7060 NW 52nd Street, Miami, Fl.

, 33166
Tel (786) 336-5780, fax (786) 336-5790
E-mail:info@[Link]

X803 ELECTRONIC CARD

Control unit for generating sets

OPERATING MANUAL

The technical data and description in the operation manual is subject to alterations and changes at any time and have no
contractual value. The X803 device should be used by skilled and qualified personnel and in compliance with the regulations in
force for electrical systems in order to avoid damages to persons and property.

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CONTENTS Page
DESCRIPTION 3
Front plate 3
OPERATING MODE DESCRIPTION 4
RESET Mode 4
AUTOMATIC Mode 4
MANUAL Mode 4
TEST Mode 4
OPERATING DESCRIPTION 5
Start-up cycle of generating set 5
Stop cycle of generating set 5
Engine started signal 5
Mains voltage present 6
Generator voltage present 6
Mains/Gen and Gen/Mains 6
changeover
Alarm tripping 7
Siren relay 7
Global alarm relay 7
Readings display 7
Generating set’s operation hour-meter 8
Maintenance 8
FUNCTIONS 9
Automatic test 9
Enabling and disabling automatic test 9
Emergency stop 9
Remote starting 9
Remote stop 10
EJP function 10
EJP/T function 10
SCR function 10
Closed coupled pump operation 10
Decelerator function 11
Gas solenoid valve function 11
Starter function 11
Air function 11
REMOTE CONTROL 11
INFORMATION - ALARMS- 12
ERRORS
Information 12
Alarms 12
Alarms table 14
Errors 14
INPUTS AND OUTPUTS 14
Inputs table 14
Outputs table 14
PROGRAMMING 15
PARAMETERS 15
Option menu 15
Set up menu 16
TECHNICAL CHARACTERISTICS 17
REFERENCE STANDARDS 19
TERMINAL BLOCK CONNECTIONS 20
DIAGRAMS 21

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DESCRIPTION
The digital control unit X803 is a device able to conduct RMS RESET Mode
voltage reading and accurate timely controls of all the necessary • When the unit is in RESET mode, all outputs are de-energized,
functions, to obtain the optimum operation of the generating set. in other words in the same condition as when the set is
The extensive programming of input and output functions as well unpowered, except for the global alarm output that continues to
as the numerous operating parameters contribute to the X803 unit operate as normal.
a flexibility so that it is easily adaptable to different application • In this mode the mains remote control relay stays on standby,
requirements. with the contact closed.
The version with RS485 serial interface provides the generating • In addition, the control inputs and siren output are disabled.
set to be remotely supervised without any limitation. • Whereas the warning LED's, reading display and alarms are
active.
Front Plate • When passing from MAN/AUT/TEST mode to RESET mode
• 3-digit display for reading, alarm, message or error indication and the generating set is running, the unit proceeds to stop it
• RESET-MAN-AUT-TEST keys for operating mode selection automatically without waiting for the cooling time (option P.09).
• SELECT-MIS key for display selection
• START-STOP keys for engine starting and stopping in manual AUTOMATIC Mode
mode • In AUT mode, when there is no mains voltage after the delay
• MAINS (TLR)-GEN(TLG) keys for mains and generator contact for mains voltage absence (option P.03), the mains contact
change-over in manual mode output is de-energized and the starting cycle of the generating
• RESET- AUT - MAN -TEST LED’s for indication of selected set is begun.
operating mode • When the generating set is running and the generator voltage
• MAINS(VRE)-GEN(VGE)-Hz-BATT(Vcc)-HOUR LED’s for is available, after generator voltage presence delay (delay for
indication of selected reading generator contact closing (option P.08)) has lapsed, the
• ENGINE ON LED to indicate engine running generator contact output is energized.
• Mains (L1-L2, L2-L3/L-N, L3-L1) and generator voltage • At the return of mains voltage and after the delay for mains
indication LED’s voltage presence (option P.04), the generator contact output is
de-energized, the mains contact output is energized and then,
• Generator and mains contact status LED’s
the stop cycle of the generating set is activated.
• The external controls of the emergency stop and remote
starting are enabled.

MANUAL Mode
• In MAN, the generating set can be started or stopped by
pressing START or STOP keys. An unrequired STOP control
can be invalidated at once by pushing the START key.
• It is possible, to change the contactor MAINS(TLR)or
GENERATOR(TLG) or vice versa, for to make this it's
necessary pressing the MAN button together button
(TLR)MAINS or (TLG)GENERATOR
• The control of the generator contact output is inhibited if the
generating set is not running.
• A mains/generator interlock time (set up -15) is always
imposed at each load changeover control, between the de-
energizing of one output and the energizing of another.
• The passage from AUT or TEST to MAN mode leaves the
operating state of the generating set unchanged.

TEST Mode
• The start cycle of the generating set takes place whenever
OPERATING MODE DESCRIPTION TEST mode is selected.
• The load is automatically switched over to the generator only
Note In this manual, all underlined texts refer to those with the lack of mains voltage. At its return, the load remains
parameters that can be programmed through access to the on the generator.
two menus named OPTION and SETUP. See the • Reinstating AUT mode, in presence of mains voltage, the
corresponding section for further information. changeover to the mains can take place and the generating set
is stopped.
• The X803 unit can operated in four different operating modes:
RESET, AUT, MAN and TEST
• By pressing one of the operating mode keys, the relative LED
switches on indicating the exact operating mode selected. The
change from one operating mode to another is possible at any
time.
• The operating mode remains stored even if the supply is
removed.
• The flashing operating mode LED indicates that the unit is con-
trolled by a supervising system. Since the controls can be
remotely conducted, it is essential to operate with care.

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OPERATING DESCRIPTION generating set voltage, thus applying the threshold specified by
the following parameter: generating set voltage started motor
Start-up cycle of the generating set threshold (set-up -07).
The generating set start-up cycle includes the following operations • In every case, for safety reasons, the started motor signal is
in MAN, AUT, TEST modes or by remote starting facility: also detected by overcoming the generating set minimum
• If preset, glow plug preheat output is energized. voltage intervention threshold (option p.05). If there is
generating set voltage, the motor is considered as started.
• The fuel solenoid valve output is energized two seconds before
the lapsing of glow-plug preheat time (set up -19), • The started motor signal is visualized by led “ENGINE ON”.
• After these two seconds, the glow plug preheat output is de-
energized and the start output is simultaneously energized for Mains voltage present
a time equal to the starting attempt duration (set up -11). • If the three-phase/single-phase mains voltage control (set up -
• If the glow plug preheat output is not programmed, the fuel 37) is programmed as three-phase, it is conducted on the three
solenoid value output energizes always for two seconds before voltages between lines. An asymmetry control is carried out in
the start output is. addition to the voltage one.
• During the starting attempt if the engine starts, the start output • The mains voltage is considered present when the voltages
is instantly de-energized. between lines L1-L2, L2-L3 and L3-L1 are within the minimum
mains voltage trip threshold (option P.01), maximum mains
• If the engine running signal is not detected within the starting
voltage trip threshold (option P.02) and maximum mains
attempt duration (set up -11), the interval between starting
asymmetry (set up -42) limits. The presence of voltage is
attempts (set up -12) begins.
indicated by the L1-L2, L2-L3 and L3-L1 LED’s when switched
• In case of false start-up, another equal number of starting
on.
attempts (set up -10) is repeated as per the preset value.
• In AUT mode, mains contact output is energized after mains
• After the engine starts if the engine-started signal is no longer
voltage presence delay (option P.04).
detected, the start output is re-energized once again after the
• The mains voltage is considered absent when one or more
delay between false start and the subsequent start (set up -13)
voltages between line, L1-L2, L2-L3 and L3-L1, are not within
(if preset). This starting is not included in the starting attempts
limits indicated above. The absence of voltage is shown when
count.
the L1-L2, L2-L3 and L3-L1 are switched off if the relative
• The actual interval between starting attempts is equal to the
voltage between lines is not within the preset minimum and
total time of the starting attempt interval (set up -12) and, if
maximum threshold limits. Otherwise the LED’s are flashing if
preset, also the time for glow plug preheat duration (set up -
the voltage is within the limits but asymmetry is higher than the
19). During this interval, the fuel solenoid valve output is de-
pre-set value.
energized and, if preset, the stop magnet output is energized to
• In AUT mode, mains contact output is de-energized after the
assure engine stopping before the subsequent starting attempt.
lapsing of the mains voltage absence delay (option P.03).
• “StA” (Start) is indicated on the display during the start-up cycle
• In the case of single-phase mains voltage, the set must be
and until the engine is running.
programmed as a single-phase control. IN this case the control
• If the engine has not started after the preset number of starting
will only be made on the voltage at terminals 22-21, in the
attempts (set up -10), the audible alarm is energized and “A10”
same manner as the three-phase control. In this case the LED
(STARTING FAILURE) alarm is displayed.
involved in the control is L2-L3/L-N, whereas the others will be
• The alarm is reset by means of /RESET key. off.
Stop cycle of the generating set Generator voltage presence
The stop cycle of the generating set comprises the following
• Generator voltage control is only single phase.
operations in MAN or AUT modes:
• Generator voltage is considered present when its value falls
• “StO” (Stop) appears on the display.
within minimum generator voltage trip threshold (option P.05),
• The generator contact output is de-energized, the cooling time maximum generator voltage trip threshold (option P.06). The
(option P.09) of the engine starts. presence of voltage is indicated when the relative LED GE
• At the end of the cooling time (option P.09), the fuel valve VAC is switched on.
output is de-energized and the stop magnet output is • The alarm for the lack of generator voltage can be tripped at
energized, if preset. the absence of the generator voltage failure delay (option P.07)
• Once the engine-started signal is no longer detected and after after the engine-started signal. This delay time can eventually
the subsequent energizing time of stop magnet (option P.09) include slow-running time (set up -18), if preset.
has lapsed, the stop magnet output is de-energized. • In AUT mode, generator contact output is energized after the
• In case of alarm that provides for the stopping of the generator voltage presence delay (option P.08), which thereby
generating set or when in RESET mode, the cooling time takes on the function of a delay for putting a load on the motor
(option P.09) is not conducted. (contact closing delay).
Engine started signal • The generator voltage is considered absent when it is not
• The voltage threshold for the started motor detection can be within the limits mentioned previously. The voltage absence is
applied either to the voltage supplied by the battery-charger indicated when the LED is switched off.
alternator or to the voltage supplied by the generating set. This • In AUT mode, after the absence of generator voltage failure
choice can be made through the following parameter: started delay (option P.07), the mains contact output is de-energized.
motor signal choice (set-up -05).
• If the motor is detected as running by the battery-charger
• If set-up -05 is programmed onto 0, then the system will detect alternator signal, but the generator voltage is not present for
the started motor signal from the inlet of the battery-charger longer than the no generator voltage alarm time (set up -38)
alternator (permanent magnets or pre-excited type), thus alarm E04 is generated. This alarm can be disabled with the no
applying the threshold specified by the following parameter: generator voltage alarm disabling parameter (set up -35).
alternator voltage started motor threshold (set-up -06).
• On the contrary, if set-up -05 is programmed onto 1, then the
system will detect the started motor signal directly from the

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• This relay can be used for the gas solenoid valve function
(please see set-up -29). In that case, the global alarm signal is
Mains/Generator and Generator/Mains changeover not available.
• A mains/generator interlock time (set up -15) is imposed
between the mains contact output de-energizing and the Readings display
generator contact energizing and vice versa. • MAINS(Vre), GEN(Vge), Hz, BATT (Vcc) and HOURS LED’s
• In MAN mode, the load can be changed over to the mains or to are switched on by pushing the /MIS key,. indicating the
the generator by pressing MAINS(TLR) or GEN(TLG) key. relative reading on the display.
Press them together with the MAN button in order to avoid • The displayed readings are: mains voltage, generator
accidental movements. By pressing one of these repeatedly, voltage, generator frequency, battery voltage and the operating
the relative contact is closed or opened. hours of the generating set. Mains and generator voltages are
• The mains contact output is permanently energized when the expressed as RMS (root-mean-square) values.
control unit is not supplied. • The reading accuracy of the mains and generator voltages is
1VAC, 0.1Hz for generator frequency, 0.1VDC for battery
Alarm tripping voltage while 1 hour for the operating hours (true accuracy is 1
• The display normally shows one of the readings indicated by minute but it is not displayable).
the MAINS(Vre), GEN(Vge), Hz, BATT(Vcc) or HOURS LED’s. • To display the voltages between line of the three-phase line,
• In case of alarm, the display indicates the alarm code, the SELECT/MIS key is to be pressed three times. At each
meaning of which is given in the table on the X803 front plate. pressing, the LED corresponding to the voltage between lines
• Depending on the alarm importance, this can trip the will flash along with MAINS(Vre) LED.
generating set operation or energize the audible alarm output. • Usually the display visualizes the system voltage. When the
• In case more than one alarm is present at the same time, they motor is started up, the display automatically goes to the
are visualized on the display one after another. generating set voltage and vice versa. It is always possible to
• Almost all the alarms are retentive and remain in this status select the desired reading through the SELECT-MIS button.
even if the conditions that have generated the alarm no longer • In case of alarm and temporary impossibility to remove the
persist. Under these circumstances, the user is obliged to alarm, the readings can be displayed by pressing SELECT/MIS
identify the faults and remove the alarm state. For further key for 3seconds. If it is not pressed again for 20 seconds, the
details see the alarm table. display shows the previous alarm situation.
• The alarms are reset by pushing RESET, which has effect on
both the alarms and on the operating mode of X803. If the Operating hour counter of the generating set
alarm situations persist, resetting the unit is not possible. • Each time the engine is started, the hour counter for the
• In case the alarm situation cannot be resolved immediately, it operating minutes is activated.
is possible to have access to the readings by pressing the • The operating time is however displayed in hours.
SELECT-MIS key for 2 seconds. After 20 seconds since last • The control unit keeps the accumulated operating time stored
being pressed, the display reinstates the situation of the in lack of supply voltage.
previous alarm condition. • It is possible to modify and/or to alter the operating hours count
• More details on the alarms and their properties are given in through the following procedure:
“Alarms Table”. • 1. Select reading “Operating hours” through button SELECT-
MIS (LED HOUR on).
Siren relay • 2. Push the RESET button for more than 5 seconds until HOU
The siren relay is activated when there is an alarm. It stays appears on the display.
activated for a programmable time through the siren alarm time • 3. With buttons START and STOP you can increase or
parameter (option P.10). Afterwards, it is inactivated. decrease the count. By pushing them together, you
Furthermore, this relay is activated before starting up the motor automatically set the count to zero.
(due to an automatic test or to an external start or to an EJP • 4. Push RESET to store and exit.
start). In this case the sound has a fixed length corresponding
to 5 seconds and is followed by a 3-second pause before the Maintenance interval
real start-up. This will help maintenance operators realize that • Each time the engine is started, the hour counter for the
the group is going to be started up even if the mains are operating minutes for the maintenance requested interval (set
plugged in. up -16) of the generating set, expressed in minutes, is
If you want the siren relay not to be activated for reasons other activated.
than an alarm, it is possible to specifically program the • Alarm code “A05” (Maintenance requested) is displayed and
following parameter: siren signal activation before start-up (set- the audible alarm output is energized when the generating set
up -02). reaches the programmed operating hours for the maintenance
If the unit is in the reset mode, the siren will never be activated requested interval (set up -16).
even if an alarm is going on. • In presence of this alarm, the generating set can continue to
operate normally but at each new starting the audible alarm
Global alarm relay output is energized.
• The global alarm relay is activated when there is an alarm • After having carried out maintenance on the generating set, the
situation and it stays activated until all alarm situations are alarm is reset with the RESET button. This also zeroes the
terminated and until the operator has switched them off by maintenance hour counter.
pushing the reset button.
• If there is a power failure, the set keeps the operating time of
• The only alarms that do not require the closing of the global the generating set relative to the maintenance interval in
alarm relay are the external EO3 stop and, possible, the memory.
programmable alarms, provided that they have been
programmed in order to be visible alarms only.
• For the global alarm relay we have provided a separate
common switch and an exchange contact.

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generating set is stopped. On the other hand, if the mains

FUNCTIONS voltage is absent, the generating set continues to regularly
Automatic test operate supplying the load.
• Automatic test is the periodic start-up testing of the generating Remote stop
set at fixed intervals programmable by means of the automatic • When, in the AUT mode, the remote start-up inlet is closed, the
test interval time (option P.11). It has the purpose of checking equipment carried out the instantaneous opening of the
operation and/or keeping the generating set efficient. The generating set switch and the stop of the cooling cycle group.
duration of the testing is determined by the automatic test • The automatic start-up is inhibited. The display visualizes the
duration (option P.12), at the end of which the generating set is corresponding code (E03 External stop).
stopped. • Automatic re-activation with inlet opening.
• The beginning of automatic test is displayed by “[Link]” • For the operations requiring a connection of a floating contact,
(Automatic test), if enabled and if programmed to energize the this inlet avail itself of an anti-bounce filter that allows for the
audible alarm output for 5 seconds. At its de-energizing and signal to be changed over with a time not lower than 5
after a 3-second interval, the start-up cycle begins. seconds.
• During the test cycle, the load normally stays connected to the EJP function
mains and there is no switchover. • The EJP function can be activated through the set-up -03
• In the event of there being no mains voltage, the control unit parameter.
automatically changes over the load to the generator. At the • When this function is activated, the remote start-up inlet is
return of the mains voltage, the load remains on the generator. reprogrammed as EJP start ; the stop inlet is reprogrammed as
• At the end of the automatic test, in the presence of mains EJP change-over approval.
voltage, the load is changed over to the mains and the • When the start inlet is activated, the motor start-up delays after
generating set is stopped. EJP start (option P13) is also activated. At the end of it, the
• Automatic test can take place if the unit is in AUT mode and is start-up cycle is carried out. During that time, the display will
enabled. visualize EJP.
Enabling and disabling the automatic test • Then, when the changeover approval arrives (only if the motor
• The enable or disable function of automatic test does not has started up regularly), the mains/generator exchange is
influence the unit operation. Therefore, it can be done, at any carried out.
moment, independent of the operating mode of the control unit. • The load comes back to the mains after the changeover
• At the moment automatic test is enabled, a chronometer for the approval opening; the group performs the stop cycle at the
automatic test interval (option P.11), expressed in days, is opening of the start inlet.
activated. In this way, automatic test will regularly take place at • The EJP function is only enabled when the system is in
its exact enabling time. automatic mode.
• To enter automatic test enable or disable function, push • Protection devices and alarms work as usual.
SELECT/MIS and keeping it pressed, then push TEST key. EJP/T function
Either “OFF” will be displayed if the automatic test is disabled • The EJP function is a simplified version of the preceding EJP.
or, if pre-set, the number of days of the programmed automatic The motor start-up is controlled in the same way but the load
test interval (option P.11). Automatic test is enabled pressing changeover is carried out through a time delay and not through
START or disabled pushing STOP. a special external signal. This function only uses one digital
• If you want to change the test interval, please read the option entry (external start).
menu chapter. • The delay time in order for the changeover to be performed
• Press RESET to exit the enable/disable functions of automatic starts when the start-up control is closed; it is programmable
test. through the following parameter: changeover delay for EJP/T
• During this function if no keys are pressed for 120 seconds, the (option P14).
control unit will automatically exit this function. • In order to select the EJP/T function please program parameter
Emergency stop set-up -03.
• The emergency stop input is to be connected to a NC contact SCR function
otherwise the control unit will prevent all start attempts of the • The SCR function is very much like the preceding EJP
generating set. function; you can program it by setting the set-up -03 value to
• The emergency stop control (opening of the input contact) 2.
causes the immediate stopping of the generating set, • In this mode the external start entry allows for the start-up of
independently of the operating state of the unit, without cooling the group as in EJP but without waiting for the delay time.
time (option P.09), E01 alarm code (Emergency stop) appears • The stop entry still has the changeover approval function; the
on the display and the audible alarm output is energized. difference with the EJP function is that changeover takes place
• For alarm reset and audible alarm mute, the input contact of after the generating set voltage presence delay (option P08).
the emergency stop is to be necessarily pressing RESET. Motorized pump operation
Remote starting • In the motorized pump applications it is possible to use the
• In AUT mode, remote or external starting is enabled. following parameter: no mains intervention disabling (set-up -
• The remote starting control of the generating set is shown with 04). It disables the mains voltage control and the generating
“[Link]” (External start) display and, if preset, the audible alarm set no voltage alarm.
output is energized for 5 seconds. When the audible alarm • With this kind of operation, the motorized pump group start-up
output is de-energized after a 3-second interval, the start-up can be controlled either through the MAN mode (with START
cycle begins. or STOP buttons) or through the AUT mode (with the external
• The control unit automatically changes the load over to the start signals and external stop).
generator when the generating set is running and there is a • It is also possible to program the set-up -04 parameter so that
lack of mains voltage. the equipment detects alarms as usual or in such a way as to
• By removing the remote starting control, with mains voltage be able to visualize alarms without ever stopping the group
present, the load is changed over to the mains and the

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Decelerator function REMOTE CONTROL

• If the deceleration exit is available, this is activated as soon as
the motor has started up; it is inactivated at the end of the • X803 in its version with serial interface RS485 (ordering code
decelerated operation time (set-up -18). ..............), is capable of talking to a PC (or intelligent terminal)
to carry on functions of remote control and supervision.
• This function can be enabled as an alternative to the stop
magnet and to the pre-heat spark plugs. The choice is made • To ensure correct operation and reliability in an industrial
through the following parameter: programmable relay 1 environment, the set's RS485 interface is galvanically isolated.
function (set-up -17). • The link between the PC and RS485 interface of the X803 is
made with a galvanically isolated RS232-RS485 converter with
Gas solenoid valve function automatic control of the enable line.
• During the starting cycle, if a gas solenoid valve output has • X803. /RC is supplied with: PC/Windows supervision software
been provided for, this is activated after the gas solenoid valve diskette, supervision software user manual and communication
energizing delay (set up -30) by the activation of the starting protocol manual.
output. The gas solenoid valve output stays activated while the • The RS232-RS485 converter can be supplied separately,
motor is running. code: 4XC22348T
• When the motor needs to be stopped, the gas solenoid valve • Technical data of the RS485 serial interface:
output is deactivated 3 seconds before running approval is - Half-Duplex communication with 2 wires (braided pair with
removed (fuel solenoid valve). end resistors)
- Mutidrop configuration with the possibility of linking up to 32
Starter function stations
• The starter function relay is activated with the excitation of the - Transmission format 9600 baud, 8 bit data, 1 stop bit, no
gas solenoid valve during the first attempt to start the motor parity
only. - Maximum length of communication line 1000m
• It stays excited for a time that can be adjusted through the • Main technical features of supervision software:
following parameter: starter time length (set-up -31). - Total control of operator panel (front of X803)
- Possibility of remote control by modem with no restriction
• This function can be programmed onto the programmable relay
- Graphic and numerical display of all readings
2 as an alternative to the fuel solenoid valve or air function
- Alarm status display
(through parameter set-up -28).
- Display of status of all inputs and outputs
- Display of events with data and time (events-log)
Air function
- Possibility of displaying, editing, saving and/or loading the set
• The air function relay is activated two seconds before activating up and option data from files
the starter (only for the first three start-up attempts). It stays - Possibility of accessing the operating manual on-line.
closed for a maximum tine that can be adjusted through
parameter airtime length (set-up -32).
• If the motor starts up, the air relay is inactivated as soon as the
generating set voltage goes over the air inactivation threshold
(set-up -33).
• This function can be programmed onto the programmable relay
2 as an alternative to the fuel solenoid valve and to the starter
function (through parameter set-up -28).

INFORMATION - ALARMS - ERRORS

Information
The information codes on the display indicate a few of the most important activities of the control unit.

Messages table
Code Meaning Display condition
StA Start During the start-up cycle of the generating set
Sto Stop During the stopping of the generating set after the cooling time
[Link] Automatic test During the automatic test cycle
[Link] Remote starting With remote starting signal
EJP EJP function When the EJP start entry is active and the system is in automatic mode
Scr SCR function When the SCR start entry is active and the system is in automatic mode

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Alarms This is generated by the closing of the contact on the relevant

The alarm codes on the display indicate conditions or situations input.
why the generating set can or could not provide energy. This alarm can be programmed in order to stop the set or not
through the external alarm A09 (set-up -24).
A01 HIGH TEMPERATURE
When the engine is running, it is displayed, after alarm trip delay A10 STARTING FAILURE
(set up -08), when the input contact of the engine temperature is This is displayed when the number of starting attempts (set up -
closed. The tripping de-energizes the generator contact output 10) are carried out and the engine is not yet running.
and immediately stop the generating set, without any cooling.
A11 GENERATOR UNDER FREQUENCY
A02 LOW OIL PRESSURE Activates when, with the alarms on (the motor running for longer
With the engine is running, it is displayed, after alarm trip delay, than the alarm delay set up -08) and with the decelerator output
when the input contact of the pressure switch is closed. The deactivated, the generator frequency (depending on the number
tripping de-energizes the generator contact output and of motor spins) is inferior to the minimum frequency alarm
immediately stops the generating set, without any cooling. threshold (set up -41) that lasts longer than the generator
voltage absence delay (option P.07). Activation deactivates the
A03 BATTERY CHARGER ALTERNATOR FAILURE generator contact output and immediately stops the generator
This is activated with motor running (voltage and/or set without cooling.
frequency of generator). The alternator battery charge signal
remains under the motor running voltage threshold (set up -06) A12 LOW BATTERY VOLTAGE
for longer than the battery charger alternator fault delay (set up - This is displayed when battery voltage is below the low battery
14). This alarm stops the generating set. voltage alarm threshold (set up -39). During the starting output
energizing, this alarm is temporarily disabled. The alarm
A04 UNEXPECTED STOP resetting threshold is 5% higher than the preset value. The
This alarm is activated when the motor stops without external battery voltage is controlled at the unit supply terminals. Any
intervention having caused the shut down disparity between the displayed voltage and the one detected at
the battery terminals is to be attributed to a voltage drop in the
A05 MAINTENANCE REQUESTED supply cables.
This is enabled when the minute counter of the maintenance
interval reaches the programmed Maintenance interval duration A13 HIGH BATTERY VOLTAGE
(set up -16). To reset the alarm and counter, go into the RESET Activates when the battery voltage increases over the maximum
mode. With this alarm the set continues to run properly. battery voltage alarm threshold (set up -40). The alarm threshold
resets at 5% inferior to that which is programmed. Battery
A06 GENERATOR OVER FREQUENCY voltage is controlled on the machine terminals. A contingent
This is activated when the generating set frequency discordance between the voltage visualized and that controlled
(depending on the motor’s number of revolutions) is 10% higher on the terminals is due to a voltage drop in the supply wires.
than the nominal value. This condition has to last for a time
whose length is inversely proportional to the importance of the E01 EMERGENCY STOP
over frequency. This time interval can last for a maximum of 4 Activated by one of the following causes:
seconds (frequency +10% if compared with nominal value) down 1) Opening of the contact connected to the emergency stop
to a minimum of 0 seconds (immediate intervention when input.
frequency is + 20% if compared with the nominal value). We 2) Opening of the contact connected to the external stop input, if
remind you that the nominal frequency can be chosen between this has been programmed NC on the parameter set up -25.
50 and 60 Hertz through the following parameter: nominal 3) Pressing the STOP button on the front panel when the
frequency (set-up -01). The intervention of this alarm inactivates system is in AUT mode
the output of the generating set’s disconnecting switch and the This alarm causes the set to stop immediately without cooling.
immediately stops the generating set without cooling down. This
alarm can also be inactivated through the following parameter: E03 EXTERNAL STOP
top frequency alarm inactivation (set-up -34). This is activated when the contact on the external stop is closed
in AUT mode. This alarm provokes the immediate functioning of
A07 LOW FUEL LEVEL the generator remote control switch and main stop with cooling
This is caused by the contact closing of fuel level input. The cycle. For applications that provide a connection with a floating
alarm can be configured to stop the set or not with the external device, an anti-ricochet filter has been inserted that permits the
alarm A07 (set up -22). commutation of the signal with a maximum time of 5 seconds.

A08 - USER ALARM E04 GENERATOR VOLTAGE FAILURE

This is generated by the closing of the contact on the relevant Activates when the generator voltage is not within the provided
input. This alarm can be programmed in order to stop the set or limits of the alarm enable delay E04 (set up –38) with the
not through the external alarm A08 (set-up -23). generator set functioning in a non-decelerating mode. Activation
disables the generator contact output and immediately stops the
generator set without cooling.

A09 - USER ALARM

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ALARM SUMMARY TABLE

Code Description Retentive Immediate Cooling Stop Alarm G activated Siren activated
Stop
A01 High temperature YES YES YES YES
A02 Low oil pressure YES YES YES YES
A03 Alt charge B. 500 failure YES YES YES YES
A04 Unexpected Stop (MECHANICAL ALARM) YES YES YES YES
A05 Maintenance requested YES YES YES
A06 Generator over frequency YES YES YES YES
A07 Prog. 7/feul level Prog Prog. Prog. Prog Prog
A08 Prog. 8 Prog Prog. Prog. Prog Prog
A09 Prog. 9 Prog Prog. Prog. Prog Prog
A10 Starting failure YES YES YES YES
A11 Generator under frequency YES YES YES YES
A12 Low battery voltage YES YES YES
A13 High battery voltage YES YES YES
E01 Emergency Stop YES YES YES YES
E03 External Stop YES
E04 Generator voltage failure YES YES YES YES

Errors
The displayed error codes indicate an operation fault or anomaly of the program memories and of the preset parameters.
ERRORS TABLE

Code Meaning Display condition

IE1 Internal error, incorrect Alteration of the program memory. Return the X803 to Miami Breaker for repair; ask for
program authorization beforehand.
IE2 Internal error, incorrect Alteration of parameter memory. Remove X803 supply; resupply and check all parameters. In
parameters case the IE2 error persists, return the X803 to Miami Breaker for repair; ask for authorization
beforehand.

INPUTS AND OUTPUTS

Inputs table (alarm and control)

Terminal Function Alternative Alternative function No. Alternative function No. 3 Parameter reference
No. function No. 1 2
3 High temperature
sensors
4 Oil pressure sensor
5 External stop EJP COMMUT. SCR COMMUT. EMERGENCY STOP SETUP 03
SETUP 25
6 External Start EJP START SCR START SETUP 03
35 Low fuel level A07 PROG. PROG. SETUP 22
36 Programmable PROG. PROG. SETUP 23
Alarm A08
37 Programmable PORG. PROG. SETUP 24
Alarm A09
41 Emergency Stop
OUTPUT TABLE
Terminal No. Function Alternative function No. 1 Alternative function No. 2 Parameter Reference
14 Start
16 Stop Deceleration Glow plug Setup 17
17 Fuel Valve Starter function Air Set up 28
18 Siren
29,30 Mains Contactor
31,32 Generator Contactor
33,34,34C General Alarm Gas SV-EV Set up -29

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PROGRAMMING

• The parameter setting is done by accessing two different menus: option and set up.
• Option: In this menu the parameters are set in relation to the mains characteristics and user requirements. Normally, the setting of
these parameters is done by the installer of the generating set.
• To access the Option menu, place the unit in RESET mode and keep the RESET key pressed then push the SELECT/MIS key for 5
seconds. Access to the Option menu is displayed with “P.01” indicating the setting to be modified.
• Set up: In this menu the parameters are set in close relation to the generating set characteristics. Normally, setting these
parameters is reserved to the manufacturer of the generating set and/or control panel.
• To access the Set up menu, place the unit in RESET mode and, keeping the RESET key pressed, press the START button twice,
the STOP button 3 times and SELECT/MIS 4 times. Now release the RESET button. The display will show Set. Press Start to
access the first parameter, indicated by code -01.
• In the set up function, to access the subsequent parameter, press GEN(TLG), while for the previous one, presses MAINS(TLR).
After having selected the required parameter, to increase the value, press STOP or, to decrease, press START. The variation can
be made only within the foreseen limits. To store the set parameters, press the RESET key.

PARAMETERS

The following tables group the Option and Set up parameters. RANGE indicates the field of possible settings, DEFAULT the classic
setting of a board straight after leaving the factor. It is recommended to attach a table to each electrical panel showing the settings
associated with that type of panel.

Menu Option
Option Description Range Default
P.01 Minimum mains voltage trip threshold 80 – 480 VAC (3 phase) 340 VAC (three phase)
160 – 230 VAC (Mono
phase)
P.02 Maximum mains voltage trip threshold 110 – 600 VAC (three 480 VAC (three phase)
phase)
253 – 345 VAC (mono
phase)
P.03 Mains voltage absence delay 0-120 sec 5 sec
P.04 Mains voltage presence delay 0-240 sec 10 sec
P.05 Minimum generator voltage trip threshold 80 – 480 VAC (three phase) 340 VAC (three phase)
160 – 230 VAC (mono
phase)
P.06 Maximum generator voltage trip threshold 110 – 600 VAC (three 480 VAC (three phase)
phase)
253 – 345 VAC (mono
phase
P.07 Generator voltage absence delay 1-180 sec 5 sec
P.08 Generator voltage presence delay (generator contact 1-180sec 20 sec
closing delay)
P.09 Cooling duration 1 – 300 sec 30 sec
P.10 Audible alarm duration 0-60 sec 20 sec
P.11 Automatic test interval 1 - 7 days 3 days
P.12 Automatic test duration 1-30 min 10 min
P.13 Engine start delay after EJP start 0 – 99 min 25 min
P.14 EJP/T commutation delay (1 wire) 0-30 min 5 min

Set up menu (the password is only for skilled personnel)

Set up Description Range Default
-01 Rated frequency generator 0(50Hz)-(60 Hz) 0
-02 Started engine signal source 0(disabled)-1(activated) 1
-03 Normal function EJP-SCR-EJP/T 0(nor) 0
1(EJP)
2(SCR)
3(EJP/T)

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Set up Description Range Default

-04 Voltage control exclusion (for pump) 0(nor) – 1(alarm stop pump)-2(no alarm stop 0
p.)
-05 500RPM signal select (C.B. alternator or 0 (alt) – 1(gen) 0
generator)
-06 Alternator tension threshold for motor start up 6 – 60V 10 V
-07 Generator tension threshold for motor start up 5 – 200 VAC 10 VAC
-08 Alarm enable delay at engine starting 1 – 60 sec 15sec
-09 Stop duration 1-30sec 20 sec
-10 Number of starting attempts 1-10 5
-11 Starting attempt duration 1-30sec 5 sec
-12 Interval between starting attempts 1-20sec 10 sec
-13 Delay between interrupted and subsequent 2 - 5sec 3 sec
startings
-14 Delay 500 RPM failure enable 2 – 5 sec 3 sec
-15 Mains/Generator interlock delay 0-10sec/10 5 sec/10
-16 Maintenance interval 10 – 250 hours 50 hours
-17 Function exit born 16-0(electromanet1 0 (nor) – 1(acc) 2(preheating) 0
(accelerator) 2(preheating)
-18 Deceleration duration 1 – 180 sec 60
-19 Spark plug heating time 1 – 60 sec 10 sec
-20 Automatic test activation with external stop 0 (disabled) – 1(activated) 0
activated
-21 Disable AUT and TEST (paper functions only in 0 (nor) – (disabled) 0
MAN or OFF)
-22 External alarm A07 (disable /alarm only/alarm 0(disabled) 1(alarm) 2(stop) 0
and stop)
-23 External alarm A08 (disable /alarm only/alarm 0(disabled) 1(alarm) 2(stop) 0
and stop)
-24 External alarm A09 (disable /alarm only/alarm 0(disabled) 1(alarm) 2(stop) 0
and stop)
-25 External stop NF over ride NO 0(NO) 1 (NF) 0
-26 Additional delay for alarm A08 (from alarm start) 0 – 120 sec 0
-27 Serial communications address 01 - 32 01
-28 Program 2 (fuel/Advance/Air) 0(fuel) 1 (Ad) 2 (Air) 0(fuel)
-29 Program 3 (general alarm/Gas) 0 (alarm) – 1 (Gas) 0(alarm)
-30 Gas delay (after start) 1 – 5 sec 2 sec
-31 Advance duration 1 – 10 sec 5sec
-32 Air duration 0 – 10 sec 8 sec
-33 Air transmission brake threshold 0 – 200 V 8V
-34 Maximum frequency alarm disable (A06) 0 (act) 1 (disable) 0 (act)
-35 Disable alarm with generator voltage absence 0 (act 1(disable) 0 (act)
(E04)
-36 New commutation main block during EJP alarm 0 (nor) 1 (block) 0 (nor)
-37 Mono phase / Three phase line 0 (mono) 1 (three) 1 (three)
-38 Alarm enable E04 (generator voltage absence) 15 – 240 sec 240 sec
-39 Minimum battery voltage 7 – 12 VDC (12V) 9V (12V)
13 – 24 VDC (24V) 18V (24V)
-40 Maximum battery voltage 13 – 17 VDC (12V) 16V (12V)
26 – 34 VDC (24V) 32V (24V)
-41 Minimum frequency alarm threshold 20-50/60Hz 40Hz
-42 Maximum main asymmetry 5 – 20 % 15%

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TECHNICAL CHARACTERISTICS

- Supply circuit
Battery supply (Us) 12Vcc o 24Vcc
12Vdc or 24Vdc
Maximum current consumption ≈160mA (250mA con RS485)
≈160mA (250mA with RS485)
Stand-by current ≈110mA (200mA con RS485)
≈110mA (200mA with RS485)
Operating range 12V 6,2÷16,5 Vcc
6.2-16.5Vdc
Operating range 24V 13÷33 Vcc
13-33Vdc
Immunity time for micro breakings ≈150ms
Maximum ripple 10%

- Mains voltage control circuit (single or three phase)

Rated voltage (Ue) 100÷480Vca

100-480Vac
70÷624Vca
Operating range 70-624Vac
Rated frequency (keyboard adjusted) 50/60Hz
Minimum voltage tripping (keyboard adjusted) 0,7÷1Ue
0.7-1Ue
Maximum voltage tripping (keyboard adjusted) 1÷1,5Ue
1-1.5Ue
Asymmetry tripping (only three-phase) 5÷20% Ue
5-20Ue
Resetting hystersis 5%
Precision ±1%
Accuracy

- Generator voltage control circuit (single phase)

Rated voltage (Ue) 100÷480Vca
100-480Vac
Operating range 70÷624Vca
70-624Vac
50/60Hz
Rated frequency (keyboard adjusted)
0,7÷1Ue
Minimum voltage tripping (keyboard adjusted) 0.7-1Ue
Maximum voltage tripping (keyboard adjusted) 1÷1,5Ue
1-1.5Ue
Resetting hysteresis 5%
±1%
Accuracy

- Remote control circuit

Input negative
Voltage applied at contacts 12Vcc (24Vcc)
12Vdc (24Vdc) battery
Maximum current 8mA

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- Started engine control circuit

- Battery charger permanent magnet alternator
Operating range 0-40Vca
0-40Vac
Adjustment range 6-30Vca
6-30Vac
Input current <10mA
- Battery charger energised alternator
Operating range 0-40Vcc
0-40Vdc
Adjustment range 6-30Vcc
6-30Vdc
Maximum input current <10mA
+D Circuit voltage 12Vcc (24Vcc)
12Vdc (24Vdc) battery
Energising current Ue 12Vcc 170mA
Ue 12Vdc
Energising current Ue 24Vcc 130mA
Ue 24Vdc

- Output relay contacts to exclude mains, Generator and Audible Alarm

arrangement 1 NO contact
Rated operational voltage 24Vdc
Maximum operational voltages 30Vdc
Rated capacity Ith 5A
Rated capacity DC13 (or DC14) 5A-24Vdc

- Ouput relay contacts of common alarm

Contact arrangement 1 changeover contact

Rated operational voltage 24Vcc

24Vdc
Maximum operational voltage 125Vac 30Vdc
Rated capacity Ith 5A
Rated capacity DC13 (or DC14) 5A-24Vdc

- Output contacts of Mains and Generator contactors

Mains contactor control 1 NC contact
1 NO contact
Generator contactor control 1 NO contact
Rated operational voltage 250Vac

Maximum operating voltage 440Vac

Rated capacity Ith 5A
Rated capacity AC15 2A 220Vac
Contacts/coil insulation 5kVac 1min
Open contacts insulation 1kVac 1min

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Other characteristics

- Enclosure
Version Incasso
Flush mount
Overall dimensions lxhxd 144x144x125mm
IP41
Degree of protection without protective cover
Degree of protection with protective cover IP54

Weight ≈880g

- Operating ambient conditions

Operating temperature 0÷60°C
0-60°C
Storage temperature -30÷80°C
-30 to +80°C

- Connections
Type of terminals Estraibile
Plug in
Cable cross-section 2,5mmq
2.5mmsq

REFERENCE STANDARDS
• Dielectric test (IEC255-5)
Industrial frequency (50Hz) : 2.5kV for one minute
Impulse (1.2/50ms): 5kV (3 positive and 3 negative at intervals longer than 5 seconds)
• Climatic sequence (IEC 68-2-61)
Method 1: hot dry, hot damp, cold, hot damp
• Vibration test (IEC 68-2-6 or according to Lloyd’s Register specifications)
Fc test (sinusoidal vibrations)
• Damp-saline ambient test (RINA specifications)
• Electromagnetic compatibility test (EN 50081-1, EN 50082-2)
Electrostatic discharge immunity (EN 61000-4-2)
Fast transient / burst immunity (EN 61000-4-4)
Radiated radio-frequency electromagnetic field immunity (ENV 50140)
Conducted radio disturbance electromagnetic field immunity (ENV 50141)
Emission level of radiated electromagnetic fields (EN 55011)
Emission level of conducted electromagnetic fields (EN 55011)

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CONNECTION ONLY FOR ENGINS

WITH BATTERY CHARGER ALTERNATOR
[Link]

29 21 L3
TLR
30 22 L2 INPUT MAINS
400V AC
31 23 L1
TLG
32 11 L2 R
INPUT GENERATOR
12 400V AC
L1 +
LE
+BATTERIA

33
REMOTE 41
ALARM
34C EMERGENCY STOP
34 37 A09 (ALLARM)

+BATTERY SUPPLY 44 36 A08 (ALLARM)

STOP ECITATIO 16 35 A07 (ALLARM) 8

ONLY FOR ENGINS WITH 14 5
STARTING REMOTE STOP 7
ALTERNATOR BATTERY CHARGER
WITH D+ BUZZER ALARM 18 6 REMOTE START 9 D+
STOP DE ENERGIZING 17 4 OIL PRESSURE 2 -BATTERY
D+ 19 3 TEMPERATURE 1 +BATTERY
EXITATION D+

39 EXIT FOR RS485

OR RS232 OPTION
40

45 EXIT(OPTION)FOR 19 SIGNAL
REMOTE ALARMS IN THE SPECIAL
46 ELECTRONIC CARD

RGAMTE

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