AMF 5220 O&M Manual

SUNLIGHT Model AMF 5220 Automatic Mains Failure & Instrumentation System Operators Manual
AMF 5220 AUTOMATIC MAINS FAILURE MODULE

OPERATING MANUAL
GERMANOS S.A.
Headquarters: 23 klm N.R. Athens-Lamia

GR 145 65, Agios Stefanos
Tel.: +30-10-6219300 FAX: +30-10-6216911
Factory: N. Olvio Xanthi (North Greece)
Tel.: +30-25410-95241 Fax: +30-25410-95446
<<< THIS PAGE INTENTIONALLY BLANK >>>
2 AMF 5220 OPERATING MANUAL
TABLE OF CONTENTS
Section
Page
INTRODUCTION...............................................................................................5
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. .........5
OPERATION .....................................................................................................6
3.1
3.2
3.3
PROTECTIONS ..............................................................................................10
4.1
4.2
4.3
4.4
4.5
4.6
AUTOMATIC MODE OF OPERATION ............................................................................... 6

MANUAL OPERATION ....................................................................................................... 8
TEST OPERATION ............................................................................................................. 9
WARNINGS ....................................................................................................................... 11
ANALOGUE PRE-ALARMS.............................................................................................. 11
HIGH CURRENT WARNING ALARM ............................................................................... 12
SHUTDOWNS ................................................................................................................... 13
HIGH CURRENT SHUTDOWN ALARM ........................................................................... 15
ELECTRICAL TRIPS......................................................................................................... 15
DESCRIPTION OF CONTROLS.....................................................................16
5.1
TYPICAL LCD DISPLAY SCREENS ................................................................................ 17
5.2
LCD DISPLAY AREAS...................................................................................................... 18
5.3
VIEWING THE INSTRUMENTS ........................................................................................ 19
5.3.1
CANBUS MESSAGES................................................................................................ 20
5.4
VIEWING THE EVENT LOG ............................................................................................. 21
5.5
INDICATORS..................................................................................................................... 22
5.6
CONTROLS....................................................................................................................... 22
FRONT PANEL CONFIGURATION................................................................23

6.1
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR..................................... 23
6.1.1
EDITING AN ANALOGUE VALUE ............................................................................. 24
6.1.2
EDITING THE CURRENT DATE/TIME...................................................................... 26
INSTALLATION INSTRUCTIONS ..................................................................27

7.1
7.2
7.3
7.4
7.5
PANEL CUT-OUT.............................................................................................................. 27
COOLING .......................................................................................................................... 27
UNIT DIMENSIONS........................................................................................................... 27
FRONT PANEL LAYOUT.................................................................................................. 28
REAR PANEL LAYOUT .................................................................................................... 28
ELECTRICAL CONNECTIONS ......................................................................29

8.1
CONNECTION DETAILS .................................................................................................. 29
8.1.1
PLUG A 8 WAY........................................................................................................ 29
8.1.2
PLUG B 11 WAY...................................................................................................... 29
8.1.3
PLUG C 3 WAY (OPTIONAL).................................................................................. 29
8.1.4
PLUG D 4 WAY (OPTIONAL).................................................................................. 30
8.1.5
PLUG E 8 WAY........................................................................................................ 30
8.1.6
PLUG F 4 WAY ........................................................................................................ 30
8.1.7
PLUG G 5 WAY ....................................................................................................... 30
8.1.8
PLUG H 4 WAY........................................................................................................ 31
8.1.9
PC CONFIGURATION INTERFACE CONNECTOR.................................................. 32
8.1.10 EXPANSION OUTPUT CONNECTOR ...................................................................... 32
8.2
CONNECTOR FUNCTION DETAILS................................................................................ 33
8.2.1
PLUG A 8 WAY........................................................................................................ 33
8.2.2
PLUG B 11 WAY...................................................................................................... 33
8.2.3
PLUG C 3 WAY (OPTIONAL).................................................................................. 34
8.2.4
PLUG D 4 WAY (OPTIONAL).................................................................................. 34
8.2.5
PLUG E 8 WAY........................................................................................................ 34
8.2.6
PLUG F 4 WAY ........................................................................................................ 34
8.2.7
PLUG G 5 WAY ....................................................................................................... 34
8.2.8
PLUG H 4 WAY........................................................................................................ 35
8.2.9
PURCHASING ADDITIONAL CONNECTOR PLUGS FROM SUNLIGHT................. 35
8.3
ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS......................... 36
8.3.1
CUMMINS ISB / ISBE................................................................................................. 36
8.3.2
JOHN DEERE............................................................................................................. 37
8.3.3
PERKINS 2800 SERIES ............................................................................................. 38
8.3.4
SCANIA S6 ................................................................................................................. 39
8.3.5
VOLVO TAD12 ........................................................................................................... 40
COMMISSIONING.......................................................................................... 42
9.1.1
PRE-COMMISSIONING ............................................................................................. 42
10
FAULT FINDING ......................................................................................... 43
11
FACTORY DEFAULT CONFIGURATION................................................... 44
12
TYPICAL WIRING DIAGRAM ..................................................................... 47
13
APPENDIX .................................................................................................. 48
13.1 ALTERNATIVE WIRING TOPOLOGIES........................................................................... 48

13.1.1 3 PHASE, 3 WIRE ...................................................................................................... 48
13.1.2 1 PHASE, 2 WIRE ...................................................................................................... 48
13.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) ......................................... 49
13.2 ICONS AND LCD IDENTIFICATION................................................................................. 50
13.2.1 PUSH BUTTONS........................................................................................................ 50
13.2.2 STATUS / MEASUREMENT UNITS........................................................................... 50
13.2.3 ALARM INDICATIONS ............................................................................................... 50
13.3 5220 IDMT TRIPPING CURVES (TYPICAL) .................................................................... 51
13.4 SENDER WIRING RECOMMENDATIONS ....................................................................... 52
13.4.1 EARTH RETURN SENDERS ..................................................................................... 52
13.4.2 INSULATED RETURN SENDERS ............................................................................. 52
13.4.3 FUEL LEVEL SENDERS ............................................................................................ 53
13.5 J1939 CANBUS INTERFACE (OPTIONAL) ..................................................................... 54
13.5.1 EXAMPLE OF CONNECTING 5220 CONTROLLER TO ENGINE CANBUS. ........... 54
13.6 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE........ 55
13.7 OUTPUT EXPANSION ...................................................................................................... 55
13.7.1 RELAY OUTPUT EXPANSION (157) ......................................................................... 55
13.7.2 LED OUTPUT EXPANSION (548).............................................................................. 55
13.8 INPUT EXPANSION .......................................................................................................... 56
AMF 5220 OPERATING MANUAL
1 INTRODUCTION
The AMF 5220 automatic mains failure module has been designed to allow the OEM to meet most of the industrys
complex specifications. It has been primarily designed to monitor the mains (utility) supply, starting the generator
automatically should it fall out of limits. Transfer of the load is automatic upon a mains supply failure. If required the
generator and can be started and stopped manually, and if required, the user can transfer the load to the generator
either manually (via external push-buttons) or automatically. The user also has the facility to view all the system
operating parameters via the LCD display.
The AMF 5220 module monitors the mains (utility) supply indicating the status of the mains on the modules integral
LCD id splay. Additionally the module monitors the engine, indicating the operational status and fault conditions,
automatically shutting down the engine and giving a true first up fault condition of an engine failure by a flashing
common alarm LCD indicator. The exact failure mode is indicated by combined hidden til lit LEDs and the LCD
display on the front panel.
The powerful microprocessor contained within the module allows for a range of complex features to be incorporated
as standard:
Graphical Icon based LCD display (excluding the need for translations and languages).
Voltage, Current and Power monitoring.
Engine parameter monitoring.
Fully configurable inputs for use as alarms or a range of different functions.
Extensive range output functions using built in relay outputs or relay expansion available.
Selective operational sequences, timers and alarm trips can be altered by the customer via a PC using the 5200
series configuration software and P810 interface. Additionally, a subset of this information can be adjusted from the
modules front panel configuration editor.
The module is housed in a robust plastic case for front panel mounting. Connections to the module are via locking
plug and sockets.
2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

NOTE:
Highlights an essential element of a procedure to ensure correctness.
CAUTION!
Indicates a procedure or practice which, if not strictly observed, could

result in damage or destruction of equipment.
WARNING!
Indicates a procedure or practice, which could result in injury to personnel

or loss of life if not followed correctly.
SUNLIGHT owns the copyright to this manual, which cannot
be copied, reproduced or disclosed to a third party without prior written
permission.
Compliant with BS EN 60950 Low Voltage Directive
Compliant with BS EN 50081-2 EMC Directive
Compliant with BS EN 50082-2 EMC Directive
Indicates a function only applicable when the controller is configured for
connection to a J1939 engine controller
Year 2000 Compliant
3 OPERATION
The following description details the sequences followed by a module containing the standard factory configuration.
Always refer to your configuration source for the exact sequences and timers observed by any particular module in
the field.
FIG 1
3.1
AUTOMATIC MODE OF OPERATION

NOTE:- If a digital input configured to panel lock is active, the LCD will display the
icon. When in panel lock, changing module modes will not be possible. Viewing the instruments
and event logs
is NOT affected by panel lock.
This mode is activated by pressing the

action.
pushbutton. An LED indicator beside the button confirms this
Should the mains (utility) supply fall outside the configurable limits for
longer than the period of the mains transient delay timer, the mains
(utility) failure indicator will illuminate and the mains (utility) available
GREEN indicator LED extinguishes. Additionally, while in AUTO mode,
the remote start input (if configured) is monitored. If active, the
Remote Start Active indicator (if configured) illuminates.
Overvoltage
Undervoltage
Overfrequency
Underfrequency
Whether the start sequence is initiated by mains (utility failure) or by remote start input, the follow sequence is
followed :
To allow for short term mains supply transient conditions or false remote start signals, the Start Delay timer is
initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated, and the
corresponding auxiliary output (if configured) will energise.
NOTE:- If the mains supply returns within limits, ( or the Remote Start signal is removed if the
start sequence was initiated by remote start) during the Start Delay timer, the unit will return to a
stand-by state.
After the above delays the Fuel Solenoid is energised, then one second later, the Starter Motor is engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter
motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts,
the start sequence will be terminated and
Fail to Start
fault will be displayed accompanied by a flashing shutdown
symbol.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator
output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is
selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect
the starter motor, however it cannot be used for underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the
fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before
accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would then activate.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing
excessive wear on the engine.
On the return of the mains supply, (or removal of the Remote Start signal if the set was started by remote signal) ,
the Stop delay timer is initiated, once it has timed out, the load Transfer signal is de-energised, removing the load.
The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once
the Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop.
Should the mains supply fall outside limits again (or the Remote Start signal be re-activated) during the cooling
down period, the set will return on load.
3.2
MANUAL OPERATION
in panel lock, changing module modes will not be possible. Viewing the instruments
affected by panel lock.
To initiate a start sequence in MANUAL, press the
and event logs
icon. When
is NOT
pushbutton. When the controller is in the manual mode
(indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.
NOTE:- There is no Start Delay in this mode of operation.
If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised.
After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged.
the start sequence will be terminated and Fail to Start
shutdown
fault will be displayed accompanied by a flashing
indicator.
fault.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it can
be loaded.
The generator will run off load, unless the mains supply fails or a Remote Start on load signal is applied. If Close
generator has been selected as a control source, the appropriate auxiliary output will then activate.
The generator will continue to run On load regardless of the state of the mains supply or remote start input until the
Auto mode is selected.
If Auto mode is selected, and the mains supply is healthy with the remote start on load signal not active, then the
Remote Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load
allowing the engine a cooling down period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
3.3
TEST OPERATION
in panel lock, changing module modes will not be possible. Viewing the instruments
affected by panel lock.
To initiate a start sequence in TEST, press the
and event logs
icon. When
is NOT
pushbutton. When the controller is in the test mode (indicated
by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.
NOTE:- There is no Start Delay in this mode of operation.
If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised.
After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged.
the start sequence will be terminated and Fail to Start
shutdown
fault will be displayed accompanied by a flashing
indicator.
fault.
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it can
be loaded.
The generator will continue to run On load regardless of the state of the mains supply or remote start input until the
Auto mode is selected.
If Auto mode is selected, and the mains supply is healthy with the remote start on load signal not active, then the
Remote Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load
allowing the engine a cooling down period.
Selecting STOP (O) removes the Close Generator output (if configured) and de-energises the FUEL SOLENOID,
bringing the generator to a stop.
4 PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The LCD display will indicate a common alarm either :
(warning),
(shutdown) or
(electrical trip)
If appropriate, the LCD display or LED indicators will display the
appropriate alarm icon i.e. for battery charging failure :
NOTE:- Alarm icons in the LED display area are hid until lit. This means that the display area
appears totally clear, and free from clutter. The advantage of this is that when an alarm does occur,
the respective LED icon will illuminate on the otherwise blank fascia. This makes alarm identification
much clearer.
If no alarms are present the LCD

will extinguish any alarm icons.
In the event of a warning alarm the LCD will display the appropriate icon. If a shutdown then occurs the module will
display the appropriate icon. The original warning alarm icon will remain displayed.
Example:-
Low battery volts warning (all symbols steady)
Followed by.
Low battery volts warning indicator still

present, common alarm indicator has
changed to a shutdown symbol and is
now flashing.
Also present is the flashing underspeed
LED.
Underspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain displayed as long at
the triggering conditions remain. Any subsequent warnings or shutdowns that occur will be displayed steady,
therefore only the first-up shutdown will appear flashing.
10
4.1
WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to
draw the operators attention to an undesirable condition.
In the event of a warning alarm the LCD will display:-
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the
auxiliary charge alternator the
icon will illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low volts setting
level, the module will display:-
V
The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting
level, the module will display:-
V
The Battery High Voltage alarm is delayed by the High DC Volts Delay timer.
FAIL TO STOP, If the module detects the engine is still running when the Fail to stop timer expires, then the
module will display:-
NOTE:- Fail to Stop could indicate a faulty oil pressure sender - If engine is at rest check oil
sender wiring and configuration.
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD segment will be
displayed:-
!
LOW FUEL LEVEL. If the fuel level detected by the fuel level sender falls below the low fuel level setting, a warning
will occur.
The
4.2
ANALOGUE PRE-ALARMS
The following alarms are termed pre-alarms as they pre warn the operator of a potentially more serious alarm
condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to
notify the operator. If the temperature falls below this level, then the alarm ceases, and the set will continue to run
as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the
warning is escalated and a high coolant temperature shutdown is initiated.
During a pre-alarm condition, the warning symbol
icon:
is displayed on the LCD display, along with the appropriate
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure prealarm setting level after the Safety On timer has expired, a warning will occur.
The
HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high
engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur.
The
OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated.
The
Overspeed is not delayed, it is an immediate warning.
UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has expired, a
warning is initiated.
The
GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of
the pre-set pre-alarm, a warning is initiated.
The
Generator High Frequency is not delayed, it is an immediate warning.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.
The
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a
shutdown is initiated.
The V icon will illuminate.
High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set prealarm after the Safety On timer has expired, a warning is initiated.
The
CAN ECU ERROR If the module is configured for J1939 operation and receives an error message from
the engine control unit, Can ECU fail is shown on the modules display and a warning alarm is generated.
Usually, an associated alarm code is also displayed, detailing the exact alarm detected. For details on
these code meanings, refer to the ECU instructions provided by the engine manufacturer.
4.3
HIGH CURRENT WARNING ALARM
GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a
The
If this high current condition continues for an excess period of time, then the alarm is escalated to a shutdown
condition. For further details of the high current alarm, please see High Current Shutdown Alarm.
12
4.4
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the
module.
In the event of a shutdown alarm the LCD will display:(flashing).
The appropriate icon will also be displayed flashing
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm
condition remains it will not be possible to reset the unit (The exception to this is the Low Oil
Pressure alarm and similar delayed alarms, as the oil pressure will be low with the engine at rest).
Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only the firstup shutdown will appear flashing.
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be
initiated.
The
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates the following
sequence, firstly it will initiate a controlled shutdown of the Generator and prevent any attempt to restart the
Generator until the Emergency Stop push-button has been reset. Secondly it removes the +ve DC supply from both
the Fuel Solenoid and Starter Solenoid.
The

NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will shutdown.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure trip
setting level after the Safety On timer has expired, a shutdown will occur.
The
HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high
engine temperature trip setting level after the Safety On timer has expired, a shutdown will occur.
The
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated.
The
Overspeed is not delayed, it is an immediate shutdown.
NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an extra
trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 5200 series
configuration software manual under heading Overspeed Overshoot for details.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is
initiated.
The
GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of
the pre-set trip a shutdown is initiated.
The
Generator High Frequency is not delayed, it is an immediate shutdown.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set trip after the Safety On timer has expired, a shutdown is initiated.
The
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a
shutdown is initiated.
The V icon will illuminate.
High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip
after the Safety On timer has expired, a shutdown is initiated.
The
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender
(open circuit) a shutdown is initiated. The LCD will indicate:(Steady) (And ----- on the engine oil pressure instrument). Sender failure is not delayed, it is an immediate
shutdown.
AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate LCD segment will be
displayed:-
!
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated.
The
icon will illuminate. (Steady) (And ----- on the engine RPM instrument).
NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety
on timer. If the signal is lost during normal operation the Generator will shutdown with an Underspeed alarm.
CAN DATA FAIL If the module is configured for J1939 operation and does not detect data on the engine
CANbus datalink, a shutdown will occur and Can data fail is shown on the modules display
CAN ECU FAIL If the module is configured for J1939 operation and receives a fail message from the
engine control unit, the engine is shutdown and Can ECU fail is shown on the modules display. Usually,
an associated failure code is also displayed, detailing the exact failure detected. For details on these code
meanings, refer to the ECU instructions provided by the engine manufacturer.
14
4.5
HIGH CURRENT SHUTDOWN ALARM
GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a
warning is initiated. This warning will continue for a period of time depending upon the level of overload that the
generator is subjected to, and the configuration setting for Generator High Current in the 5200 series configuration
software.
For instance the factory default settings for Generator High Current allow for a loading of the generator to 110% for
one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while
the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the
5220 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration.
Additionally, the
NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with
the factory default configuration, an overload level twice that of the trip level ( typically 200%) will
result in a Generator High Current shutdown condition after 36 seconds.
For details of the relationship between the overload and the shutdown time, please see the Appendix
section of this manual.
4.6
ELECTRICAL TRIPS
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip
condition the module will de-energise the Close Generator Output to remove the load from the generator. Once
this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down
the engine. The alarm must be accepted and cleared, and the fault removed to reset the module.
In the event of an electrical trip alarm the
Additionally, During the cooling timer the warning symbol

symbol
is displayed followed by the flashing shutdown
when the cooling timer has expired.
AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate LCD segment will
be displayed:-
!
GENERATOR HIGH CURRENT. If the module detects a generator output current in excess of the pre-set trip a
The
If this high current condition continues for an excess period of time, then the alarm is escalated to either a shutdown
or electrical trip condition (depending upon module configuration). For further details of the high current alarm,
please see High Current Shutdown Alarm.
5 DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
Scroll
Configure
/ log
Stop
Manual
Test
FIG2
16
Auto
Start
5.1
TYPICAL LCD DISPLAY SCREENS
INSTRUMENTS
The LCD displays the various engine parameters such as ENGINE
SPEED, OIL PRESSURE, HOURS RUN, etc.
Each instrument is displayed with the appropriate units of measure.
In this example, the values being displayed are Generator
phase to neutral L1-N, AC
voltages V.
STATUS ICONS
The LCD also displays the status of the controller by showing (for
example) an hourglass symbol when a timer is in progress or by
displaying a common alarm symbol. This display is indicating that a
timer is in progress and a warning alarm is present. See the
Protections section of this manual for details of the alarms.
In this example the values being displayed are the three
generator
USER DEFINED
INDICATIONS
AC
currents A
The LCD displays the user-defined indications when configured and

active. The icons will illuminate and point to the appropriate text
insert label. These indications can be used to indicate the
operation of external equipment (i.e. Battery Charger On, Breaker
Closed etc) or to indicate internal states (i.e. Engine Running,
Safety On, etc).
USER DEFINED ALARMS

The LCD displays the user-defined alarms when configured and
active. The icons will illuminate and point to the appropriate text
insert label. These alarms can be used to indicate the operation of
external alarms (i.e. Low Fuel Level, Low Coolant level etc) or to
indicate internal alarms (i.e. Fail to Stop, MPU fault, etc).
5.2
LCD DISPLAY AREAS
Instrument values
Display information &

units of measure
Alarm icons
Status icons
User configurable display

icons
18
5.3
VIEWING THE INSTRUMENTS
It is possible to manually scroll to display the different instruments by repeatedly operating the scroll button. Once
selected the instrument will remain on the LCD display until the user selects a different instrument or after a period
of inactivity the module will revert to the initial display (Hz/RPM).
Instrument Page Order: Generator RPM / Frequency (Hz)
Generator AC Voltage Line-Neutral
Generator AC Voltage Line-Line
Oil Pressure
Coolant temperature
Fuel level (%)
Engine Hours Run
DC Battery Voltage
AC Line Current
Total kW
Total VA
AC phase angle (cos )
CanBus J1939 messages (optional)
Mains (Utility) Frequency (Hz)
Mains (Utility) AC Voltage Line-Neutral
Mains (Utility) AC Voltage Line-Line
Manually Selecting an Instrument
Initial display (Hz/RPM)
Pressing the DOWN button the LCD will

then show (Generator L-N voltages)
Pressing the DOWN button the LCD will

then show (Generator L-L voltages)
Pressing the
button again will scroll through each individual instrument eventually returning to the original
instrument displayed.
NOTE:-Once selected the instrument will remain on the LCD display until the user selects a
different instrument or after a period of inactivity the module will revert to the initial display.
5.3.1
CANBUS MESSAGES
On J1939 enabled 52xx controllers connected to a CanBus ECU, alarm status messages are transmitted to the
52xx controller and displayed on the CanBus message instrumentation page.
Can alarm message
Suspect Parameter Number (SPN) = 102
Failure Mode Indicator (FMI) = 16
Examples of SPN / FMI numbers, taken

from the Volvo Penta TAD12 manual are :
SPN 110 Engine coolant temperature

FMI 0 Out of range
FMI 3 Above normal
FMI 4 Below normal
NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine
manufacturer.
NOTE:- When using 52xx configuration and instrumentation PC software, hovering the mouse
cursor over the SPN/FMI numbers will display the J1939 messages where appropriate.
20
5.4
VIEWING THE EVENT LOG
The model 5220 remote start module maintains

a log of the last 15 shutdown alarms to enable
the operator or engineer to view the past alarms
history. Only shutdown and electrical trip alarms
are logged; warning alarms are not logged.
Once the log is full (15 shutdown alarms), any
subsequent shutdown alarms will overwrite the
oldest entry in the log. Hence the log will always
contain the 15 most recent shutdown alarms.
The alarm is logged, along with the date and
time of the event in the format shown in this
example.
To view the event log, press the log button
event log has been entered.
. The LCD display will flash the log symbol
to confirm that the
In this example, the oil can symbol represents

an oil pressure shutdown, backed up by the
flashing shutdown symbol in the LCD display.
The value displayed means that the oil pressure
shutdown occurred on November 1st 2002 at
8:17.
Press down
to view the next most recent shutdown alarm:

In this example, the hand/button symbol
represents an emergency stop shutdown,
backed up by the flashing shutdown symbol in
the LCD display.
The value displayed means that the emergency
stop button was pressed on November 1st 2002
at 11:50.
Continuing to press down

will cycle through the past alarms until all 15 logged alarms have been viewed,
after which the most recent alarm will again be showed and the cycle will begin again.
To exit the event log and return to viewing the instruments, press the log
button.
5.5
INDICATORS
COMMON ALARM LCD indicators

These indicate when an alarm condition is present. The Alarm icons or
LEDs will detail the exact nature of the alarm.
USER CONFIGURABLE LCD INDICATORS
These LCDs can be configured by the user to indicate any on of the
different functions based around the following: INDICATIONS - Monitoring of a digital input and indicating associated
functioning users equipment - Such as Battery Charger On or
Louvres Open, etc.
WARNINGS and SHUTDOWNS - Specific indication of a particular
warning or shutdown condition, backed up by LCD indication (!)Such as Low Oil Pressure Shutdown, Low Coolant level, etc.
STATUS INDICATIONS - Indication of specific functions or
sequences derived from the modules operating state - Such as
Safety On, Pre-heating, Generator Available, etc.
5.6
(warning) or
(shutdown)
CONTROLS
STOP/RESET
This button places the module into its Stop/reset mode. This will clear any alarm conditions for
which the triggering criteria have been removed. If the engine is running and this position is selected,
the module will automatically instruct the changeover device to un-load the generator (Load transfer
becomes inactive (if used)). The fuel supply will be removed and engine will be brought to a
standstill. Should a remote start signal be present while operating in this mode, a remote start will
not occur.
MANUAL
This mode is used to allow manual control of the generator functions. Once in Manual mode the
module will respond to the start (I) button and start the engine and run off load. If the engine is
running off-load in the Manual mode and a remote start signal becomes present, the module will
automatically instruct the changeover device to place the generator on load (Load transfer becomes
active (if used)). Should the remote start signal then be removed the generator will remain on load
until either the STOP/RESET or AUTO positions is selected.
AUTO
This button places the module into its Automatic mode. This mode allows the module to control the
function of the generator automatically. The module will monitor the remote start input and once a
start condition is signalled the set will be automatically started and placed on load (Load transfer
becomes active (if used)). If the starting signal is removed the module will automatically transfer the
load from the generator and shut the set down observing the stop delay timer and cooling timer as
necessary. The module will then await the next start event. For further details please see the more
detailed description of Auto Operation earlier in this manual.
TEST
This button places the module into its Test mode. This mode allows the operator to perform an on
load test of the system. Once in Test mode the module will respond to the start (I) button and start
the engine and run on load (Load transfer becomes active (if used)). The generator will continue to
run on load until Auto mode is selected. Then, If the starting signal is removed the module will
automatically transfer the load from the generator and shut the set down observing the stop delay
timer and cooling timer as necessary. The module will then await the next start event.
For further details please see the more detailed description of Test Operation earlier in this manual.
START
This button is only active in MANUAL
or TEST
mode. Pressing this button in manual or
test mode will start the engine and run off load(manual) or on load (test).
22
6 FRONT PANEL CONFIGURATION

Although full configuration of the module is possible using the 5200 series configuration software, selected
parameters that may require adjustment in the field are able to be adjusted via the modules fascia.
NOTE:- Care should be taken to ensure that changes made via the front panel editor are carefully recorded
and fed back to the generator supplier if applicable. This is to safeguard against using the 5200 series configuration
software to configure the module at a later date, possibly overwriting the changes made using the front panel editor.
When using the 5200 series configuration software to make configuration changes, the first operation should be to
read configuration from controller to ensure that any changes made to the controllers configuration by the front
panel editor are loaded into the PC before any changes are made.
Full details of this procedure can be found in the 5200 series configuration software manual.
6.1
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR
Press the configure/log
and Stop/Reset
@ will
buttons simultaneously. The LCD configure indicator
flash to indicate that the module is in configuration mode. Release the Stop/Reset
configure/log
button and the
button.
The first configurable parameter is then displayed :

The parameter being displayed in this example is the
Low Oil Pressure prealarm, being indicated by the
illuminated oil can.
The warning symbol
is indicating that it is the
warning (pre-alarm) parameter that is being
displayed.
NOTE:- To exit the front panel configuration editor at any time, press the Stop/Reset
have saved any changes you have made by pressing the
button first.
button. Ensure you
6.1.1
EDITING AN ANALOGUE VALUE
Press the
button to enter edit mode. This is indicated by the flashing parameter. In this example, entering edit
mode will cause the 1.2 value to flash.
When in edit mode, pressing the + or buttons will adjust the parameter to the desired value. Press the
button to save the value. The value will stop flashing to confirm that it has been saved.
To select another value to edit, press the + button :
The next parameter being displayed in this example
is the Low Oil Pressure shutdown, being indicated by
the illuminated oil can.
The shutdown symbol
is indicating that it is the
shutdown (trip) parameter that is being displayed.
Continuing to press the + or
Parameter
Type
Analogue senders
Low Pressure
Pre Alarm
Low Pressure
Trip
High Temperature
Pre Alarm
High Temperature
Trip
Calendar
Timers
Mains (utility) supply
Generator output
24
buttons will cycle through the adjustable parameters in the following order :
Config Section
Icons displayed
Fuel Level %
Pre Alarm
Date/time
Date/time
Mains transient delay
Timer (secs)
Start delay
Timer (secs)
Preheat
Timer (secs)
Crank attempt
Timer (secs)
Crank rest
Timer (secs)
Safety delay
Timer (secs)
Overspeed overshoot
Timer (secs)
Warming up
Timer (secs)
Transfer delay
Timer (secs)
Return delay
Timer (secs)
10
Cooling run
Timer (secs)
11
E.T.S.(Energise to stop) solenoid hold
Timer (secs)
12
Mains Low Voltage
Trip
Mains High Voltage
Trip
V
V
Mains Low Frequency
Trip
Mains High Frequency
Trip
Generator Under Voltage L1-N
Trip
Generator Under Voltage L1-N
Pre Alarm
Generator Over Voltage
Pre Alarm
Generator Over Voltage
Trip
Generator Under Frequency
Trip
Generator Under Frequency
Pre Alarm
Generator Over Frequency
Pre Alarm
Generator Over Frequency
Trip
Delayed Overcurrent %
Trip
V
V
V
V
Front panel configurable items continued:
Config Section
Parameter
Type
Engine speed
Under Speed (RPM)
Trip
DC Voltages
Under Speed (RPM)
Pre Alarm
Over Speed (RPM)
Pre Alarm
Icons displayed
Over Speed (RPM)
Trip
Low DC Voltage
Warning
High DC Voltage
Warning
Charge Alternator Failure
Warning
NOTE:- The timers are numbered to enable them to be identified when in configuration mode. In
the following example timer number 2 (Start delay from the above list) is currently set to 5.0
seconds. Ie the hour glass
indicates that it is a timer being displayed. The 2 indicates that it is
timer number 2 (Start delay). The current setting is 5.0 (seconds).
6.1.2
EDITING THE CURRENT DATE/TIME
The date/time should be initially set using the 5200 series configuration software. However there may be certain
circumstances where a minor change to the modules time is required. One such instance is correction for daylight
saving.
NOTE:- The 5220 controller maintains the current date/time so long as it connected to a DC supply within the
operating range. Disconnection of the supply will result in the date/time being frozen until the modules power is
reapplied. When this occurs, the date/time will resume operation from the time the power was disconnected. If this
occurs you can use the front panel editor to correct the date/time or reset it using the 5200 series configuration
software.
NOTE:- The calendar is used by the 5220s run scheduler and the event log.
Press the configure/log
and Stop/Reset
@ will
buttons simultaneously. The LCD configure indicator
flash to indicate that the module is in configuration mode. Release the Stop/Reset
configure/log
button and the
button.
Press the + button until the calendar is shown :

This display is showing a time of 4:30 on 21st October
2002.
To edit the time, press the
button. The time, 4.30 in this example, will begin flashing. Press the + or buttons to
adjust the time in one minute steps until the desired time is shown. Press the
time stops flashing to confirm that is has been successfully stored.
26
button to save the change. The
7 INSTALLATION INSTRUCTIONS
The model AMF 5220 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly.
7.1
PANEL CUT-OUT
160.00mm
(6.3)
220.00mm
(8.7)
FIG 3
Maximum panel thickness 8mm (0.3)
In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings.
7.2
COOLING
The module has been designed to operate over a wide temperature range -30 to +70 C. Allowances should be
made for the temperature rise within the control panel enclosure. Care should be taken NOT to mount possible heat
sources near the module unless adequate ventilation is provided. The relative humidity inside the control panel
enclosure should not exceed 95%.
7.3
UNIT DIMENSIONS
Panel cutout 220mm x 160mm ( 8.7 x 6.3)
FIG 4
7.4
FRONT PANEL LAYOUT
FIG 5
7.5
REAR PANEL LAYOUT
FIG 6
28
8 ELECTRICAL CONNECTIONS
Connections to the Module are via plug and sockets.
8.1
CONNECTION DETAILS
The following describes the connections and recommended cable sizes to the 7 plugs and sockets on the rear of
the Module. See rear panel layout FIG 6.
8.1.1
PIN
No
1
PLUG A 8 WAY
DESCRIPTION
DC Plant Supply Input

(-ve)
DC Plant Supply Input
(+ve)
Emergency Stop Input
4
5
6
7
8
Fuel relay Output

Start relay Output
Auxiliary Output relay 1
8.1.2
PIN
No
9
10
11
12
13
14
15
16
17
18
19
CABLE
SIZE
2.5mm
NOTES
2.5mm
(Recommended Maximum Fuse 21A)
2.5mm
Plant Supply +ve. Also supplies fuel & start

outputs.
(Recommended Maximum Fuse 32A)
Plant Supply +ve from pin 3. 16 Amp rated.
Plant Supply +ve from pin 3. 16 Amp rated.
Plant Supply +ve. 5 Amp rated.
2.5mm
2.5mm
1.0mm
1.0mm
1.0mm
PLUG B 11 WAY
DESCRIPTION
Charge fail / excite
Auxiliary input 1
Auxiliary input 2
Auxiliary input 3
Auxiliary input 4
Auxiliary input 5
Auxiliary input 6
Functional Earth
Magnetic pickup +ve
Magnetic pickup -ve
Not connected
CABLE
SIZE
2.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
2.5mm
0.5mm
0.5mm
-
NOTES
Do not connect to ground (battery ve)
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
Connect to a good clean earth point
Connect to Magnetic Pickup device
Connect to Magnetic Pickup device
NOTE:- Ensure magnetic pickup screen is connected to ground at one end only.
NOTE:- When the module is configured for CanBus J1939 operation, terminals 17 & 18 should be
left unconnected. Engine speed is transmitted to the 52xx controller on the CanBus link.
8.1.3
PIN
No
20
21
22
PLUG C 3 WAY (OPTIONAL)

DESCRIPTION
CanBus port Common
CanBus port H
CanBus port L
CABLE
SIZE
0.5mm
0.5mm
0.5mm
NOTES
Use only 120W CanBus approved cable
8.1.4
PIN
No
23
24
25
26
DESCRIPTION
RS485 port Common
RS485 port B
RS485 port A
Not connected
8.1.5
PIN
No
27
28
29
30
31
Mains loading relay

Mains loading relay
Generator loading relay
Generator loading relay
Mains (utility) L1 voltage
monitoring input
monitoring input
monitoring input
Mains (utility)Neutral input
33
34
8.1.6
PIN
No
35
Generator L1 voltage
monitoring input
monitoring input
monitoring input
Generator Neutral input
37
38
8.1.7
30
NOTES
Use only 120W RS485 approved cable
CABLE
SIZE
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
NOTES
Connect to mains contactor coil
Connect to mains contactor feed supply
Connect to generator contactor coil
Connect to generator contactor feed supply
Connect to mains L1 (AC)
(Recommend 2A fuse)
(Recommend 2A fuse)
(Recommend 2A fuse)
Connect to mains Neutral (AC)
PLUG F 4 WAY
DESCRIPTION
36
CABLE
SIZE
0.5mm
0.5mm
0.5mm
-
PLUG E 8 WAY
DESCRIPTION
32
PIN
No
39
40
41
42
43
PLUG D 4 WAY (OPTIONAL)
CABLE
SIZE
1.0mm
1.0mm
1.0mm
1.0mm
NOTES
Connect to generator L1 output (AC)
(Recommend 2A fuse)
(Recommend 2A fuse)
(Recommend 2A fuse)
Connect to generator Neutral terminal (AC)
PLUG G 5 WAY
DESCRIPTION
CT Secondary for L1
CT Secondary for L2
CT Secondary for L3
CT secondary common
Not connected
CABLE
SIZE
2.5mm
2.5mm
2.5mm
2.5mm
-
NOTES
Connect to secondary of L1 monitoring CT
Connect to secondary of all monitoring CTs
8.1.8
PIN
No
44
45
46
47
PLUG H 4 WAY
DESCRIPTION
Oil Pressure Input
Coolant Temperature
Input
Fuel Level input
Sender Common Return
CABLE
SIZE
0.5mm
0.5mm
NOTES
Connect to Oil pressure sender
Connect to Coolant Temperature sender
0.5mm
0.5mm
Connect to Fuel Level sender

Return feed for senders*.
NOTE*:- If using single terminal senders refer to connection diagram. If using earth return type
senders connect return terminals to pin 47 and also connect pin 47 to earth. This is detailed in the
Appendix section entitled Sender wiring recommendations elsewhere in this manual.
left unconnected. Engine oil pressure and coolant temperature is transmitted to the 52xx controller
on the CanBus link.
8.1.9
PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via the 810 configuration interface.
Module can then be re-configured utilising the 5200 series configuration
software.
8.1.10 EXPANSION OUTPUT CONNECTOR

The expansion connector allows connection to the 157 relay expansion module
or to the 548 LED Remote annunciator module.
32
8.2
CONNECTOR FUNCTION DETAILS
The following describes the functions of the 3 connectors on the rear of the module. See rear panel layout FIG 5.
8.2.1
PIN
No
1
2
3
4
5
6
7
8
8.2.2
PIN
No
9
10
11
12
13
14
15
16
17
18
19
PLUG A 8 WAY
DESCRIPTION
DC Supply -ve. System DC negative input. (Battery Negative).
DC Supply +ve. System DC positive input. (Battery Positive).
Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is
not connected to positive the module will be locked out, and if the engine is
running it will shutdown immediately. The Positive Supply is also removed from
Starter and Fuel outputs, therefore only a single pole Emergency Shutdown button
is required.
Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or
engine fuel control system.
Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor.
Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration
Manual for options available.
PLUG B 11 WAY
DESCRIPTION
Charge Fail input / Excitation output. Supplies excitation to the Plant Battery
Charging Alternator, also an input for the Charge Fail detection circuitry.
Auxiliary input 1. This is a negative switched configurable input, see Calibration
Manual for options available. It is possible to configure the input to be a normally
closed signal or a normally open signal.
Functional Earth - Ensure connection to a good clean earth point.
Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing.
Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing.
Not connected
NOTE:- Ensure magnetic pickup screen is connected to ground at one end only.
left unconnected. Engine speed is transmitted to the 52xx controller on the CanBus link.
8.2.3
PIN
No
20
21
22
8.2.4
PIN
No
23
24
25
26
8.2.5
PIN No
27
28
29
30
31
32
33
34
8.2.6
PIN
No
35
36
37
38
8.2.7
PIN No
39
40
41
42
43
34
PLUG C 3 WAY (OPTIONAL)

DESCRIPTION
CanBus port Common. Do not connect this terminal to earth. Use only screened 120W cable
approved specifically for use in CanBus applications.
CanBus port H. Use only screened 120W cable approved specifically for use in CanBus
applications.
CanBus port L. Use only screened 120W cable approved specifically for use in CanBus
applications.
PLUG D 4 WAY (OPTIONAL)

DESCRIPTION
RS485 port Common
RS485 port B. Use only screened 120W cable approved specifically for use in RS485 applications.
RS485 port A. Use only screened 120W cable approved specifically for use in RS485 applications.
Not used. Do not connect to this terminal.
PLUG E 8 WAY
DESCRIPTION
Mains loading relay, normally closed. Volts free contact to terminal 28.
Mains loading relay, normally closed. Volts free contact to terminal 27.
Generator loading relay, normally open. Volts free contact to terminal 30.
Generator loading relay, normally open. Volts free contact to terminal 29.
Mains L1 voltage monitoring input. Connect to mains L1 supply
Mains L2 voltage monitoring input. Connect to mains L2 supply. If using single phase AC system
do not connect to this terminal.
Mains L3 voltage monitoring input. Connect to mains L3 supply. If using single phase or two
phase AC system do not connect to this terminal.
Mains Neutral input. Connect to mains N supply. If using 3phase 3wire AC system, do not
connect to this terminal.
PLUG F 4 WAY
DESCRIPTION
Generator L1 sensing input. Connect to alternator L1 output.
Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do not
connect this terminal.
Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do not
connect this terminal.
Generator N sensing input. Connect to alternator N output.
PLUG G 5 WAY
DESCRIPTION
Generator L1 current transformer connection.
Generator L2 current transformer connection. If single phase is used do not connect this pin.
Generator L3 current transformer connection. If single phase is used do not connect this pin.
Generator current transformer common connection and CT earth connection.
Not used. Do not connect to this terminal.
8.2.8
PIN
No
44
45
46
47
PLUG H 4 WAY
DESCRIPTION
Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to connection
diagram for details.
Coolant Temperature sensing input. Connect to resistive type coolant temperature sender. Refer
to connection diagram for details.
Fuel Level sensing input. Connect to resistive type fuel level sender. Refer to connection diagram
for details.
Sender Common connection. Return feed from sender units - refer to connection diagram for
details.
left unconnected. Engine oil pressure and coolant temperature is transmitted to the 52xx controller
on the CanBus link.
8.2.9
PURCHASING ADDITIONAL CONNECTOR PLUGS FROM SUNLIGHT
If you require additional plugs from SUNLIGHT, please contact our Sales department using the part numbers below.
5220 Terminal
1-8
9-19
20-22
23-26
27-34
35-38
39-43
44-47
Connector
A
B
C
D
E
F
G
H
Plug descriptio
BL08 8way 5.08mm spacing connector plug
SUNLIGHT Part nr.

007-125
007-135
007-409
007-408
007-410
007-003
007-329
007-100
8.3
ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS
This section of the manual is intended to describe only the connections between the 52xx controller and J1939
enabled controllers. All other connection details are described in the previous sections.
NOTE:- The CANbus specification, used by J1939, requires that a 120W terminator is fitted to each end of the
communications link. This termination resistor is fitted internally into the 52xx controller so is not required externally.
Ensure that the 52xx controller is the last device on the communications link where more than one device is
connected to the engine ECUs J1939 connector.
8.3.1
CUMMINS ISB / ISBE
PLUG A 8 WAY
52xx
52xx
PIN No
DESCRIPTION
4
Fuel relay output
5
Start relay output
6
Aux output 1
PLUG C 3 WAY
52xx
52xx
PIN No
DESCRIPTION
36
Cummins ISB OEM Harness

connector B
39
Use to control a 30A external
slave relay to supply DC battery
power to 01,07,12,13
Cummins ISB 9 pin Deutsch

connector
SAE J1939 shield
21
CANbus H
SAE J1939 signal
22
CANbus L
SAE J1939 return
NOTES
key switch input.
Connects directly to engine starter
solenoid.
Configure 52xx aux op 1 to be Louvre
control and configure 52xx ETS Hold
Timer to 20 seconds. This is used to
power down the engine ECU 20seconds
after the set comes to rest.
NOTES
Screen for the J1939 cable. Connect at
Cummins ECU end only.
J1939 + Use only screened 120W
impedance cable approved specifically
for use in CANbus applications.
J1939 - Use only screened 120W
8.3.2
JOHN DEERE
PLUG A 8 WAY
52xx
52xx
PIN No
DESCRIPTION
4
Fuel relay output
5
Start relay output
John Deere 21-pin Deutsch

connector
G, J
D
PLUG C 3 WAY
52xx
52xx
PIN No
DESCRIPTION
20
CANbus common
John Deere 21-pin Deutsch

connector
-
21
CANbus H
22
CANbus L
NOTES
G = Switched ECU power, J = Ignition
Start
NOTES
52xx end only.
8.3.3
PERKINS 2800 SERIES
PLUG A 8 WAY
52xx
52xx
PIN No
DESCRIPTION
4
Fuel relay output
5
Perkins Customer interface

connector
1, 10, 15, 33, 34
Start relay output
PLUG C 3 WAY
52xx
52xx
PIN No
DESCRIPTION
20
CANbus common
Perkins Customer interface

connector
-
21
CANbus H
31
22
CANbus L
32
NOTES
Powers up ECU and enables the
injectors.
solenoid.
NOTES
52xx end only.
NOTE:- According to Perkins, warning lamps or equivalent must be connected to Perkins

customer interface connector terminals 3, 4, 5, 8, 9, 16, 17. Failure to connect to these terminals will
results in open circuit alarms from the ECU. Perkins have advised that a suitable equivalent for the
warning lamp is a 220W 5W resistor. Be aware that outputs on terminals 4,5, & 16 are battery positive
outputs. The outputs on terminals 3, 6, 8, 9 & 17 are battery negative outputs.
38
8.3.4
SCANIA S6
PLUG A 8 WAY
52xx
52xx
PIN No
DESCRIPTION
4
Fuel relay output
5
Start relay output
PLUG C 3 WAY
52xx
52xx
PIN No
DESCRIPTION
20
CANbus common
Scania EMS B1 connector

3
-
Scania EMS B1 connector

-
21
CANbus H
22
CANbus L
10
NOTES
Ignition U15
solenoid.
NOTES
52xx end only.
8.3.5
VOLVO TAD12
PLUG A 8 WAY
52xx
52xx
PIN No
DESCRIPTION
4
Fuel relay output
5
Start relay output
6
Aux output 1
Volvo TAD12 Stand alone

connector terminal
H
E
P
PLUG C 3 WAY
52xx
52xx
PIN No
DESCRIPTION
20
CANbus common
Volvo TAD12 Data bus

connector terminal
-
21
CANbus H
1 (Hi)
22
CANbus L
2 (Lo)
ADDITIONAL CONNECTIONS TO TAD12 ECU

Volvo TAD12 Stand alone
connector terminal
R
ECU Power negative supply
Q
ECU Power positive supply
NOTES
TAD12 STOP input.
TAD12 START input.
Aux output 1 configured to Louvre
control.
NOTES
52xx end only.
NOTES
NOTE:- Should the TAD12 ECU detect an engine fault not monitored by the 52xx, an external
reset must be provided to reset the ECU.
Volvo specify that the reset is performed using external pushbuttons to give an input to TAD12
Standalone connector terminal J (diagnostics), P (power) and H(stop).
According to Volvo, the reset sequence is :
Press and hold down the diagnostic button (terminal J) and apply power to H (stop)
Apply power to P (but dont start the engine).
Hold these inputs for three seconds.
Release the diagnostic button (terminal J).
Remove power from H (stop).
Remove power from P (power).
40
SPECIFICATION
DC Supply
Cranking Dropouts
Typical Standby Current

Max. Operating Current
Alternator / Mains (Utility) Input
Range
Single phase 2 wire system
3Phase 4Wire System
3Phase 3Wire System
2Phase 3Wire System
Alternator / Mains (Utility) Input
Frequency
Magnetic Input Range (if fitted)
Magnetic Input Frequency
CanBus interface type (optional)
Start Relay Output
Fuel Relay Output
Auxiliary Relay Outputs
Dimensions
Panel cutout
Charge Fail / Excitation Range
Operating Temperature Range
C.T. Burden
C.T. Secondary
C.T. Class
Electromagnetic Compatibility
Electrical Safety
Cold Temperature
Hot Temperature
Humidity
Vibration
Shock
8.0 to 35 V Continuous.
Able to survive 0 V for 50mS, providing supply was at least 10 V before
dropout and supply recovers to 5V. This is achieved without the need for
internal batteries.
250. mA at 12 V. 125. mA at 24 V.
425. mA at 12 V. 215. mA at 24V
15V AC - 277 V AC (ph-N) (+20%)

15V AC - 277 V AC (ph-N) 3 Phase 4wire (+20%)
30V AC - 480 V AC (ph-ph) 3 Phase 3wire (+20%)
30V AC - 480 V AC (ph-ph) / 15V AC - 277V AC (ph-N) (+20%)
50Hz - 60 Hz at rated engine speed
+/- 0.5 V to 70 V Peak
10,000 Hz (max) at rated engine speed.
J1939
16 Amp DC at supply voltage.
240mm x 172mm x 57mm (9.45 x 6.77 x 2)
220mm x 160mm ( 8.7 x 6.3) Maximum panel thickness 8mm (0.3)
0 V to 35 V
-30 to +70C
2.5VA
5A
Class 1 Recommended
BS EN 50081-2 EMC Generic Emission Standard (Industrial)
BS EN 50082-2 EMC Generic Immunity Standard (Industrial)
BS EN 60950 Safety of I.T. equipment, including electrical business
equipment.
BS EN 60068-2-1 to -30 oC
BS EN 60068-2-2 to +70oC
BS2011-2-1 to 93% RH @ 40C for 48 Hours
BS EN60068-2-6
10 sweeps at 1 octave/minute in each of 3 major axes.
5Hz to 8Hz @ +/-7.5mm constant displacement
8Hz to 500Hz @ 2gn constant acceleration
BS EN 60068-2-27
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration
9 COMMISSIONING
9.1.1
PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:7.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the
system.
7.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
7.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module
will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC
positive (+ve)
7.4. To check the start cycle operation take appropriate measures to prevent the engine from starting (disable the
operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery
supply. Select MANUAL, the unit start sequence will commence.
7.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start
the engine for the pre-set number of attempts the LCD will display its icon indicating; Failed to start
Select the STOP/RESET position to reset the unit.
7.6. Restore the engine to operational status (reconnect the fuel solenoid), again select MANUAL, this time the
engine should start and the starter motor should disengage automatically. If not then check that the engine is
fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to
operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input
wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the
engine and alternator parameters - refer to the Description of Controls section of this manual.
7.7. Select AUTO on the front panel, the engine will run for the pre-set cooling down period, then stop. The
generator should stay in the standby mode. If not check that there is not a signal present on the Remote start
input and that the mains (utility) supply is healthy and available.
7.8. Initiate an automatic start by supplying the remote start signal or failing the mains(utility) supply. The start
sequence will commence and the engine will run up to operational speed. Once the generator is available a
load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator
Contactor Coil (if used). Check the Warming timer has timed out.
7.9. Remove the remote start signal and/or ensure the mains (utility) supply is healthy, the return sequence will
start. After the pre-set time period, the load will be removed from the generator. The generator will then run for
the pre-set cooling down period, then shutdown into its standby mode.
7.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging
functions. For details of this procedure see section entitled Front Panel Configuration Editing the date/time.
7.11. If despite repeated checking of the connections between the 5220 and the customers system, satisfactory
operation cannot be achieved, then the customer is requested to contact the factory for further advice.
42
10 FAULT FINDING
SYMPTOM
Unit is inoperative
Unit shuts down
Unit locks out on Emergency Stop
Intermittent Magnetic Pick-up

sensor fault
Low oil Pressure fault operates
after engine has fired
High engine temperature fault

operates after engine has fired.
Shutdown fault operates
Warning fault operates
Fail to Start is activated after preset number of attempts to start
Continuous starting of generator
when in AUTO
Generator fails to start on receipt

of Remote Start signal or mains
(utility) supply failure.
Pre-heat inoperative
Starter motor inoperative
Engine runs but generator will not

take load
Incorrect reading on Engine
gauges
POSSIBLE REMEDY
Check the battery and wiring to the unit. Check the DC supply. Check the DC
fuse.
Check DC supply voltage is not above 35 Volts or below 9 Volts
Check the operating temperature is not above 70 C. Check the DC fuse.
If an Emergency Stop Switch is not fitted, ensure that a positive is connected
to the Emergency Stop input. Check emergency stop switch is functioning
correctly. Check Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only connected at one end, if
connected at both ends, this enables the screen to act as an aerial and will
pick up random voltages.
Check engine oil pressure. Check oil pressure switch/sender and wiring.
Check configured polarity (if applicable) is correct (i.e. Normally Open or
Normally Closed) or that sender is compatible with the 5220 Module and is
correctly configured.
Check engine temperature. Check switch/sender and wiring. Check configured
polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that
sender is compatible with the 5220 Module.
Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Check relevant switch and wiring of fault indicated on LCD display. Check
configuration of input.
Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery
supply is present on the Fuel output of the module. Check the speed sensing
signal is present on the 5220 inputs. Refer to engine manual.
Check that mains (utility) supply is healthy and check that its protection fuses
are in place and are not blown
Check that there is no signal present on the Remote Start input. Check
configured polarity is correct.
Check Start Delay timer has timed out.
If remote start fault, check signal is on Remote Start input. Confirm input is
configured to be used as Remote Start.
Check wiring to engine heater plugs. Check battery supply. Check battery
supply is present on the Pre-heat output of module. Check pre-heat has been
selected in your configuration.
Check wiring to starter solenoid. Check battery supply. Check battery supply is
present on the Starter output of module. Ensure that the Emergency Stop
input is at +Ve.
Check Warm up timer has timed out. Ensure generator load inhibit signal is not
present on the module inputs.
Check engine is operating correctly. Check sender and wiring paying particular
attention to the wiring to terminal 47 (refer to appendix). Check that sender is
compatible with the 5220 Module and is correctly configured.
NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the
module to be configured to provide a wide range of different features always refer to the source of
your module configuration if in doubt.
11 FACTORY DEFAULT CONFIGURATION

In the tables below, the icon @ indicates an item that can be adjusted from the modules front panel editor.
Absence of the @ icon beside an item means that adjustment of this parameter is only possible using the 5200
series configuration software in conjunction with the P810 interface.
For further details on adjustment from the front panel editor, see the section entitled Front panel configuration
elsewhere within this manual.
5200 series configuration software. Configuration for 5220 module.
Filename 5220a.XCF
Printed on 29/10/02 10:42:03
Module settings
Base module
Value
5220 automatic mains failure module
Miscellaneous settings
Alternator fitted
Poles
Magnetic pickup fitted
J1939 enabled
AC System
VT Ratio
Mains failure detection
Number of start attempts
Enable fast loading feature
Immediate mains dropout
Value
Yes
4
No
No
3 phase, 4 wire
Disabled
Enabled
3
No
Disabled
Input settings Analogue | Oil pressure

Low oil pressure input type
Value
VDO 10 bar
@
@
Low oil pressure pre-alarm

Low oil pressure shutdown
Input settings Analogue | Coolant temp

High coolant temp input type
High coolant temp pre-alarm
High coolant temp shutdown
Trip
1.17 Bar 17.0 PSI
1.03 Bar 14.9 PSI
Value
@
@
VDO 120 degrees C

115C 239F
120C 248F
Input settings Analogue | Fuel level
Value
Fuel level input type
VDO Ohm
Range
No
10%
Fuel pump control

Low fuel level
Input settings - Digital
1 Remote start
2 Lamp test
3 User configured
4 User configured
5 User configured
6 User configured
44
Return
1.24 Bar 18.0 PSI
N/A
110C 230F
N/A
Value
Close to activate
Close to activate
Close to activate, Warning Active from safety on
Close to activate, Shutdown Always active
Close to activate, Shutdown Active from safety on
Close to activate, Electrical trip Always active
Output settings Relay

1 Energise
2 Energise
3 Energise
4 Energise
5 De-energise
Value
Preheat (during pre-heat timer)
Common alarm
System in auto mode
Close generator
Close mains
Output settings Expansion A

1 Energise
2 Energise
3 Energise
4 Energise
5 Energise
6 Energise
7 Energise
8 Energise
LCD indicator settings
1 Lit
2 Lit
3 Lit
4 Lit
Timer settings
Mains transient delay
Start delay
Pre-heat
Cranking time
Crank rest time
Smoke limit
Smoke limit off
Safety on delay
Overspeed overshoot
Warming up time
Transfer time
Breaker close pulse
Breaker trip pulse
Return delay
Cooling time
ETS solenoid hold
Fail to stop delay
Generator transient delay
Battery low volts delay
Battery high volts delay
LCD page timer
Value
Output not used
Output not used
Output not used
Output not used
Output not used
Output not used
Output not used
Output not used
Value
Digital input 1 active
Digital input 2 active
System in auto mode
Common alarm
@
@
@
@
@
@
@
@
@
@
@
Value
1s
5s
0s
10s
10s
0s
0s
10s
2s
0s
0.7s
0.5s
0.5s
30s
30s
0s
30s
1s
1m
1m
5m
Mains (utility) settings Voltage/frequency

Under volts trip
Over volts trip
Under frequency trip
Over frequency trip
@
@
@
@
Trip
180V AC
280V AC
45Hz
52Hz
Return
200V AC
260V AC
48Hz
55Hz
Generator settings Voltage/frequency

Under volts trip
Under volts pre-alarm
Over volts pre-alarm
Over volts trip
Under frequency trip
Under frequency pre-alarm
Over frequency pre-alarm
Over frequency trip
Generator settings Current/power
Generator CT primary
Generator full load rating
Delayed overcurrent
Trip Curve
@
@
@
@
@
@
@
@
Engine settings Crank disconnect

Crank disconnect on generator frequency
Crank disconnect oil pressure
Check oil pressure prior to starting
Engine settings speed
Underspeed trip
Underspeed prealarm
Overspeed prealarm
Overspeed trip
Overspeed overshoot
Exercise scheduler settings

Enable exercise scheduler
Comms
Site identity
Genset ID
Modem mode
Modem init (not auto answer)
Modem init (auto answer)
Modem Hang
Master inactivity timeout
46
Return
N/A
207V AC
265V AC
N/A
N/A
45.0 Hz
52.0 Hz
N/A
Value
600 A
500 A
100% ( 500 A )
36
Value
21.0 Hz
<Disabled>
Yes
Value
1250 RPM
1350 RPM
1650 RPM
1750 RPM
0%
@
@
@
@
Plant battery settings

Under volts warning
Over volts warning
Charge alternator warning
Trip
184V AC
196V AC
253V AC
276V AC
40.0 Hz
42.0 Hz
55.0 Hz
57.0 Hz
@
@
@
Trip
8.0 V DC
33.0 V DC
8.0 V DC
Return
9.0 V DC
32.0 V DC
N/A
Value
No
Value
No modem
+MS=11,1,,S7=60S0=0&S0&C1&D3
+MS=11,1,,S7=60S0=2&S0&C1&D3
H0
0
12 TYPICAL WIRING DIAGRAM
5200 series
configuration software
L1
42
43
CT
Earth
F2A
35
F2A
F2A
38
29
LOAD
Mechanical interlock
Electrical interlock
30
27
Mains
loading
relay
12
F2A
28
13
31
F2A
32
F2A
15
33
To plant supply +ve
14
34
Optional
RS232
9 way D
Configurable auxiliary output 3
37
10
36
47
Generator
loading
relay
Configurable auxiliary input 3
L1
Mains (utility)
24
25
Optional
RS485
20
COM
21
22
Optional
CanBus
16
17
18
Not connected 19
Not connected 26
23
SCR
L2
CT
common
46
5220 controller
45
11
L2
41
44
L3
40
internal emergency stop
Oil pressure sender
L3
39
Fuel
Supply for
controller
1
Crank
These ground connections must be

on the engine block and must be
a sound electrical connection
to the sender bodies.
The ground wire to terminal 47 must
not be used to provide a ground
connection to any other device.
Fuel level sender
Generator
810
Not connected
Charge WL
alt.
Coolant temp. sender
810 interface
157/548
Output expansion
157 relay board
or
548 annunciator
Starter
motor
Battery
MPU
Ground screen
at one end only
Functional
Earth
Emergency
stop
13 APPENDIX
13.1 ALTERNATIVE WIRING TOPOLOGIES
The 5200 series controllers can support many different wiring topologies (AC systems) to suit the many systems in
use worldwide. The Typical connection diagram details how to connect the module when used in a 3 phase, 4 wire
system (3 phase star connected alternators). Changes to this typical wiring diagram for other AC systems are
detailed below.
NOTE:- The factory default configuration for the 5220 module is for use with the 3 phase, 4 wire
AC system. If another system is to be used, the controller must be reconfigured using the 5200 series
configuration software.
13.1.1 3 PHASE, 3 WIRE

The alternator is 3 phase delta connected. Phases are separated by 120
LOAD
Generator
Mains (utility)
L1
L1
CT
Earth
L2
L2
L3
L3
F2A
F2A
F2A
F2A
F2A
F2A
CT
common
42
35
43
36
37
29
30
Generator
loading
relay
38 34
27
Not connected
41
Not connected
40
Not connected
39
31
28
32
33
Mains
loading
relay
13.1.2 1 PHASE, 2 WIRE

Single phase alternator with neutral conductor.
LOAD
L1
L1
CT
Earth
Mains (utility)
Generator
F2A
F2A
F2A
F2A
G
48
36
37
38
29
30
Generator
loading
relay
27
28
Mains
loading
relay
31
32
33
Not connected
35
Not connected
43
Not connected
Not connected
42
Not connected
41
Not connected
40
Not connected
CT
common
39
34
13.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL)

The alternator is 2 phase star connected. The live phases are separated by 180
LOAD
Generator
Mains (utility)
L1
L1
CT
Earth
L2
L2
F2A
F2A
F2A
G
F2A
CT
common
40
41
42
43
35
Not connected
39
36
37
38
29
30
Generator
loading
relay
27
28
Mains
loading
relay
31
32
33
34
13.2 ICONS AND LCD IDENTIFICATION

13.2.1 PUSH BUTTONS
Display
Description
Display
Description
Display
Description
Stop/Reset
Configure / log
Auto mode
Scroll
Test mode
Start (when in
Manual or Test
mode)
Display
Description
Manual mode
13.2.2 STATUS / MEASUREMENT UNITS

Display
L1
L1-
Description
Display
L2
Phase
Phase - Neutral
L2-
L1- L2
Phase - Phase
L2- L3
BAR
Pressure
Voltage
A
kW
Description
Phase
Phase
Phase - Neutral
L3-
Phase - Phase
L3- L1
Phase - Phase
KPa Oil Pressure

Units
PSI
Pressure
Temperature
Hz
Frequency
Amperes
Temperature
RPM
Speed
KiloWatts
kVA
Apparent power
KW divided by
kVA
Hours Run
AC
Generator
Timer in progress
DC
Mains (Utility)
Fuel level
Event log
Configuration
mode active
Panel locked by
configurable input
L3
KPa
Can
Canbus J1939
messages
Display
Description
Phase -Neutral
13.2.3 ALARM INDICATIONS

Display
Description
Warning Alarm
Shutdown Alarm
Fuel
Low Oil Pressure

High Coolant
Temperature
Fail to start (Overcrank)
Charge Fail
Emergency Stop
Description
Electrical Trip
High Current
Warning
Over Voltage (AC)
Under Voltage
(AC)
Over Voltage (DC)
Over-speed
Over frequency
Under Voltage
(DC)
Under-speed
Under frequency
Auxiliary Indication
50
Display
Auxiliary Alarm
(Warning or Shutdown)
13.3 5220 IDMT TRIPPING CURVES (TYPICAL)

5220 Delayed over-current protection
1000000
Tripping time in seconds
100000
10000
1000
100
10
1
1
2
Current as a multiple of the trip-point setting (tripping curve = 36)
13.4 SENDER WIRING RECOMMENDATIONS

13.4.1 EARTH RETURN SENDERS
Connection Name
Terminal Number
Oil pressure Sender
44
Coolant temperature
sender
45
Fuel level sender
46
Sender common
47
NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth

point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection
NOTE:- . If you use PTFE insulating tape on the sender thread when using earth return senders,
ensure you do not insulate the entire thread as this will prevent the sender body from being earthed
via the engine block.
13.4.2 INSULATED RETURN SENDERS

Connection Name
Terminal Number
Oil pressure Sender
44
Coolant temperature
sender
45
Fuel level sender
46
Sender common
47
NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth

point on the ENGINE BLOCK, not within the control panel .
52
13.4.3 FUEL LEVEL SENDERS

The resistive fuel level senders supported by the 5200 series controllers are devices that translate fuel level into
resistance. A change in fuel level translates directly to a change in the resistance of the sender. In the case of a
parallel sided fuel tank, an accurate measure of the fuel level can easily be made, however as shown in the
example below, this is not the case with non-parallel sided fuel tanks. Therefore it is recommended that only parallel
sided fuel tanks are used to ensure correct fuel level detection.
The fuel sender measures
the distance between the top
of the tank and the fuel level.
Typically, they use a ball
float.
In this example, the distance
between the top of the tank
and the level of the fuel is
50% of the height of the
tank. The fuel level sender
will report the tank correctly
as being 50% full.
For a parallel-sided tank like
this one, 50% distance
and the level of the fuel will
occur when the tank is 50%
full of fuel.
In this example, the distance
and the level of the fuel is
again 50% of the height of
the tank, the fuel level
sender will report the tank as
being 50% full.
However, as the bottom of
the tank is curved, the actual
amount of fuel in the tank is
only about 40%. The fuel
sender is incorrectly
reporting the amount of
remaining fuel.
13.5 J1939 CANBUS INTERFACE (OPTIONAL)

Modules fitted with the J1939 CANbus interface (specify on ordering) are capable of receiving engine data
from engine CANbus controllers compliant with the J1939 standard.
Canbus enabled engine controllers monitor the engines operating parameters such as engine speed, oil
pressure, engine temperature (among others) in order to closely monitor and control the engine. The data that is
gathered by the engine controller is then transmitted on an industry standard communications interface (Canbus
J1939). This allows generator controllers such as the SUNLIGHT 52xx range to access these engine parameters
with no physical connection to the sensor device.
13.5.1 EXAMPLE OF CONNECTING 5220 CONTROLLER TO ENGINE CANBUS.

LOAD
L1
L1
CT
Earth
L2
L2
L3
L3
Generator
Mains (utility)
F2A
F2A
F2A
F2A
G
810 interface
F2A
F2A
M
Optional
RS232
CT
common
47
+
Battery
Charge WL
alt.
These ground connections must be

on the engine block and must be
a sound electrical connection
The ground wire to terminal 47 must
not be used to provide a ground
connection to any other device.
33
34
9 way D
10
11
23
24
25
Not connected 19
Not connected 26
Not connected
Not connected
To plant supply +ve
17
18
CanBus
12
13
14
15
Fuel
Crank
Starter
motor
54
46
32
Mains
loading
relay
5220 controller
45
31
28
Generator
loading
relay
Fuel level sender
Output expansion
157 relay board
or
548 annunciator
44
27
30
29
38
Emergency
stop
37
Supply for
controller
36
35
Not connected
internal emergency stop
157/548
43
Not connected
42
41
Not connected
40
39
810
5200 series
configuration software
Optional
RS485
SCR
20
21
COM
COM
22
16
Functional
Earth
13.6 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE

The 5220 module can be calibrated by using PC with Interface Module 810 and 5200 series configuration
software.
The 5200 series configuration software kit comprises the following: 810 Interface Module
25 to 9 way adapter
RJ45 (8 Pin) Connecting Lead
SUNLIGHT SoftwareCD with configuration software
13.7 OUTPUT EXPANSION

There are several methods of output expansion available for the 5220 module:-
13.7.1 RELAY OUTPUT EXPANSION (157)

An expansion module is available, which connects to the configuration socket, and enables the 5220 to use eight
additional relays, providing Volt-free contacts for customer connection.
POWER ON LED
RELAY ACTIVE LED'S
LINK LOST LED

FUNCTION
SELECTOR
Refer to technical data sheet on the 157 relay module for further details.
13.7.2 LED OUTPUT EXPANSION (548)

An expansion module is available, which connects to the configuration socket, and enables the 5220 to use eight
additional LEDs, providing remote LED indication up to 50 metres away.
Refer to technical data sheet on the 548 LED module for further details.
It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion of the same 8 items if
required (Please refer to our Technical Support department for details.).
13.8 INPUT EXPANSION

It is possible to increase the number of monitored inputs available by utilising a SUNLIGHT 54x Protection
Expansion/Annunciator. Please refer to our Technical department for details.
56
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SUNLIGHT Model AMF 5220 Automatic Mains Failure & Instrumentation System Operators Manual

AMF 5220 AUTOMATIC MAINS FAILURE MODULE

Headquarters: 23 klm N.R. Athens-Lamia

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2 AMF 5220 OPERATING MANUAL

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. .........5

AUTOMATIC MODE OF OPERATION ............................................................................... 6

FRONT PANEL CONFIGURATION................................................................23

INSTALLATION INSTRUCTIONS ..................................................................27

ELECTRICAL CONNECTIONS ......................................................................29

3 AMF 5220 OPERATING MANUAL

FAULT FINDING ......................................................................................... 43

FACTORY DEFAULT CONFIGURATION................................................... 44

TYPICAL WIRING DIAGRAM ..................................................................... 47

13.1 ALTERNATIVE WIRING TOPOLOGIES........................................................................... 48

AMF 5220 OPERATING MANUAL

2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

Highlights an essential element of a procedure to ensure correctness.

Indicates a procedure or practice which, if not strictly observed, could

Indicates a procedure or practice, which could result in injury to personnel

5 AMF 5220 OPERATING MANUAL

AUTOMATIC MODE OF OPERATION

and event logs

is NOT affected by panel lock.

This mode is activated by pressing the

pushbutton. An LED indicator beside the button confirms this

AMF 5220 OPERATING MANUAL

fault will be displayed accompanied by a flashing shutdown

7 AMF 5220 OPERATING MANUAL

To initiate a start sequence in MANUAL, press the

and event logs

pushbutton. When the controller is in the manual mode

fault will be displayed accompanied by a flashing

AMF 5220 OPERATING MANUAL

To initiate a start sequence in TEST, press the

and event logs

pushbutton. When the controller is in the test mode (indicated

fault will be displayed accompanied by a flashing

9 AMF 5220 OPERATING MANUAL

If no alarms are present the LCD

Low battery volts warning (all symbols steady)

Low battery volts warning indicator still

AMF 5220 OPERATING MANUAL

icon will illuminate.

is displayed on the LCD display, along with the appropriate

11 AMF 5220 OPERATING MANUAL

icon will illuminate.

icon will illuminate.

icon will illuminate.

icon will illuminate.

HIGH CURRENT WARNING ALARM

AMF 5220 OPERATING MANUAL

icon will illuminate.

icon will illuminate.

icon will illuminate.

13 AMF 5220 OPERATING MANUAL

icon will illuminate.

icon will illuminate.

AMF 5220 OPERATING MANUAL

HIGH CURRENT SHUTDOWN ALARM

icon will illuminate.

In the event of an electrical trip alarm the

icon will illuminate.