1. Features and Characteristics             

• High end Micro-controller(DSP) technology
• Wide range of auxiliary supply: 7V to 45Vdc.
• Low power Consumption : 200 mA @ 12 V DC.
• Alphanumeric 16X4 or 16X2 LCD display with keypad for ease of operation.
• Input Keys: Multi Function  7 Keys for mode selection and interaction with leds on them.
• Display and supervision of Mains & D.G voltages for UV, OV, Phase missing.
• Excellent load monitoring- no-load, overload and unbalanced load warning, & trip.
• GSM modem for communication through SMS to 2 nos of Mobiles. To send info about last 24 hour performance ( parameters can be selected) . Alert on , warning & trip, SMS.
• Measurements of different Mains and Generator parameters.
• Ten internal fault annunciation for start failure, over speed, low battery, stop failure etc.
• Four spare terminals for connecting to external fault signals.
• Display and supervision of battery voltage.
• Isolated inputs and outputs (through relay board).
• Parameter settings from front panel keypad (password protected).
• Periodic test feature.
• Six modes: Auto, Manual, Test, Bypass mode, Mains Display and Programming mode.
• Over speed indication/shutdown.
• DG starting process supervision.
• Indication of CB status.
• Wide array of time settings for start delay, stop delay, mains restoration, re-cooling etc.
• Energize to On (run) and energize to Off (stop) option , programmable.
• Real Time Clock (RTC) provided. Periodic SMS, Maintenance overdue dates programmable.
• Size: 165W X 125 H X 50 D in mm

Optional Features

• Sensing of telecom voltage (48 V) & or cabin temperature to start the generator.
• Aviation timer for switching ON/Off cabin lights.
• Serial communication Modbus RS232.

2.   Operating Modes

ICON operates in of the six  modes described below.

Operating modes can be selected from the front keypad. Proper messages are displayed on LCD & led in each of the modes.

These six modes are:-

1.      Auto---- to be selected from front key pad

2.      Manual ----  to be selected from front key pad

3.      Test ----- to be selected from front key pad

4.      Bypass ----- (Not from the Front keypad)

5.      Mains Display ----- (Not from the Front keypad)

6.      Programming----  to be selected from front key pad

2.1 Auto Mode

In the auto mode of operation, GENSET is started automatically, if the mains either fail or exceed operating limits , the mains CB is opened and generator CB is closed.

2.1.1 Auto Stand by Mode: In Normal condition the controller remains in this mode. Voltages of the three phases are monitored continuously for operating limits . Operating limits are specified by UV / OV , phase connection error or phase missing. If any of these operating limits are exceeded  then  ICON takes following action:

2.1.2 Auto start Mode: The Genset Start process is initiated.

         Start Delay : During engine start delay it waits to see if mains has returned to normal operating limits . This avoids false tripping .

         Preheater : Optional . Starts supply to the preheater  coil.

         Fuel Solenoid On : After a delay the fuel Solenoid relay is energised with  2 options.

• Energise to ON  is the normal  operation .  The fuel solenoid relay is made ON   which in turn makes the Fuel Solenoid ON & supply of Fuel to Genset.
• Energise to OFF-The Fuel Solenoid is always On & supplies Fuel to Genset.

Cranking : After engine start delay is over , crank relay operates. Min Cranking time is 2 sec & max time is 4 sec. If Oil Pressure & Speed  develops above  specified threshold limits , bet 2 and 4 secs  the crank relay is made OFF. The threshold limits for Oil P is warning limit set through programming & the threshold limit for speed is 1000 rpm

If the Oil P & Speed are not developed above specified limits another crank is attempted after a  delay of 6 seconds. The process continues till the threshold limits are reached. If  the Oil P & speed is still not reached after certain  no of Crank attempts ( as programmed )  “Start Fail” is declared.

If the cranking is successful the Genset checking process starts.

Genset Checking : A delay is provided to check the following parameters .

Engine Speed :  within  Underspeed & Overspeed trip limits

Genset Voltage : within UV/OV trip Limits.

If above parameters are within limits then Genset is declared as STABLE. DG ON led ismade ON.

Mains Contactor OFF : After the Engine is found stable , the mains contactor is made OFF. Mains Contactor led gets OFF.

Genset Contactor ON : After  programmable delay Genset Contactor is made ON.

LCD display starts displaying Genset parameters.

The Genset remains in this mode till ----- Mains is restored  or any fault occurs.

2.1.3 Auto Normal Shut Down  Mode:

When the Mains is restored, the Generator CB is opened and Mains CB is closed after the Mains restoration time. Then after a pre-programmed  re-cooling time, the GENSET is shut down.

The Mains restoration time ensures that the Mains supply voltage is stable before it is made available to consumer load.

Genset CB closure is confirmed by checking that there is NO  LOAD on Genset. If Genset CB non closure is sensed  or Genset does not stop properly it goes to Fault Acknowledge Mode.

Otherwise at the End of this process the Controller goes back to 2.1.1 Auto Stand by Mode.

2.1.4 Auto Fault Shut Down  Mode:

When the fault occurs  the Generator CB is opened and Mains CB. The Controller goes to FAULT Acknowledge Mode  with proper message on LCD Display as well as leds.

After acknowledging the fault ( correcting the fault ) it goes to Manual Mode & proper mode is to be selected at this time.

2.2 Manual Mode

2.2.1 Manual Stand by Mode

In this mode ICON ignores mains voltage. It only responds to Start and Stop commands from the keypad  

 Precaution: Before giving Start command to generator, one must ensure that the generator CB is open

2.2.2 Manual start Mode

Start key operation initiates the start operation.

The sequential process mentioned in the Auto Start is executed. This whole process can be made manual , if specified accordingly. If Manual Process is selected , after each STEP , Start key is required to be pressed as displayed on the LCD.

When Genset is ON,  The generator CB may now be switched on from keypad provided that the Mains CB is off .

LCD display starts displaying Genset parameters.

The Genset remains in this mode till ----- STOP KEY pressed  or any fault occurs

2.2.3 Manual Normal Shut Down  Mode:

Stop key initiates this mode. The Controller follows all the steps automatically or manually (if  specified ) as mentioned in the 2.1.3 Auto  Normal Shut Down  Mode.

Genset CB closure is confirmed by checking that there is NO  LOAD on Genset. If Genset CB non closure is sensed  or Genset does not stop properly it goes to Fault Acknowledge Mode.

 If this process isexecuted successfully Controller goes to 2.2.1 Manual Stand by Mode.

2.2.4 Manual Fault Shut Down  Mode:

When the fault occurs  the Generator CB is opened and Mains CB. The Controller goes to FAULT Acknowledge Mode  with proper message on LCD Display as well as leds.

After acknowledging the fault ( correcting the fault ) it goes to Manual Mode & proper mode is to be selected at this time.

2.3 Test Mode

Test Mode  is selected by pressing the TEST key on the front pad, entering thepasswaord.Test Mode can be selected only in 2.1.1 Auto Stand by Mode & 2.2.1 Manual Stand by Mode. In this mode no-load and load test run of the GENSET is possible

If  Test Mode is selected , it passes through all the STEPS mentioned in 2.1.2 Auto start Mode.

If the start process is executed successfully , Genset Parameters are displayed for at least 2 times before Shut down process starts ( the timing for test mode run can be specified ).

The Shut down process starts as mentioned in 2.1.3 Auto Normal Shut Down  Mode:

If Fault is generated during the operation shut down process starts as mentioned in 2.1.4 Auto Fault Shut Down  Mode:

If Mains failure is occurred during the test mode operation, the Mains emergency operation is initiated automatically.

At the end of successful completion of Test Mode the controller goes back to Previously selected mode.

2.4 By Pass mode

Bypass mode is selected by selecting proper digital input.

In the Bypass mode all the Genset Parameters are displayed and it keeps on displaying them unless and until the Bypass digital input is restored to normal position.

In Bypass mode the Controller has no control over the Generator operations. The Genset has to be Started / Stopped externally .

This mode cannot be selected from the front keypad

2.5 Mains Display Mode.

Mains Display Mode is selected from respective digital input .

In this mode all the parameters of the Mains  are displayed and it keeps on displaying them unless and until the respective digital Input  is restored to normal position.

This mode cannot be selected from the front keypad

2.6 Programming Mode

This mode basically helps in programming various parameters of  the ICON3.There are various sub modes in this mode and they are: (All the following passwords are editable)