panel.
NFPA-110 COMPLIANT
The AMF controller compares the electrical parameters of the MAINS (that is the Utility Power) with a set of internal settings. When one or more parameters are out of range, the relay triggers the Mains Failure Flag. This could be used to perform miscellaneous functions: disconnect the load and start the engine for example. This AMF controller is designed for general purpose standby applications. When you build AMF systems for BTS installations, we recommend that you install the
AMF CONTROLLER LINKS
HOW DOES THE AMF CONTROLLER WORK?
The AMF controller features a 128X64 graphic display, operating in a temperature range between -15°C and +50°C. It indicates parameters, alarms, and miscellaneous information about your standby generator's status. The AMF controller measurements include Vac, Aac, Vdc, kVA, kVar, kW, Energy, Pdf, Hz, hour count, R.p.m., Oil Pressure, Engine Temperature, Battery Vdc (Engine), Fuel Level and a variety of miscellaneous data and parameters. The AMF controller complies with NFPA-110 / NFPA-99 specifications.
THE FRONT VIEW
The AMF controller is usually placed on the frontal door of the AMF control panel. A user-friendly interface made of push buttons and LED indicators offers instantaneous information about the status of the entire standby system.
SILICON GASKET UV-PROOF
The BeK3 AMF controller, thanks to a silicon gasket, is IP65-compliant. This prevents humidity, and dust from deteriorating the inside components of the AMF panel.
A "ROCK SOLID " AMF CONTROLLER WITH AN ENCLOSURE MADE OF STEEL
A reliable AMF controller features a metallic rear cover. The enclosure is made of zinc double-coated steel. Zinc is a heavy element, and when alloyed with other metals, it provides better corrosion resistance, stability, dimensional strength and impact strength.
The rear cover made of metal is the best solution for shock-proof equipment. It is an excellent protection against electromagnetic fields by enclosing the 32-bit processor into a Faraday cage. The AMF controller with metallic enclosure provides an extraordinary advantage over competitors' plastic-based enclosures.
AMF CONTROLLER REMOVABLE CONNECTIONS
The AMF controller features a set of removable connectors. The connectors are organized in a particular order. The choice of using different connectors avoids unpleasant mistakes. Connecting a connector one by one will allow you easy AMF controller troubleshooting.
In the above picture, you can observe the following connections:
[1] Power supply [2] Modbus port [3] Digital / Analog Inputs / CanBus [4] Generator & Utility power connections [5] Protection Ground [6] Current transformers
CANBUS AND MODBUS
Regarding engines with ECU, this AMF controller features a fully isolated CANbus. It supports the J1939 protocol.
CANBUS terminals are also provided on this connector (your ECU must be SAE J1939 compliant).
MODBUS-RTU
The AMF controller features an RS485 powerful serial interface. The RS485 can drive a 1000m twisted pair and 127 nodes. It completely supports the MODBUS-RTU protocol.
AMF CONTROLLER MODBUS PROTOCOL
We supply accessories and serial interface adapters with free-of-charge remote monitoring software.
Despite the possibility to set up the controller by using the navigation buttons and display, the BeK3 controller offers a USB 2.0 connection. You can plug a B-TYPE male connector on the Be-K3 and an A-TYPE male connector on your computer. The software is provided free of charge.
PANEL MANUFACTURER SETTINGS
When the AMF controller is placed in the OFF mode, the display shows the MAIN MENU
It consists of two pages that include all programmable and adjustable settings. USER and OEM parameters include all settings required for an efficient STANDBY SYSTEM. Some important parameters have a factory setup. Other parameters are inhibited by default.
By choosing the METER & ALARM menu, a list of all instruments appears on the screen.
The display shows instruments about GENERATOR, MAINS, FUEL, and others.
THE OEM PARAMETERS
The OEM parameters are included in three menus. The first one does include the most important parameters.
The second page presents miscellaneous options that include INPUT-OUTPUT programming.
With the last one, you set up an auxiliary temperature channel, Fuel Level and OIL pressure. You can also restore the factory settings.
END-USER SETTINGS
This menu is reserved for the end user. There are wide choices for scheduling the service (oil change for example).
The user can disable the AMF controller during the weekend. He can set up periodic tests for the engine and miscellaneous settings related to the optimal use of the standby generator.
This AMF controller application wiring diagram shows the basic connections. In particular, this example shows how to make a CONTACTORS-BASED AMF panel. The version capable of driving motorized transfer switches is more complex and explained ahead in this document.
The AMF wiring diagram shows digital and analogue inputs committed to interfacing the engine. You can see the MAINS and GENERATOR connections, CURRENT TRANSFORMERS connections and various mandatory connections. The next sections describe all the details.
THE AMF CONTROLLER OUTPUTS
On the removable connector JC you are required to wire auxiliary relays. The AMF controller provides a common supply rail (JC8) suitable for automotive relays providing at the same time over-voltage protection, short circuit protection, and EMI protection. You are required to use 90-200 OHM DC coil relays (12 V or 24 according to your engine battery).
The flywheel diodes are included in the controller.
The AMF controller's outputs are described in the following table:
| #JC-1 | Configurable Output 1: you have 80 settings for this output. In other words 80 different automation functions. |
| #JC-2 | Configurable Output 2: you have 80 settings for this output. In other words 80 different automation functions. |
| #JC-3 | Configurable Output 3: you have 80 settings for this output. In other words 80 different automation functions. |
| #JC-4 | Start Pilot output. Connect the terminal "50" of the starter motor via a pilot relay. The minimum recommended rating is 50 amps. |
| #JC-5 | Contactor Generator output. You can connect the driver relay KKG for the GCB (GENERATOR circuit breaker) via normally open contacts. |
| #JC-6 | Contactor of the Mains output. You can connect the driver relay KKM for the GCB (MAINS circuit breaker) via normally closed contacts. |
| #JC-7 | Fuel Solenoid output. You must connect the KFS relay that drives the fuel solenoid. It is energized to run. In other words, you have to disable this output when you want to stop the engine. You can use one of the programmable outputs (1, 2, or 3) with the option "80" if you need a stop solenoid. |
| #JC-8 | Output supply for external relays. |
THE AMF CONTROLLER DC INPUTS
The connector JF is used for the ANALOG and DIGITAL sensor fitted on the engine. You can use various sensors. Default settings allow the use of VDO-CONIINENTAL devices. You can change the setup according to your sensors.
| JF-1 INPUT 1 OPTION [ 1 ]
JF-1 INPUT 1 POLARITY [N.O.] |
See Table 9.07 in the installation manual for the available 35 option list. You can select N.O. (normally open) or N.C. (normally closed). These are free programmable digital inputs. You activate one input when you connect it to the battery minus. The inputs are fully protected up to 100V in all polarities. In square brackets, you see the factory setting:
[ 1 ] Immediate Stop [ 26 ] Remote Start [ 12 ] Mains Presence Simulated |
| JF-2 INPUT 2 OPTION [ 26 ]
JF-2 INPUT 2 POLARITY [N.O.] |
|
| JF-3 INPUT 3 OPTION [ 12 ]
JF-3 INPUT 3 POLARITY [N.O.] |
THE AMF CONTROLLER AC INPUTS
The JA removable plug is used to connect the Mains & GENERATOR VOLTAGE sensing. The electrical parameters must be in the range of 80-600V and 20-99HZ. The removable connectors JP and JL connect the CURRENT TRANSFORMERS. Their size must be suitable for the EARTH FAULT current sensing and the 3-PHASE GENERATOR nominal load.
The JA removable plug is used to connect the Mains voltages. Electrical parameters must be in the range of 80-600V and 20-99HZ.
Connect the current transformer on the LOAD side. In this way you will get current measurements all the time, When you set an overload warning or shutdown, only the measurement from the generator will cause the alarm.
HOW DOES AN AMF CONTROLLER WORK?
The AMF controller governs the backup generator and transfers the load to the generator or mains smoothly and with short downtime. After detecting a MAINS failure, the AMF controller starts the engine. It may be cold. The AMF controller waits for a warm-up: the engine will run offload. After the engine warms up, supposing the generator provides the correct frequency and voltage, the AMF controller transfers the load from the MAINS to the GENERATOR. This could be done via a CONTACTOR-BASED changeover or a MOTORIZED-BASED transfer switch, Once the mains have been restored, the AMF controller will disconnect the LOAD for a few seconds and automatically connect the LOAD to the MAINS. After a time delay, the engine is then stopped.
IT CONNECTS THE LOAD TO THE GENERATOR
The AMF CONTROLLER activates the KG (contactor of the generator) using the KM-AUX and KG-PILOT contacts. The KM-AUX are the auxiliary contacts fitted on the body of the utility power contactor (KM). When the KM is open, the KM-AUX contacts enable the KG. The AMF CONTROLLER finally activates the KG via the KG-PILOT relay.
IT CONNECTS THE LOAD TO THE MAINS
The KM contactor connects the LOAD to the MAINS. The coil of the KM energizes via the KG-AUX and KM-PILOT contacts. The KG-AUX auxiliary contacts have a mechanical connection with KG, the contacts close when the KG opens. The KM-PILOT is the MAINS control relay. This relay is OFF when the MAINS is within the settings. Using the normally closed contacts, we prioritise the MAINS in case the AMF controller is damaged or without supply. In case of utility power failure, the AMF controller energizes the KM-PILOT. The KM-PILOT contacts will open the KM. Once the KM is open, the auxiliary contacts KM-AUX will close.
When the AMF CONTROLLER switches the generator to the utility power, the user observes a short ‘power outage’. Normally it is about 2 seconds. This is the typical behaviour of the automatic transfer switch: BREAK-BEFORE-MAKE.
THE "DUAL GENERATOR" AMF CONTROLLER CONNECTION
In addition to the common configuration of a single MAINS-GENERATROO-LOAD arrangement, the AMF CONTROLLER allows the connections of one of two generators to one load. This is not a parallel configuration. It is a basic BREAK-BEFORE-MAKE configuration. In a prolonged power outage, you can use one generator as a master. In case of failure, the second one will supply the load.
You can set up a timer to supply the load. For example, you can set up 6 hours for each generator.
THE "DUAL LOAD" AMF CONTROLLER CONNECTION
Using this AMF CONTROLLER wiring diagram, you can connect one generator as an emergency standby to serve both loads. This is not a parallel configuration. The generator will supply the only load that suffers a utility power condition.
It could be only one load or both. The generator will start in case of one utility power failure and stop when the utility power can supply the loads.
THE CHANGEOVER WITH CONTACTORS
There are two basic solutions to transfer the LOAD to GENERATOR or UTILITY POWER: by contactors and by motorized transfer switches. The matter is quite complex. In a few words, we can say that it is preferable to use contactors changeover when the total power is up to 100kVA. Over this power, it is better to use motorized switches. In particular cases, a combination of both is required.
THIS IS A CONTACTOR-BASED CHANGEOVER
The changeover is made by two contactors capable of carrying the nominal current of the panel. This is in the range from 63 amps up to 250 amps. The contactors are activated and held in position by electric coils. Three are auxiliary contacts on each contactor. The two contactors are interlocked. In this way, only one contact can be activated.
THIS IS A MOTORIZED-SWITCH-BASED CHANGEOVER
The motorized changeover switch is a complex piece of equipment. An electric motor moves the switch to a desired position. Before closing a circuit, the switch is always placed in the OFF position. The motorized transfer switch can manage an enormous amount of current. Once the switch is in position there is no current consumption because there are no coils. On the other hand, you can not pretend flexibility of use. It finally requires a special driving electronic board.
The installation of the AMF controller in combination with the RS485 extension board and the motor driver board, facilitates the assembling of complex AMF panels. These boards reduce 70% of cabling and miscellaneous components. Non mention over 50% of workmanship time.
Voltage Supply:
5.5Vdc to 36Vdc, 50-150mA
Protection:
internal 300mA thermal fuse
Dimensions:
192mm X 144mm X 40mm
Panel Cut-out:
187mm X 139mm, indoor operation
Operating temperature range:
-15 deg C up to +70 deg C
Humidity range:
5% up to 95% non-condensing
Weight/IP:
710 grams / IP65
Static output characteristics:
300mA/100Vdc short circuit proof, negative.
Supply output for relays:
Max 1A at V battery minus 1Vdc (short circuit proof)
Mains and Generator voltage input:
Nominal Voltage input: 70 Vac-600Vac
Overvoltage: 4KVac phase to neutral
Measurement precision:
+/- 1%. Input impedance: 2 Mega Ohm
Current transformer input size:
10/5Aac up to 9900/5Aac
Digital inputs Open circuit voltage:
Battery voltage minus 2V - Trigger level: < 2V
Charger alternator monitoring:
Operating voltage up to 36Vdc/3W, accuracy +/- 5%
AMF CONTROLLER FEATURES
80 OPTIONS ON 3 ADJ. OUTPUTS
35 OPTIONS ON 3 ADJ. INPUTS
7-DC OUTPUTS / 6-DC INPUTS
600VAC 3-Ph 4-WIRE MONITORING
1/C.T. EARTH FAULT MONITORING
3/C.T. LOAD MONITORING
OVER 150 ADJUSTABLE SETTINGS
200 EVENTS LOG HISTORY TAGGED BY R.T.C.
14 PUSH BUTTONS
USER-FRIENDLY INTERFACE
GRAPHIC 128X64 LCD DISPLAY
GENERATOR & ENGINE INSTRUMENTS
DRIVES MOTORIZED CIRCUIT BREAKERS
REMOTE CONTROL MONITORING
Push the [AUTO] push button until the yellow LED illuminates. The engine starts when the BeK3 detects a Mains failure. The Mains circuit disconnects the LOAD after the [MAINS BREAKER] timing. After the [WARM UP] time if the voltage and frequency are within the settings, the GCB will close. If the Mains is restored, the MCB will open. The KM will close following a programmed [KM CHANGEOVER] timing. The engine will stop after a [ COOL DOWN ] time. If the engine shuts down, because of an alarm, the KM closes independently of the Mains status if the [ NFPA-110 ] is on, otherwise, the KM will close only if the parameters of the Mains are within the programmed settings. In AUTO mode, the BeK3 will periodically test the engine if the periodic test is correctly programmed. During the test, the yellow LED AUTO in mode will continue to blink. The BeK3 can start and stop the engine if the remote control is activated.
THE TEST MODE
Push and hold the [AUTO] push button until the yellow LED blinks. The BeK2 will start the engine and transfer the load to the Generator only in case of MAINS failure if not otherwise programmed by the parameter [KG TEST CONTROL]. To exit the TEST mode, push the [AUTO] push button shortly or select another mode of operation.
THE MANUAL MODE
Push the [MAN] pushbutton to select the MAN mode. Push one of the [I-START] pushbuttons until the engine starts; the display will automatically open the ‘ENGINE STATUS PAGE’ with information about the start sequence (see section 5.04A). During cranking the Be-K3 turns off the light of the display.
When the engine is running, the green LED, on the engine drawing, turns on. Wait until the green LED Generator Available turns on. Push the [ KG ] push button to close the generator contactor. To transfer the load to the Mains wait for the Green Light Mains available and push the [ KM ] pushbutton: the KG will open and KM will close after a 2-second delay; the programmable changeover timer works only in AUTO mode. To stop the engine, push one of the [0-STOP] pushbuttons until the [STOPPING] message appears on the display. If the engine has already stopped, it is possible to reset the stop sequence by pressing the [0-STOP] pushbutton.
THE OFF MODE
Push and hold, for 2-3 seconds, the [ 0-STOP ] pushbutton: you turn OFF the Be-K3 and clear the fault alarms. You are allowed to program the parameters or modify settings. Push [ MAN ] or [ AUTO-TEST ] pushbutton on the front panel to turn on the AMF CONTROLLER on.
AMF CONTROLLER PRICE
If your business is to make AMF panels you can purchase a sample of the BeK3 AMF controller. You can evaluate the product.
PURCHASE YOUR AMF CONTROLLER
You can pay online or ask for a Proforma Invoice and pay via bank transfer
299€
FREE-SHIPPING WORLD-WIDE
SUPPORT
+39 335 70 77 148
SAVE MONEY BY PURCHASING TWO PIECES
199€/each
FREE-SHIPPING WORLD-WIDE
You can pay online or ask for a Proforma Invoice and pay via bank transfer
SUPPORT
+39 335 70 77 148
AMF CONTROLLER REMOTE CONTROL MONITORING
The BeK3-PLUS automatic mains failure controller features an RS485 serial interface capable of supporting Modbus RTU. We offer GSM remote monitoring, TCP/IP connection, and Modbus remote monitoring.
The most simple way to monitor your standby generator is by using SMS: the most stable and reliable solution.
READ MORE ABOUT GSM MONITORING
BY ADDING THE BE16-K3 GSM GATEWAY AND A 4G-5G MODEM YOU WILL GET FULL MODBUS CONTROL OF YOUR POWER GENERATOR VIA A SET OF SMS COMMANDS
PURCHASE OF THE BE16-K3 GSM SYSTEM DOES INCLUDE THE 4G-5G F1403 INDUSTRIAL-GRADE MODEM.
PURCHASE THE KIT
399€/each
FREE-SHIPPING WORLD-WIDE
You can pay online or ask for a Proforma Invoice and pay via bank transfer
SUPPORT
+39 335 70 77 148
THE F1403 MODEM IS INCLUDED IN THE KIT TOGETHER WITH ALL ACCESSORIES NEEDED TO IMPLEMENT A GSM POWER GENERATOR MONITORING SYSTEM
In the following table, you can see the basic SMS commands that will allow you full access to your standby system
| STATUS | It sends a request to read the engine's status and mode of operation and to read the power supply of the BE16 module. |
| ALARM | It sends a request to get information about active alarms. In case there is no active alarm, you will receive the message ‘NO ALARMS’. |
| GENP | It sends a request to read all the instruments related to electric power. |
| GENV | It sends a request to read the voltages, currents and frequency of the generator. |
| MAINS | It sends a request to read the voltages and frequency of the Mains. |
| ENGINE | It sends a request to read Battery Voltage, Speed, Oil Pressure, Fuel %, Temperature, and h-meter. |
|
CLEAR (*) |
It clears a warning or it cancels a shutdown. Please note that in case of a shutdown, the Be16 will force the BeK3 to enter the OFF mode of operation. After that, you are required to take an action. Otherwise, the controller will remain in OFF mode of operation. |
| OFF | It commands the BEK3 to enter the OFF mode of operation and eventually shuts down the engine. The command is ignored if the BeK3 controller is in manual mode of operation. |
| AUTO | It forces the BeK3 to enter the AUTO mode of operation (only if it was in OFF mode). You cannot change a MODE of operation if the BeK3 is locally in MANUAL mode. So, this command is ignored in the MANUAL mode of operation |
| TEST | It makes the BeK3 start the engine. If the option [KG TEST CONTROL] (see section 8.03 of the OEM manual) is set to [ON], when the electrical parameters are within programmed settings, the BeK3 will transfer the LOAD to the generator. This function works only if the BeK3 is in the AUTO mode of operation. To stop the engine or quit the function, send the SMS ‘AUTO’. The BeK3 will enter the AUTO mode of operation. If all conditions are met, the BeK3 will stop the engine. |
AMF CONTROLLER LONG TERM RELIABILITY
This is how it looks like a controller after 12 years of service day and night on a beach resort
Thanks, for the high-quality materials and silicon gasket, this is how it looks like the AMF controller after 12 years of full exposition to elements.
12 years of exposition to the elements
The customer asked us to replace the metal cabinet but we recommended refurbishing it with a special coating resin. The control panel is fully functional. A replacement of the cabinet is time-consuming.
12 years of exposition to the elements
After seeing the shocking images of the panel, you will experience a bigger shock looking at the interior of this AMF panel.
12 years of exposition to the elements
As you can see, the AMF controller seems brand new. There is no particular evidence of rust or damage. It works perfectly.
BERNINI DESIGN SRL
ITALY
Industrial Park
46035 OSTIGLIA
SUPPORT
+39 335 70 77 148