BeK3-ZERO AMF CONTROLLER

          BEK3-ZERO AMF INSTALLATION MANUAL

The AMF Controller BeK3-ZERO is an Automatic Mains Failure module designed for industrial power generators. It easily interfaces with diesel-gas-gasoline engines via analog or digital sensors. This controller is suitable for Automatic Mains Failure control panels up to 1000kVA.

EQUIPEMENTS POUR GROUPES ÉLECTROGÈNES BEK3

 

BY FOLLOWING OUR APPLICATION NOTES YOU WILL BE ABLE TO MAKE ANY AUTOMATIC MAINS FAILURE CONTROL PANELS. YOU CAN FIT THE BEK3-ZERO CONTROLLER ON A GENERATOR AS WELL IN A WAY TO TRANSFORM YOUR POWER GENERATOR INTO HIGH-TECH STATE OF ART AUTOMATIC POWER GENERATOR BY ADDING ONLY 2 AUTOMOTIVE RELAYS.

IF YOUR ENGINE IS CANBUS COMPATIBLE YOU CAN USE THE BEK3-CAN CONTROLLER

SUITABLE FOR GSM - GPRS - TCP/IP - MODBUS REMOTE CONTROL & MONITORING

MAINS+GENERATOR INSTRUMENTS
 ENGINE INSTRUMENTS
200 LOG EVENT REGISTER
MORE THAN 150 ADJUSTABLE SETTINGS
ON SITE TROUBLESHOOTING
AMF+ATS+ENGINE CONTROLLER ALL IN ONE UNIT

 

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AVERAGE DELIVERY TIME 72 HOURS.

 

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BEk3 COMBINED ATS & AMF CONTROLLER

 What is an AMF Controller? AMF controller means Automatic Mains Failure controller. This kind of controller is used in generator control panel when you have to control a generator that is connected in standby configuration. It is about a system that is waiting for a failure of the power utility. A panel fitted with an AMF controller automatically controls the connection assignment of the LOAD to POWER UTILITY or GENERATOR. The generator control panel avoids back-feeding by using mechanical and electrical interlock. In other words, inside the panel there are two contactors that connect the load to power utility or generator. It is not allowed the connection GENERATOR-POWER UTILITY. The panel includes the AMF controller and contactors and additionally includes the automatic battery charger and a set of electronic circuit boards complete with power relays. The AMF controllers interfaces with the engine by means of relays. The AMF controller is conveniently tasked with driving the contactors via driving relays as well.

To read more about AMF panel you can visit the AMF control panel tutorial page

BEK-ZERO AMF CONTROLLER FRONT FASCIA

BEK3-ZERO FRONT FASCIA

 THE BEK3-ZERO AMF CONTROLLER IS AN USER FRIENDLY AMF CONTROLLER 

As you can see from the image, the functions of this AMF controller are intuitive. The area indicated [1] is the alarm panel. It indicates the presence of an alarm. The LCD displays is able to provide alarm information and log event record as well. By using the [ACK] push button you can silence the horn and push the alarm into the memory. The panel [2] allows you full manual control of the engine. You can start and stop the set. Two greed LED indicators informs you about the presence of the generator voltage. A green indicator informs you about the status of the engine. The panel [3] is committed to manually control the status of the circuit breakers. By using the commands [4] you can change the mode of operation. The indicators in the area [5] inform you in real time about the presence of the utility power and generator together with indications of the circuit breaker status. The areas [6] and [7] contain the push buttons that will allow you to easily navigate the display. The display [7] features tens of very-well organized menus about instruments, parameters, alarms and miscellaneous information.  

THE MOST RATIONAL & COMPACT AMF CONTROLLER

The BeK3-ZERO AMF controller is easy to connect. It provides the basic I/0 functions to control a power generator. You can install the controller on a power control panel like an AMF or ATS panels. The rear protection cover is made of special magnetic-steel. This will provide an extraordinary shield against magnetic field generated by the switching of the changeover power breakers.

ENLARGE THE WIRING DIAGRAM

These are the basic features of the BEK-ZERO AMF controller:

REVERSE POWER & EARTH FAULT MONITORING

INDICATES kVA kVAr kW PF AAC VAC HZ  kWH

35 OPTIONS FOR EACH PROGRAMMABLE INPUT 

80 OPTIONS FOR EACH PROGRAMMABLE OUTPUT

200 EVENTS LOG HISTORY TAGGED BY REAL TIME CLOCK

600VAC 3-PHASE GENERATOR/MAINS MONITORING

RS485 MODBUS-RTU, GSM & TCP-IP CONNECTIVITY

AMF DAILY SCHEDULER & DAILY AUTOMATIC TEST

SEND NOTIFICATIONS ABOUT FUEL CONSUMPTION

BEK3 AMF INSTALLATION MANUAL

AMF  CONTROLLER MANUFACTURER

 Bernini  Design Srl Zona Industriale, 46035 Ostiglia Italy

 support@bernini-design.com   Tel 0039 335 7077148   24/7/365 support 0040 721241361

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PRECAUTIONS IN USING GENSET CONTROLLERS

MAKE YOUR GENERATOR CONTROL PANELS USING OUR EQUIPMENT

AUTOMATIC BATTERY CHARGER 2017 NET PRICE LIST

We provide Automatic Battery Chargers suitable for standby generator control panels for 12V & 24 batteries

POWER CONTACTORS 4 POLES WITH INTERLOCK & AUX CONTACTS

To make an automatic mains failure panel you need contactors as well. We provide solutions with 4 poles from 25 upt to 500AMPS. We can guarantee short circuit current up to 50.000 Amps and 25.000 operations at full load rated AC3.

BE142 AMF PANEL PRICE LIST    READ MORE ABOUT CHANGEOVER SWITCH      READY FOR USE PANELS           2016 CONTACTORS PRICE LIST

CHARACTERISTICS
Nominal Voltage: 690V
Nominal Current: 135A
Short Circuit: 50kA
Inrush Coil Power: 260VA
Holding Coil Power: 22VA
Coil Supply (Vac): 160-250V
Coil Supply (DC): 18-28V
Electrical Life: 25K operations
Insulation: 4KV

CHARACTERISTICS
Nominal Voltage: 690V
Nominal Current: 80A
Short Circuit: 50kA
Inrush Coil Power: 250VA
Holding Coil Power: 18VA
Coil Supply (Vac): 160-250V
Coil Supply (DC): 18-28V
Electrical Life: 25K operations
Insulation: 4KV

AMF CONTROLLER REMOTE CONTROL & MONITORING SOLUTIONS

 The BeK3 AMF controller features an RS485 serial interface that allows you remote monitoring via MODBUS, TCP-IP or GSM. Some screen shots are shown to explain the basic features of the system. The software is provided free of charge.

MODBUS MONITORING            GSM MONITORING             TCP-IP MONITORING
MAKE YOU OWN AMF controller
MAKE YOUR OWN AMF CONTROL PANEL

 THE MOST RATIONAL & COMPACT AMF CONTROLLER

As you can see how it is really easy to arrange all necessary components to make a cost effective AMF control PANEL. You can observe the BEK-ZERO controller [1] connected to all parts. The voltage measurements for the mains and generator are protected by fuses [2]. The battery charger [4] is protected as well. You can observe the contactors together with their own auxiliary contacts and mechanical interlock [5]. The current transformers are connected on the load side [6]. Then, finally the terminal block [8], [9] and [10]. An emergency switch [7] is also recommended. The BeK-ZERO controller interfaces with the engine via the output relays [3].  

 

TIRED TO WORK? YOU CAN PURCHASE OUR AMF CONTROL PANELS

 

HOW TO USE AN AMF CONTROLLER

When you apply the DC supply, the display indicates for a second, the version of the software and the date of production. A mode of operation is selected by push buttons and indicated by means of a yellow LED (indicators). Every time you activate a mode of operation, the display indicates a descriptive message (example [auto]). Every time the power supply is switched on, if the AMF controller was in TEST or AUTO prior to power down, the AMF controller returns to the “AUTO” mode. In the other cases, the AMF controller will enter the OFF mode.

HOW TO SHUT DOWN AN AMF CONTROLLER

To shut down the AMF controller and inhibit all function you are required to push and hold the button [OFF] to enter the OFF mode. The OFF mode of operation clears the fault alarms and allows you to read or program parameters or simply to disable the AMF controller. The load is always connected to the power utility. The Display Back-light and LEDs are turned off to reduce power consumption. Push one of the push buttons on the front panel to turn on the display. Push the [MAN] button to enter the manual mode of operation or push the [AUTO] button to enter the auto mode of operation. 

HOW TO ENTER THE AMF CONTROLLER MANUAL MODE

Push the [MAN] push button to select the MANUAL mode. Push the [I] START push button until engine starts; the display indicates the message [STARTING] during the starting attempts and information about pre-glow.
When the engine is running, the green LED indicator turns on. Push the [ I ] (KG) push button to close the contactor of the Generator. To transfer the Load to Mains, push the [I] (KM) push button (the [KG] will open). To open a circuit breaker, push the [O] pushbutton. In manual mode the CHANGEOVER timer lasts one second. To stop the engine, push the [0] STOP push button until the [StOP] message appears on the display. If the engine has already stopped, it is possible to reset the STOP sequence by pressing the [STOP] pushbutton.

HOW TO SELECT THE AUTO MODE OF OPERATION ON THE AMF CONTROLLER

Push the [AUTO] push button until the yellowLED illuminates. The engine starts when the AMF controller detects a Mains failur. The circuit breaker of the MAINS (KM) opens after the BREAKER timing. After the warm-up time, if the Voltage and Frequency are within the settings, the circuit breaker of the Generator (KG) will close. If the Mains restores, the KG will open. The KM will close following a programmed changeover timing. The Engine will stop after a cooling down time. If the engine shuts down, the KM closes independently of the Mains status if NFPA-110 mode is selected, otherwise the KM will close only if the Mains is within programmed settings. In AUTO mode, the AMF controller will periodically test the engine if the scheduler has been programmed. During this test, the yellow LED of the AUTO mode will continue to blink. In AUTO mode, the AMF controller can start and stop the engine according to programmed inputs (see the programming manual).

HOW TO TEST AN AMF CONTROLLER

Push & hold the [AUTO] push button until the yellow LED illuminates. The AMF controller starts the engine and transfers the load to the Generator if allowed by your settings. To stop the engine, select the AUTO mode (if Mains is present) or select the OFF mode. If the mains fails during the TEST , the AMF controller will transfer the load to generator (supposing the generator parameters are within programmed limits). If you push the [0] push button when the AMF controller is in AUTO or TEST mode, the local emergency alarm will energise. To clear the alarm, you are requires to enter the OFF mode of operation.

CALIBRATING THE BEK3-ZERO AMF CONTROLLER

The BeK3-ZERO controller is supply with a factory measurements precision of about +/-1.5%. You can reduce the error down to zero by carrying out the on-site calibration. To do this, follow the instructions.

1) - Make sure the Battery voltage is over 12.0 Vdc and select the MAN mode. Start the engine if you need to calibrate a parameter of the generator or,

2) - Push and hold the [F9→] and [ACK-F10] push buttons simultaneously, for about 5 seconds, until the yellow LED [h/Prog.] starts to blink and display indicates [-CAL]; release the buttons.

3) - If the Be142 programming is password protected, the message [42.42] will appear; follow the instructions in table 6.11. If the Be142 is not password protected, the parameter [n1.n2] will appear on the display and you can proceed as indicated in section 12.2

Calibrating a measurement   (Note: to exit the procedure push the [OFF] push button at anytime)

1) - Press the [←F8] or [F9→] push button to select a 'Parameter name' (see Table 1).

2) - Press the [ACK-F10] push button to display the reading of the measurement (example 395 V).

3) - Press the [TEST ↑] (or [AUTO ↓]) to adjust the reading according to an external reference (example 400 V).

4) - When finished, push the [ACK-F10] again to display the 'Parameter name'. Select another 'Parameter name' to calibrate by pushing the [←F8] or [F9→] push button. When finished, you have 3 options: 5A, 5B or 5C.

5 A ) - Exit the procedure without saving by pushing the [OFF] push button.

5 B ) - Restore the factory default calibration: press and hold the [←F8] and [F9→] pushbuttons simultaneously until the display blinks twice. You are required to save the setting as indicated in step 5C).

5 C ) - Save the calibration: push and hold the [ACK] and [F9→] push buttons simultaneously until the [SAVE] message appears (approximately 5 seconds); the Be142 saves the calibrations and remains in Manual mode.

 

 

Table 1 - AMF controller - List of the Measurements

 

'Parameter'

Description

Unit

Recommended Calibration Range

[MAINS R-S]

Mains Voltage phase R-S

Volt

 

300 up to 400 Vac

[MAINS S-T]

Mains Voltage phase S-T

[MAINS R-T]

Mains Voltage phase T-R

[GEN HZ]

Frequency (Mains/Generator)

Hz.

45 up to 55 Hz

[L1-L2]

Generator Voltage L1.L2

Volt

 

300 up to 400 Vac

 

[L2.L3]

Generator Voltage L2.L3

[L1-L3]

Generator Voltage L3.L1

[C 1]

Generator Current L1

Amp

 

4 up to 5 Aac (C.T. output)

[C 2]

Generator Current L2

[C 3]

Generator Current L3

[V BATT]

Battery voltage

Vdc

Voltage of the battery

[BAR]         (°)

Oil Pressure

Bar

2 Bar up to 4 Bar

[°C]           (°)

Engine Temperature

°C

80 °C up to 100 °C

[FUEL %]     (°)

Fuel Level

%

80% - 90%

An AMF controller (Automatic Mains Failure Controller) is mandatory in cases where you have to control a generator that is connected to the power utility in a standby configuration. In this case will call the power generator with the term Standby Generator. The AMF controller manages, in a fully automatic way, the connection assignment of the LOAD to MAINS or STANDBY GENERATOR avoiding direct connection MAINS to GENERATOR.  The panel AMF controller works in a control panel together with ancillary equipment:  battery charger, electronic circuit boards,  power relays  and so on. The AMF controller is conveniently tasked with driving the power contactors. The size of the contactors define the required power rating of the panel.  Available sizes on the market are normally in the range 25-250kVA.  An advanced AMF controller features a range of adjustable settings and is engineered to comply with NFPA110 CAN/CSA-C282-M89 standards. An AMF controller must include an RS485 for GSM/GPRS/TCP-IP communications and an optional CANBUS interface to communicate with CANbus engines.

READ MORE ABOUT CONTACTORS AND CHANGEOVER CIRCUITS

 

WHAT IS AN AMF CONTROLLER AND WHY WE SHOULD USE IT

The most critical set up is about power utility settings. As a matter of fact the main job of the AMF controller is to detect a failure of the power utility (so-called MAINS). A power outage can be total or partial. Can last for a few milliseconds, seconds or days. A BERNINI DESIGN made AMF controller is unique in the world. We have separated timers for power utility breaker and engine start delay. The timers can be programmed up to 24 hours. In addition to settings about Voltage, Frequency, Phase Sequence, Phase Unbalance BERNINI DESIGN has a special 'SELF LEARNING' software. It is a sort of 'FUZZY' logic that learn the characteristics of the Mains. The software continuously compare the variation of the Mains with the setting and the log history. This provides extraordinary results in system stability and fuel consumption saving.   

MAINS (POWER UTILITY) ADJUSTABLE PARAMETERS

 

UTILITY POWER ADJUSTABLE SETTINGS FOR AN AMF CONTROLLER

Supply voltage: 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: -25 deg C up to +70 deg C. Humidity range: 5% up to 95% non-condensing.

Weight: 710 grams General design: ECC 89/336, 89/392, 73/23, 93/68, IEC 68-2-6. Certification: CE

Static outputs characteristics: Output Current: 300mA/100Vdc short circuit proof. Logic: negative.

Supply output for relays (terminal JC8): Max 1A at V battery minus 1Vdc (short circuit proof).

Mains and Generator voltage input: Nominal Voltage input: 70 Vac-600Vac.

Over voltage: 4KVac phase to neutral. Measurement precision: +/- 1%. Input impedance: 2 Mega Ohm

Current transformer input size: 10/5Aac up to 9900/5Aac. Maximum admissible permanent current: 7Aac

Measurement precision: down to +/- 0%. Internal resistance: 0.05 Ohm  CT SIZE: 10/5 up to 2000/5

Digital inputs: Open circuit voltage: Battery voltage minus 2V - Trigger level: < 2Vdc (max 15mA).

Charger alternator monitoring: Operating voltage up to 36Vdc/3W. Vdc reading accuracy: +/- 5%.

 

THE BEK-ZERO AMF CONTROLLER SPECIFICATIONS

Supply voltage: the voltage range of the battery to guarantee a good performance of the controller.

Beyond the specified limits the controller may not work or could suffer severe damage.

Supply over voltage: the maximum non-repetitive voltage on the supply terminal (0,1/1 sec) 

Dimensions: it is about the total dimensions of the controller.

Panel Cut-out: the size of the hole that you are required to make on the panel door

Operating temperature range: /Humidity range. Climatic limits in which the controller can work normally.

Weight: the total net weigh of the controller without packaging material

Static outputs characteristics: the maxim voltage and current provided by a single output  

Logic: positive (PNP output)  or negative (NPN)

Supply output for relays: the maximum allowed current.

Mains and Generator voltage Nominal Voltage input: the voltage operational limits of the AMF controller.

Damage may be expected applying voltage beyond the specified limits, for uncontrolled period of time.  

Mains & Generator over voltage: the maximum allowed voltage applied for 60 seconds

Measurement precision: the maximum error of a measurement

Mains and Generator Frequency: the frequency operating range. No damage is expected beyond these limits

Current transformer input size: the minimum and maximum size of a current transformer (5Amp secondary current)

Digital inputs voltage: the maximum measured voltage when the input is 'open' 

Digital inputs current: the maximum measured current when the input is 'closed' 

Trigger level: the level of voltage that switches the logic condition H>L or L>H

Definition of 'Resolution': smallest discernible change of measurement result due to a minimum change in the input.

Definition of 'Accuracy': deviation from the actual value as fixed by universally accepted standards of frequency and time.

 

 

UNDERSTANDING THE AMF CONTROLLER SPECIFICATIONS

The basic distinction you have to do is about the final application. Bernini Design is mainly a generator panel manufacturers with over 500,000 applications worldwide. We established four segments in the market: COMMERCIAL / INDUSTRIAL / TELECOM / HOME. For each segment we designed an AMF controller very well optimized for its goals. For COMMERCIAL market (or light industry) we developed a cost effective, maintenance free AMF controller: the BE142. For industrial applications the suitable AMF controller is BeK-ZERO (BeK3 for CANbus compatible engines). For the TELECOM market the proper product is BE2K-PLUS. For home generator 4-6-9kVA we recommend that you use the EVOLVE AMF controller. You can browse the following links:

BE42       BE142      BEK3      BE2K-PLUS      EVOLVE

 

WHAT KIND OF AMF PANEL I CAN MAKE WITH AN AMF CONTROLLER BERNINI DESIGN

ALTHOUGH THE AMF CONTROLLER HAS BEEN DESIGNED IN ACCORDANCE WITH INTERNATIONAL SAFETY STANDARDS, THE AMF CONTROLLER MANUAL CONTAINS INFORMATION, CAUTIONS, AND WARNINGS WHICH MUST BE FOLLOWED TO ENSURE SAFE OPERATION AND TO RETAIN THE AMF CONTROLLER IN SAFE CONDITION. SERVICE AND ADJUSTMENTS SHOULD BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL. ANY ADJUSTMENT, MAINTENANCE AND REPAIR OF THE OPENED AMF CONTROLLER UNDER VOLTAGE SHOULD BE AVOIDED AS MUCH AS POSSIBLE AND, WHEN INEVITABLE, SHOULD BE CARRIED OUT ONLY BY A SKILLED PERSON WHO IS AWARE OF THE HAZARD INVOLVED.

 

AMF CONTROLLER SAFETY CONSIDERATIONS