manual for gc2100: genset controllers · • rpm sensing using genset’s output frequency •...

MANUAL FOR

GC2100:

GENSET

CONTROLLERS Product Manual Version #1.00

ABSTRACT This manual is intended as an information guide for operating SEDEMAC's GC2100 genset controllers.

Doc #SED-MAN-GC2100-002 Date: 16-Jul-2018

Copyright

All rights reserved. No part of this publication may be reproduced, distributed or transmitted

by any means (including photocopying or storing in any medium by electronic means or other)

without the prior written permission of the copyright holder. Any reference to trademarked

product names used within this publication is owned by their respective companies.

SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document

without prior notice. For permission requests and applications to reproduce any part of this

publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned

contact details.

SEDEMAC Mechatronics Pvt. Ltd. C9-10, C Block, MIDC Bhosari Pune 411026, INDIA Web Support: Email: [email protected] Website: www.sedemac.com Telephonic Support: +91-20-67313500 +91-8551041888 +91-8551043888 +91-8551933888 +91-8551039888

mailto:[email protected]

http://www.sedemac.com/

GC2100 SEDEMAC

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Safety Instructions

General Instructions This document includes important instructions that should be followed during installation and

maintenance of the generator Set controller.

For safety reasons, the manufacturer recommends that this equipment be installed and serviced by

an authorized service personnel. Follow all applicable state and local electrical codes.

Efficient and safe operation of the controller can be acquired only if the equipment is correctly

operated, configured and maintained. Many accidents arise due to ignorance or illiteracy towards the

elemental rules of safety and precautions.

The following safety notations found throughout this document indicate potentially hazardous

conditions to the operator, service personnel or the equipment.

• Highlights an essential element of a procedure to ensure correctness

• Indicates a procedure or practice, which could result in damage or destruction of equipment, if not strictly observed

• Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly

Electrical Safety Electric shock can cause severe personal injury or death.

Ensure the generator set must be grounded before performing any installation or service.

Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock.

Prevent contact with terminals, bare wires, connections, etc., while the generator and related

equipment are running. Do not tamper with interlocks.

To handle the maximum electrical current, sizes of wire gauge used for electrical connections and

wirings must be appropriate to which they will be subjected to.

In Operation Safety Before installing genset controller, ensure that all power voltage supplies are positively turned off at

their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental

start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.

Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal

electrical shock.

Remove electric power supply before removing controller or touching other electrical parts.

Use extreme caution when working on electrical components. High voltage can cause injury or death.

Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when

working near generator set or other electrical equipment.

Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling

electrical equipment.

Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or

feet are wet. It may result in severe electrical shock.

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Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock

or burning.

In case of an accident caused by electric shock, immediately shut down the electrical power source. If

this is not possible, try to release the victim from the live conductor. Avoid direct contact with the

victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live

conductor. If the victim is unconscious, apply first aid and get immediate medical help.

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List of Abbreviation

This list contains the list of acronyms used in this document and it can be used to refer their respective description. This list does not contain units of measure.

Acronym Description

AC Alternating Current

ACK Acknowledge

ALT Alternator

AMF Auto Mains Failure

AUX Auxiliary

BTS* Base Transceiver Station

CHG Charging

CKT Circuit

CT Current Transformer

DC Direct Current

DG Diesel Generator

DIG IN Digital Input

ENG TEMP Engine Temperature

GCU Genset Control Unit

Genset Generator Set

GND Ground

HMI Human Machine Interface

HSD High Side Driver

HWT High Water Temperature

LCD Liquid Crystal Display

LED Light Emitting Diode

LLOP Low Lube Oil Pressure

LOP Lube Oil Pressure

LVL Level

MCP Manual Control Panel

MPU Magnetic Pickup Unit

OV Over Voltage

PID Proportional Integral Derivative

PWM Pulse Width Modulation

RMS Root Mean Square

RPM Revolutions Per Minute

R-Y-B Red-Yellow-Blue

SCP Sensor Common Point

SMD State Machine Diagram

TEMP Temperature

USB Universal Serial Bus

UV Under Voltage

*BTS is also referred as Site Battery Monitoring in this user manual

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Table of Contents

Introduction ......................................................................................................................... 1

Key highlights of the product ........................................................................................... 1

Product Features ............................................................................................................ 1

Specifications ..................................................................................................................... 3

Terminals ........................................................................................................................ 3

Power Supply Specifications ........................................................................................... 3

Genset Voltages and Frequency Measurements ............................................................ 4

Genset Current Measurements ....................................................................................... 4

Earth leak Measurements ............................................................................................... 4

Mains Voltages and Frequency Measurements .............................................................. 5

Digital Inputs ................................................................................................................... 5

Analog Resistive Sensor Inputs ...................................................................................... 5

Site Battery Inputs ........................................................................................................... 6

Digital outputs .............................................................................................................. 6

D+ CHG ALT ................................................................................................................ 7

Sensor common point .................................................................................................. 7

Deep Sleep Mode Feature ........................................................................................... 7

Communication ports ......................................................................................................... 8

Installation ........................................................................................................................... 9

Dimensions ..................................................................................................................... 9

Mounting on panel .......................................................................................................... 9

Terminal Pin Details ...................................................................................................... 10

Typical Wiring Diagram ................................................................................................. 13

Monitoring Mode ............................................................................................................... 14

Description of Control Keys ............................................................................................ 16

Configuration mode ....................................................................................................... 16

Configurable parameters .............................................................................................. 17

Modes selection in GC2100 ............................................................................................. 33

Start and Stop Sequence .............................................................................................. 34

Operation modes .............................................................................................................. 36

Auto mode .................................................................................................................... 36

Manual mode ................................................................................................................ 41

Load sensing ..................................................................................................................... 44

Load Sensing in Manual mode ..................................................................................... 44

Load Sensing in Auto mode .......................................................................................... 44

Features ............................................................................................................................. 44

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Auto Config Exit Mode ............................................................................................... 44

Load Histogram ......................................................................................................... 44

Alarms ................................................................................................................................ 45

Troubleshooting ................................................................................................................ 49

Communication protocol ................................................................................................. 51

Connection Details..................................................................................................... 51

Precautions ................................................................................................................ 51

Supported Functions.................................................................................................. 52

Communication settings .................................................................................................. 52

Notes ......................................................................................................................................... 59

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List of Figure

Figure 1: GC2100 genset controller's front fascia ........................................................................ 2

Figure 2: Connectors of 5.08 mm pitch ........................................................................................ 3

Figure 3: Connectors of 10.16 mm pitch ...................................................................................... 3

Figure 4: SCP connection ............................................................................................................ 6

Figure 5: Dimensions of the GC2100 genset controller ............................................................... 9

Figure 6: Fixing clip and screw supplied along with controller .................................................... 10

Figure 7: Controller mounting on the panel using the fixing clips ............................................... 10

Figure 8: Rear view of the controller for terminal detail .............................................................. 11

Figure 9: Power circuit when used in the Auto Mains Failure Mode ........................................... 13

Figure 10: Control keys function ................................................................................................ 16

Figure 11: Configuration mode screen ....................................................................................... 16

Figure 12: Configuration mode authentication page screen ....................................................... 16

Figure 13: Saving setting screen ................................................................................................ 17

Figure 14: Mode selection screen .............................................................................................. 33

Figure 15: Flow chart of start sequence ..................................................................................... 34

Figure 16: Flow chart of stop sequence ..................................................................................... 35

Figure 17: Flow chart of Site monitoring mode ........................................................................... 36

Figure 18: Flow chart of cyclic mode .......................................................................................... 38

Figure 19: Flow chart of Auto Mains Failure (AMF) mode .......................................................... 39

Figure 20: Flow chart of remote start/stop mode ........................................................................ 40

Figure 21: Flow chart of manual mode ....................................................................................... 41

Figure 22: Pictorial reference for starting the engine ................................................................. 42

Figure 23: Pictorial reference for stopping the engine ................................................................ 42

Figure 24: Pictorial reference to acknowledge the alarm in any mode ....................................... 43

Figure 25: RS485 MODBUS connection with the help of two core shielded twisted pair cable . 51

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List of Tables

Table 1: Feature list ...................................................................................................................... 1

Table 2: Terminals ........................................................................................................................ 3

Table 3: Power supply specifications ........................................................................................... 3

Table 4: Genset voltage and frequency measurements ............................................................... 4

Table 5: Genset current measurements ....................................................................................... 4

Table 6: Earth leak measurements ............................................................................................... 4

Table 7: Mains voltages and frequency measurements ............................................................... 5

Table 8: Digital inputs ................................................................................................................... 5

Table 9: Analog resistive sensor inputs ........................................................................................ 5

Table 10: Site battery inputs ......................................................................................................... 6

Table 11: Digital outputs ............................................................................................................... 6

Table 12: D+ CHG ALT ................................................................................................................. 7

Table 13: Sensor common point ................................................................................................... 7

Table 14: Communication ports .................................................................................................... 8

Table 15: Details of GC2100 terminals ....................................................................................... 11

Table 16: Screens of engine status and operating modes ......................................................... 14

Table 17: List of configurable parameters .................................................................................. 17

Table 18: Digital input source selection ...................................................................................... 29

Table 19: LOP (Resistive) sensor calibration ............................................................................. 30

Table 20: Fuel level sensor calibration ....................................................................................... 30

Table 21: Engine / shelter temperature sensor calibration ......................................................... 30

Table 22: Auxiliary (S1/S2) resistive sensor calibration .............................................................. 30

Table 23: Auxiliary (S3/S4) current sensor calibration ................................................................ 30

Table 24: LOP sensor calibration ............................................................................................... 30

Table 25: Auxiliary (S3/S4) (0 – 5V) voltage sensor calibration .................................................. 30

Table 26: Digital output source selection .................................................................................... 30

Table 27: Types of alarms actions and their descriptions ........................................................... 45

Table 28: Alarms and their causes ............................................................................................. 45

Table 29: Troubleshooting .......................................................................................................... 49

Table 30: Details of function codes ............................................................................................ 52

Table 31: RS485 MODBUS communication configuration setting .............................................. 52

Table 32: Command from MODBUS master for Function 4 ....................................................... 52

Table 33: Normal response from GC2100 slave for Function 4 .................................................. 52

GC2100 SEDEMAC

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Table 34: Register map .............................................................................................................. 53

GC2100 SEDEMAC

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Introduction

This document presents information necessary for operating SEDEMAC's GC2100 genset controller.

SEDEMAC’s GC2100 is a modern and feature rich genset controller with user-friendly HMI and full graphics LCD. The GC2100 controller comes bundled with highly versatile software & extensive I/O's and thereby supports a wide variety of industry standard features in diesel/gasoline genset applications. GC2100 controller offers Site battery monitoring feature by which there is significant saving in fuel consumption. In the above feature Shelter temperature monitoring feature is also supported. Apart from this it also supports Auto (AMF, remote start /stop modes, cyclic mode and exerciser mode) manual and test modes. The GC2100 controller's smart software offers flexibility to configure each individual Input and Output for a specific function or application. The powerful micro controller contained within the module allows for incorporation of a range of complex features such as:

• LCD display

• True RMS Voltage and Current monitoring

• RS485 base communication

• Monitoring of engine and alternator parameters

• Fully configurable inputs and outputs for range of functions

Key highlights of the product

• Auto (Site battery backup, AMF, remote start /stop, cyclic modes and exerciser mode), Manual

and Test modes

• Site battery monitoring

• Shelter Temperature Monitoring

• Mains partial healthy detection

• Real time clock

• Fuel theft alarm

• Cyclic timer

• RPM sensing using genset’s output frequency

• Backlit and full graphics display

Product Features

GC2100 is a very enhanced and feature rich genset controller. It has 9 digital inputs and 7 analog inputs. Full features list is provided in below Table 1.

Table 1: Feature list

Features Spec / Remark

Digital Switch Input 9

Analog Resistive Inputs 5

Analog Current/Voltage Inputs 2

Differential input (±60V DC) for Site battery voltage Y

Mains V-Input (AMF) Y

DG Alt V-Input, D+ CHG ALT I/O Y

Digital HSD 7

Event logs Y

USB port for PC based configuration Y

RS-485 for MODBUS communication Y

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Features Spec / Remark

Operating Battery Supply Voltage (with -32V reverse protection) 8 to 32V DC

Operating Temperature Range (deg C) -20 to 65

Ingress Protection with Optional Gasket IP65

Sensor common Input with ±2V Sensing Range Y

Warning auto clear enable/disable Y

Fuel reference selection input Y

Figure 1: GC2100 genset controller's front fascia

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Specifications

Terminals

GC2100 controller host two types of terminal blocks as shown in Figure 2 and Figure 3 given below:

Table 2: Terminals

Connector type

Pitch Male (on

controller) SM Part No

Female (mating part)

SM Part No Quantity

3-Pin 5.08 mm 5447366 SM0003213 5441977 SM0003292 1

4-Pin 5.08 mm 5447379 SM0003207 5448637 SM0003451 1

5-Pin 5.08 mm 5447382 SM0003205 5448640 SM0003293 1

6-Pin 5.08 mm 5441919 SM0003203 5441964 SM0003452 1

8-Pin 5.08 mm 5441935 SM0003201 5441951 SM0003294 1

9-Pin 5.08 mm 5447395 SM0003198 5448653 SM0003453 1

10-Pin 5.08 mm 5447405 SM0003196 5448666 SM0003501 1

4-Pin 10.16 mm 5474274 SM0003195 5453499 SM0001163 2

Figure 2: Connectors of 5.08 mm pitch

Figure 3: Connectors of 10.16 mm pitch

Power Supply Specifications

Following table gives a brief overview of power supply specifications

Table 3: Power supply specifications

GCU connector terminal # 1 & 2 (Ground & Battery +Ve respectively)

Supply voltage range 8 to 32 V-DC (Suitable for 12/24 V-DC system)

Cranking drop out period 50 mS

Maximum reverse voltage protection -32 V-DC

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Measurement accuracy (Battery Voltage) ±1% full scale

Resolution 0.1 V

Maximum current consumption ~ 0.4 A @ 12 V-DC (Excluding the current load for the high side driver output's)

Standby current consumption ~0.09 A @ 12V or 24V

Genset Voltages and Frequency Measurements

Following table gives a brief overview of genset voltage and frequency measurements

Table 4: Genset voltage and frequency measurements

GCU connector terminal # 54, 55, 56, 57 (N, B, Y, R respectively)

Measurement type True RMS

Phase to Neutral voltage reading limit 20 to 350 V-AC RMS

Phase to Phase voltage reading limit 20 to 606 V-AC RMS

Measurement accuracy (Voltage) (P-P / P-N)

±1% of full scale for Phase to Neutral

±1.5% of full scale for Phase to Phase

Resolution (Voltage) 1 V-AC RMS for Phase to Neutral

2 V-AC RMS for Phase to Phase

Frequency range 5 to 75 Hz

Measurement accuracy (Frequency) 0.25% of full scale

Resolution (Frequency) 0.1 Hz

For 1 phase genset application, it is mandatory to connect the genset phase and Neutral cables to the genset controller's phase R and Neutral terminals respectively.

Genset Current Measurements

Following table gives a brief overview of genset current measurements

Table 5: Genset current measurements

GCU connector terminal # 47 & 46 (for phase B), 45 & 44 (for phase Y), 43 & 42 (for phase R)


Maximum CT secondary current rating 5 A

Burden 0.25 VA

Measurement accuracy ±1.4% of nominal

Earth leak Measurements

Following table gives a brief overview of earth leak measurements

Table 6: Earth leak measurements

GCU connector terminal # 48 & 49


Maximum CT secondary current rating 5A

Burden 0.25 VA

Measurement accuracy ±1% of nominal

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Follow the recommended phase sequence while connecting the Current Transformer (CT).

Mains Voltages and Frequency Measurements

Following table gives a brief overview of Mains voltages and frequency measurements

Table 7: Mains voltages and frequency measurements

GCU connector terminal # 50, 51, 52, 53 (N, B, Y, R respectively)


Phase to Neutral voltage 20 to 350 V- AC RMS

Phase to Phase voltage 20 to 606 V-AC RMS

Measurement accuracy (Voltage) ±2% of full scale for Phase to Neutral

±2.5% of full scale for Phase to Phase

Resolution (Voltage) 1 V-AC RMS for Phase to Neutral

2 V-AC RMS for Phase to Phase

Frequency range 3 to 75 Hz

Measurement accuracy (Frequency) 0.25% of full scale

Resolution (Frequency) 0.1 Hz

For single phase application, it is mandatory to connect the mains phase and neutral cables to the genset controller's phase R and Neutral terminals respectively.

Digital Inputs

Following table gives a brief overview of digital inputs

Table 8: Digital inputs

GCU connector terminal # 33, 34, 35, 36, 37, 38, 39, 40, 41

Number of inputs 9

Type Negative sensing (connect to ground for activation)

Low level threshold 0.8 V-DC maximum (measured at the genset controller’s terminals and battery ground terminal)

High level threshold 8 V-DC minimum (measured at the genset controller’s terminals and battery ground terminal)

Software configurable options Emergency stop, Remote start/ stop, etc. Please refer Table 18 for more details.

Analog Resistive Sensor Inputs

Following table gives a brief overview of analog resistive sensor inputs

Table 9: Analog resistive sensor inputs

GCU connector terminal # 11, 12, 13, 14, 15 (LOP, Fuel, Temp, Aux1, Aux2)

Number of inputs 5

Type Ratio-metric sensing

Range 10 to 5000Ω

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Open circuit detection Above 5.5 KΩ

Measurement accuracy ±2% of full scale (for range 50 to 1000Ω)

Figure 4: SCP connection

Site Battery Inputs

Following table gives a brief overview of site battery inputs

Table 10: Site battery inputs

GCU connector terminal # 24, 25

Number of inputs 2

Type Differential

Range ±60V

Resolution 0.1V

Accuracy ±2% of full scale (0 to +Ve max/ 0 to -Ve max)

Site battery run hours: In this feature, controller calculates the run hours for which the site runs on the battery backup. Site battery run hours are incremented only when both the mains and genset contactors are not latched and when site battery voltage is greater than low battery voltage threshold.

Digital outputs

Following table gives a brief overview of digital outputs

Table 11: Digital outputs

GCU connector terminal # 3, 4, 5, 6, 7, 8, 9

Number of outputs 7

Type High side driver

Maximum current rating 5A (3 & 4), 1A (5, 6, 7, 8, 9)

Software configurable options Start relay, Fuel relay, Close genset contactor, close mains contactor, Stop solenoid and many more. Please refer Table 26 for more details.

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1) Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID” directly to the controller's output terminals and it is recommended to connect 3 & 4 to start & stop.

2) Genset & mains contactor latching relays should be compiled against 4kVA surge as per IEC-61000-4-5 standard.

D+ CHG ALT

Following table gives a brief overview of D+ CHG ALT

Table 12: D+ CHG ALT

GCU connector terminal # 10

Voltage range 0 to VBATT ; VBATT = 8 to 30 V-DC

Excitation PWM (Current limited to 250mA)

Accuracy ±2% of full scale

*The charge fail is a combined input and output terminal. When the genset starts, the terminal provides the excitation current to the charge alternator field winding. After the excitation is successfully done, the controller reads the charging alternator's output voltage for monitoring its health. The action for charge fail is configurable.

Sensor common point

The sensor common point (SCP) terminal (Pin # 16) of the controller should be directly connected to an electrically sound point on the engine body. This point on the engine body should serve as a common reference point for all analog sensors such as those for measuring lube oil pressure, engine temperature and fuel level. The electrical cable used for the connection should not be shared with any other electrical connection. Such a wiring practice is strongly recommended to ensure that there is negligible potential difference, if any, between the engine body and the controller's SCP terminal, and, predictable and accurate analog sensor measurements are always available in a wide variety of field conditions.

Table 13: Sensor common point

GCU connector terminal # 16

Range ±2V

Accuracy ±2% of full scale

Resolution 0.1 V

The sensor common point (SCP) terminal (Pin # 16) of the controller should be directly connected to an electrically sound point on the engine body. This point on the engine body should serve as a common reference point for all analog sensors such as those for measuring lube oil pressure, engine temperature and fuel level. The electrical cable used for the connection should not be shared with any other electrical connection. Such a wiring practice is strongly recommended to ensure that there is negligible potential difference, if any, between the engine body and the controller's SCP terminal, and, predictable and accurate analog sensor measurements are always available in a wide variety of field conditions.

Deep Sleep Mode Feature

Deep Sleep Mode is a useful feature to prolong the battery life.

In this mode, normal functions of the controller are suspended, and controller is placed into its lowest power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode. When the controller wakes up, normal operations are resumed automatically.

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The controller goes in Deep Sleep Mode when there is no user interaction for the pre-set Deep Sleep Mode Delay.

GCU does not go to Deep sleep mode in following conditions:

• In auto (Site, cyclic, exercise and remote start/stop) modes

• Mains monitoring is enabled, and mains contactor configured as output

• MODBUS communication is enabled

Comes out of deep sleep mode by pressing (not press & hold):

• Stop key

• Start key

• Auto key

• Ack key

Communication ports

Following table gives a brief overview of communication ports

Table 14: Communication ports

USB USB 2.0 Type B used for connection to PC running SEDEMAC Smart config.

RS485 Serial Port

Half Duplex

Max Baud Rate 115200

Data connection 2 wire

Termination resistor of 120Ω is provided between output pin A & B

Common-mode operating range

Maximum distance of line is 1200m

GCU connector terminal # 30, 31, 32 (GND, A, B respectively)

The RS485 port on GC2100 genset controller supports a protocol based on MODBUS.

• Pin 30 should be connected to master’s isolated ground only • Use two core shielded twisted pair cable for MODBUS RS485 connection.

• Keep pin 30 connection open if shielded cable is not available • Do not connect pin 30 to battery -ve

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Installation

Dimensions

Figure 5: Dimensions of the GC2100 genset controller

Recommended mounting panel cut-out dimensions: 189 mm X 143 mm.

Mounting on panel

To mount the controller into the panel, use the fixing clips provided along with the controller.

Follow the given steps:

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Figure 6: Fixing clip and screw supplied along with controller

Figure 7: Controller mounting on the panel using the fixing clips

• Insert the fixing clip into the slot provided on the side of the controller.

• Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is properly fitted inside the slot provided on the controller.

• Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum tightening torque is 0.19 N-m.

Over tightening of the screws may damage the controller casing.

Terminal Pin Details

Following figure shows rear view of the GCU which has terminal details printed on it.

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Figure 8: Rear view of the controller for terminal detail

Table 15: Details of GC2100 terminals

Pin # Name Description Mating connector part

1 GND Power ground

BCP-508-10GN

2 BATT + Power supply positive

3 OUT A High side driver output – A

4 OUT B High side driver output – B

5 OUT C High side driver output – C

6 OUT D High side driver output – D

7 OUT E High side driver output – E

8 OUT F High side driver output – F

9 OUT G High side driver output – G

10 D+ CHG ALT Input for charging alternator control

11 ANLG LOP / DIG J Analog input from Lube Oil Pressure Sensor/Digital Input J

BCP-508-6GN 12 ANLG FUEL LEVEL / DIG K

Analog input from Fuel Level Sensor / Digital Input K

13 ANLG ENG TEMP / DIG L Analog input from Engine Temperature

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Sensor / Digital Input L

14 ANLG AUX 1 / DIG M Analog input auxiliary/Analog input from Shelter Temperature Sensor/Digital Input M

15 ANLG AUX 2 / DIG N Analog input auxiliary/Digital Input N

16 SCP Sensor common point

17 RESERVED RESERVED

NA 18 RESERVED RESERVED



21 ANLG AUX 3/ DIG 0 Analog input auxiliary /0-5V/4-20 mA (LOP) / Digital Input O

BCP-508-5GN 22 MPU (RESERVED) Input from engine speed sensor (Inductive)

23 ANLG AUX 4 / DIG P Analog input auxiliary / 0-5V/ 4-20 mA/ Digital Input P

24 Site BATT I/P Input 1 from Site battery

25 Site BATT I/P Input 2 from Site battery

NA





30 RS485- GND RS485 – GND

BCP-508-3GN 31 RS485- A RS485 – A

32 RS485- B RS485 – B

33 DIG IN A Input from switch – A

BCP-508-9GN

34 DIG IN B Input from switch – B

35 DIG IN C Input from switch – C

36 DIG IN D Input from switch – D

37 DIG IN E Input from switch – E

38 DIG IN F Input from switch – F

39 DIG IN G Input from switch – G

40 DIG IN H Input from switch – H

41 DIG IN I Input from switch – I

42 GEN CT IN R2 CT input 2 from Phase R

BCP-508-8GN

43 GEN CT IN R1 CT input 1 from Phase R

44 GEN CT IN Y2 CT input 2 from Phase Y

45 GEN CT IN Y1 CT input 1 from Phase Y

46 GEN CT IN B2 CT input 2 from Phase B

47 GEN CT IN B1 CT input 1 from Phase B

48 GEN CT IN EL2 CT input 2 from Earth Leakage

49 GEN CT IN EL1 CT input 1 from Earth Leakage

50 MAINS V N Voltage input from Mains Neutral BCP-508-7GN-4PA 51 MAINS V B Voltage input from Mains Phase B

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52 MAINS V Y Voltage input from Mains Phase Y

53 MAINS V R Voltage input from Mains Phase R

54 GEN V N Voltage input from Gen Neutral

55 GEN V B Voltage input from Gen B

56 GEN V Y Voltage input from Gen Y

57 GEN V R Voltage input from Gen R

58 CAN L (RESERVED) CAN Low

BCP-508-4GN 59 CAN H (RESERVED) CAN High



Typical Wiring Diagram

The typical wiring diagram of GC2100 for Auto Mains Failure application

Figure 9: Power circuit when used in the Auto Mains Failure Mode

1) Genset & mains contactor latching relays should be compiled against 4kV surge as per IEC-61000-4-5 standard.

2) Wiring drawing is for representation purpose only. Please refer wiring as per given genset application drawing.

3) Relay cards that used with controller should have protection against reverse battery voltages.

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Monitoring Mode

In monitoring mode, the screen will scroll automatically after a predefined time which can be configured in configuration menu or one can use the “Navigation UP/DOWN Keys” to scroll/browse the screens.

Table 16: Screens of engine status and operating modes

STATUS SCREEN

MANUAL MODE AUTO MODE

DG AND MAINS LOAD STATUS*

LOAD KVA LOAD KW

Load Current

*These 3 screens are common for DG and Mains

Mains Healthy Mains Cumulative energy

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Generator Voltage Shelter temperature

ENGINE SCREENS

ENGINE LUBE OIL PRESSURE ENGINE FUEL LEVEL

ENGINE SPEED ENGINE TEMPERATURE

HISTOGRAM AUXILIARY SENSOR

PRODUCT INFO ENGINE BATTERY / SITE BATTERY

VOLTAGE

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Description of Control Keys

Figure 10: Control keys function

1. Display 5. Menu Navigation up & down key

2. Mains contactor latching key 6. Genset contactor latching key

3. Start key 7. Auto/Manual/Test mode selection key

4. Stop/Config key 8. Acknowledgement key

Configuration mode

To configure the controller please follow the below mentioned instructions:

• To enter the configuration mode press and hold “STOP” key, at least for 3 seconds. Following screen will appear on the GCU

Figure 11: Configuration mode screen

• If you want to only view the configuration, press “STOP” key of the GCU. If you wish to change the configuration, press “START” key of the GCU

• The GCU will ask for password (4 digit). Enter the password by using up & down arrow key for digit and “START” key for entering the digit. The 4 digits will start blinking individually as go on selecting. Press “START” button as mentioned earlier to enter the right digit.

Figure 12: Configuration mode authentication page screen

• After completion of parameter configuration, press and hold “STOP” key to exit from configuration mode. Before existing from configuration mode controller will show the following screen.

1

2

3

4 8

7

6

5

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Figure 13: Saving setting screen

Configurable parameters

Following are the configuration parameters along with the range & value for the GCU, one gets to configure after entering the “write” mode.

* Level 2 names in sentence case are written how they display on Smart Config GUI and names in bracket with capital case are written how they display on controller.

Table 17: List of configurable parameters

Level 0 Level 1 (On

screen) Level 2 (On screen) * Possible Value

Module (MODULE)

General

(GENERAL)

Profile Name profile 1

Power on Mode

(POWER ON MODE) Manual/Auto

Power on Lamp Test

(POWER ON LAMP TEST) Enable/Disable

Deep Sleep Mode

(DEEP SLEEP MODE) Enable/Disable

Load Histogram

(LOAD HISTOGRAM) Enable/Disable

Auto-Clear Warning Alarm

(AUTO CLEAR WARNINGS) Enable/Disable

Language

(LANGUAGE SUPPORT) English/Chinese

Display

(DISPLAY)

Contrast

(CONTRAST) 0 – 100 %

Power Save Mode

(POWER SAVE MODE) Enable/Disable

Communication

(RS485 COMM)

Communication Mode

(COMM MODE) None/MODBUS-SEDEMAC

Slave ID

(MODBUS SLAVE ID) 1 – 247

Baudrate

(BAUDRATE)

1200/2400/4800/9600/19200/38400/57600/115200

Parity Bit

(PARITY) None/Even/Odd

Site Battery Monitoring

(SITE BAT CONFIG)

Battery Monitoring

(BATTERY MON) Yes/No

Low Voltage Threshold

(LOW BATT THRESHOLD) 15.0 – 60.0 V

GC2100 SEDEMAC

Page | 18

Level 0 Level 1 (On


Battery Monitoring Delay

(LOW BATT MON DELAY) 5 – 300 sec

Genset Run Duration

(GEN RUN DURATION) 1 – 720 min

Cyclic Mode

(CYCLIC CONFIG)

Cyclic Mode

(CYCLIC MODE) Enable/Disable

Genset Off Time

(GEN OFF DURATION) 1 – 720 min

Genset On Time

(GEN ON DURATION) 1 – 720 min

Auto Exercise – Event 1

(AUTO EXERCISE – 1)

Auto Exercise

(EVENT 1) Enable/Disable

Event Occurrence

(EVENT OCCURENCE) Daily/Weekly/Monthly

Event Day

(EVENT DAY)

Runs Every day/Week Days/1 – 28

Start Time

(START TIME) 00 hr 00mins – 23 hr 59 mins

Duration

(GEN ON DURATION) 00 hr 01mins – 99 hr 59 mins

Load Transfer

(LOAD TRANSFER) Enable/Disable

Auto Exercise – Event 2 (AUTO EXERCISE – 2)

Auto Exercise

(EVENT 2) Enable/Disable

Event Occurrence

(EVENT OCCURENCE) Daily/Weekly/Monthly

Event Day

(EVENT DAY)

Runs Every Day/ Week Days/1 – 28

Start Time


Duration

(GEN ON DURATION) 00 hr 01mins – 99 hr 59 mins

Load Transfer

(LOAD TRANSFER) Enable/Disable

Night Mode

(NIGHT MODE)

Night Mode

(NIGHT MODE RESTRICT) Enable/Disable

Night Mode Start Time


Night Mode Off Duration

(GEN OFF DURATION) 1 – 1440 mins

Inputs

(INPUTS)

Digital Input X

(DIG IN X)

X= A/B/C/D/E/

F/G/H/I

Source

(SOURCE) Refer Table 18

Polarity

(POLARITY)

Close to Activate/Open to Activate

GC2100 SEDEMAC

Page | 19

Level 0 Level 1 (On


Action

(ACTION)

None/Warning/Electrical Trip/Shutdown/Notification

Activation

(ACTIVATION)

Never/From Engine Start/ From Monitoring On/Always

Activation Delay

(ACTIVATION DELAY) 1 – 180 sec

Analog Inputs

Analog Input 1

(LOP RES / DIG J)

Use Input As

(SENSOR SELECTION)

Not used/Dig In J/LOP Sensor

(Digital) Source

((DIG) SOURCE) Refer Table 18

(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)


(Digital) Activation

((DIG) ACTIVATION)


(Digital) Activation Delay ((DIG) ACTIVATION DELAY)

1 – 180 sec

(LOP) Low Level Shutdown (SHUTDOWN)

Enable/Disable

(LOP) Shutdown Threshold (SHUTDOWN THRESHOLD)

0 – 9.8 Bar

(LOP) Low Level Warning (WARNING)

Enable/Disable

(LOP) Warning Threshold (WARNING THRESHOLD)

0.2 – 10 Bar

(LOP) Circuit Fault Action (OPEN CKT ALARM)


(LOP) Lube Oil Pressure Calibration Table

Refer Table 19

Analog Input 2

(FUEL LVL / DIG K)

Use Input As

(SENSOR SELECTION)

Not used/Dig In K/Anlg In Fuel LVL

(Digital) Source


(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)



((DIG) ACTIVATION)


(Digital) Activation Delay

((DIG) ACTIVATION DELAY) 1 – 180 sec

(FLS) Low Fuel Level Shutdown

(SHUTDOWN)

Enable/Disable

GC2100 SEDEMAC

Page | 20

Level 0 Level 1 (On


(FLS) Shutdown Threshold (SHUTDOWN THRESHOLD)

0 – 78 %

(FLS) Low Fuel Level Warning

(WARNING)

Enable/Disable

(FLS) Warning Threshold (WARNING THRESHOLD)

2 – 80 %

(FLS) Fuel Tank Capacity (FUEL TANK SIZE)

2 – 1000 Litres

(FLS) Fuel Theft Warning (FUEL THEFT ALARM)

Enable/Disable

(FLS) Fuel Theft Alarm Threshold

(FUEL LVL THRESH)

1 – 100 % per hour

(FLS) Circuit Fault Action (OPEN CKT ALARM)


(FLS) Fuel Sensor Reference (FUEL LVL REF)

Battery Negative/Engine Body

(FLS) Fuel Level Sensor Calibration Table

Refer Table 20

Analog Input 3

(ENG TEMP / DIG L)

Use Input As

(SENSOR SELECTION)

Not used/Dig In L/Anlg In Eng Temp

(Digital) Source


(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)



((DIG) ACTIVATION)




(ETS) High Level Shutdown (SHUTDOWN)

Enable/Disable

(ETS) Shutdown Threshold (SHUTDOWN THRESHOLD)

27 – 300 deg C

(ETS) High Level Warning (WARNING)

Enable/Disable

(ETS) Warning Threshold (WARNING THRESHOLD)

25-298 deg C

(ETS) Circuit Fault Action (OPEN CKT ALARM)


(ETS) Engine Temperature Sensor Calibration Table

Refer Table 21

S1 Sensor

(AUX S1

Use Input As (SENSOR SELECTION)

Not used/Dig In M/Auxiliary Sensor/Shelter Temperature

GC2100 SEDEMAC

Page | 21

Level 0 Level 1 (On


RES/DIG M) (Digital) Source


(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)



((DIG) ACTIVATION)



1 – 180 sec

(S1) Threshold Type (THRESHOLD TYPE)

Greater Than Threshold / Less Than Threshold

(S1) Shutdown (SHUTDOWN)

Enable/Disable

(S1) Shutdown Threshold (SHUTDOWN THRESHOLD)

0 – 1000 units

(S1) Warning

(WARNING) Enable/Disable

(S1) Warning Threshold (WARNING THRESHOLD)

0 – 1000 units

(S1) Circuit Fault Action (OPEN CKT ALARM)


(S1) Calibration Table (Resistive)

Refer Table 22

(STS) High Temp Threshold (SHELT TEMP THRESH)

25 – 300 deg C

(STS) Shelter temperature hysteresis

(SHELT TEMP HYST)

1 – 100 deg C

(STS) Shelt Temp Monitoring Delay

(SHELT TEMP DELAY)

5 – 300 sec

(STS) Shelt Temp Run Duration

(GEN RUN DURATION)

1 – 720 sec

(STS) Calibration Table (Resistive)

Refer Table 21

S2 Sensor

(AUX S2 RES / DIG N)

Use Input As

(SENSOR SELECTION)

Not used/Dig In N/Auxiliary Sensor

(Digital) Source


(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)


GC2100 SEDEMAC

Page | 22

Level 0 Level 1 (On



((DIG) ACTIVATION)




(S2) Threshold Type (THRESHOLD TYPE)

Greater Than Threshold/Less Than Threshold

(S2) Shutdown

(SHUTDOWN) Enable/Disable

(S2) Shutdown Threshold (SHUTDOWN THRESHOLD)

0 –1000 units

(S2) Warning


(S2) Warning Threshold (WARNING THRESHOLD)

0 –1000 units

(S2) Circuit Fault Action

(OPEN CKT ALARM)


(S2) Calibration Table (Resistive)

Refer Table 22

Analog S3 Current Sensor/ Digital Input O

(AUX S3 CURR / DIG O)/LOP *

And

Analog S4 Current Sensor/ Digital Input P

(AUX S4 CURR / DIG P) *

Use Input As

(SENSOR SELECTION)

Not used/Dig In O/Dig In P/ S3 Sensor/S4 Sensor/0 – 5V

Sensor/LOP

(Digital) Source


(Digital) Polarity

((DIG) POLARITY)


(Digital) Action

((DIG) ACTION)



((DIG) ACTIVATION)



1 – 180 Sec

(S3/S4/LOP) Threshold Type (THRESHOLD TYPE)


(S3/S4/LOP) Shutdown

(SHUTDOWN) Enable/Disable

(S3/S4/LOP) Shutdown Threshold

(SHUTDOWN THRESHOLD)

0 – 1000 units

(S3/S4/LOP) Warning


(S3/S4/LOP) Warning Threshold

(WARNING THRESHOLD)

0 – 1000 units

(S3/S4/LOP) Circuit Fault Action

(OPEN CKT ALARM)


GC2100 SEDEMAC

Page | 23

Level 0 Level 1 (On


(S3/S4/LOP) Calibration Table (Current)

Refer Table 23 for S3/S4 and Refer Table 24 for LOP

(0-5 V Sensor) Shutdown (SHUTDOWN)

Enable/Disable

(0-5 V Sensor) Shutdown Threshold

(SHUTDOWN THRESHOLD)

0 – 1000 units

(0-5 V Sensor) Warning (WARNING)

Enable/Disable

(0-5 V Sensor) Warning Threshold

(WARNING THRESHOLD)

0 – 1000 units

(0-5 V Sensor) Threshold Type

(THRESHOLD TYPE)


(0-5 V Sensor) Circuit Fault Action

(OPEN CKT ALARM)


(0-5 V Sensor) Calibration Table (Voltage)

Refer Table 25

Outputs (OUTPUTS)

Output X

(OUT X)

X=A/B/C/D/E/F/G

Source

(SOURCE) Refer Table 26

On Activation

(ON ACTIVATION) Energise/De-energise

Timers

(TIMERS)

Cranking

(CRANKING TIMER)

Crank Hold Time

(CRANK HOLD TIME) 1 – 15 sec

Crank Rest Time

(CRANK REST TIME) 2 – 60 sec

Manual Start Delay

(MANUAL START DELAY) 0 – 300 sec

Auto Start Delay

(AUTO START DELAY) 0 – 300 sec

Start / Stop

(START / STOP TIMER)

Safety Monitoring Delay (SAFETY MONITOR DELAY)

10 – 60 sec

Mains Detect Delay

(MAINS DETECT DELAY) 1 – 300 sec

Alternator Detect Delay

(ALT DETECT DELAY) 1 – 30 sec

Warm-Up Delay

(WARM-UP DELAY) 0 – 60 sec

Return To Mains Delay

(RETN-TO-MAINS DELAY) 0 – 600 sec

Engine Cooling Time

(ENG COOL TIME) 0 – 300 sec

Stop Action Time (STOP ACTION TIME)

10 – 120 sec

GC2100 SEDEMAC

Page | 24

Level 0 Level 1 (On


Additional Stopping Time (ADDN STOPPING TIME)

0 – 120 sec

Load Transfer Delay

(LOAD TRANSFER DELAY) 1 – 60 sec

General

(GENERAL TIMER)

Power Save Mode Delay (PWR SAVE MODE DELAY)

5 – 1800 sec

Screen Changeover Time (SCRN CHNGOVER TIME)

1 – 1800 sec

Deep Sleep Mode Delay (DEEP SLP MODE DELAY)

5 – 1800 sec

Sounder Alarm Time (SOUNDER ALARM TIMER)

1 – 300 sec

Test Mode Timer

(TEST MODE TIMER) 1 – 720 min

Auto Exit Config Mode

(AUTO EXIT CNFG MODE) 10 – 1800 sec

Generator (GENERATOR)

Alternator Configuration

(ALT CONFIG)

Alternator Present

(ALT PRESENT) Yes/No

Number of Poles

(NUMBER OF POLES) 2/4/6/8 Poles

AC system

(ALT AC SYSTEM) 1/3 Phase

Min Healthy Voltage

(MIN HEALTHY VOLT) 50 – 350 V Ph - N

Min Healthy Frequency

(MIN HEALTHY FREQ) 10 – 75 Hz

Phase Reversal Detection (PHASE REVERSAL

DETECT) Enable/Disable

Phase Reversal Action (PHASE REVERSAL

ACTION)


Auto Load Transfer

(AUTO LOAD TRANSFER) Enable/Disable

Voltage Monitoring

(VOLT MONITOR)

Under-voltage Shutdown (UNDER VOLT SHUTDOWN)

Enable/Disable

Under-voltage Shutdown Threshold

(UV SHUTDOWN THRESH)

50 – 295 V Ph-N

Under-voltage Warning

(UNDER VOLT WARNING) Enable/Disable

Under-voltage Warning Threshold

(UV WARNING THRESHOLD)

55 – 300 V Ph - N

Over-voltage Shutdown Enable/Disable

GC2100 SEDEMAC

Page | 25

Level 0 Level 1 (On


(OVER VOLT SHUTDOWN)

Over-voltage Shutdown Threshold

(OV SHUTDOWN THRESH)

105 – 350 V Ph - N

Over-voltage Warning

(OVER VOLT WARNING) Enable/Disable

Over-voltage Warning Threshold

(OV WARNING THRESHOLD)

100 – 345 V Ph - N

Frequency Monitoring

(FREQ MONITOR)

Under-frequency Shutdown

(UNDER FREQ SHUTDOWN)

Enable/Disable

Under-frequency Shutdown Threshold

(UF SHUTDOWN THRESH)

10.0 – 59.0 Hz

Under-frequency Warning Enable

(UNDER FREQ WARNING)

Enable/Disable

Under-frequency Warning Threshold

(UF WARNING THRESHOLD)

11.0 – 60.0 Hz

Over-frequency Shutdown Enable

(OVER FREQ SHUTDOWN)

Enable/Disable

Over-frequency Shutdown Threshold

(OF SHUTDOWN THRESH)

26.0 – 75.0 Hz

Over-frequency Warning Enable

(OVER FREQ WARNING)

Enable/Disable

Over-frequency Warning Threshold

(OF WARNING THRESHOLD)

25.0 – 74.0 Hz

Current Monitoring

(CURRENT MONITOR)

CT Ratio

(LOAD CT RATIO) 0 – 8000 / 5

Over-current Action

(OVER CURR ACTION)


Over-current Threshold

(OVER CURR THRESHOLD) 5 – 10000 Amp

Over-current Delay

(OVER CURR DELAY) 1 – 600 sec

CT Correction Factor 0.900 – 1.100

CT Location

(CT LOCATION)

On Alt Output Cable/On Load Cable

GC2100 SEDEMAC

Page | 26

Level 0 Level 1 (On


Earth Current Monitoring

(EARTH CURR MON)

Current Monitoring

(FAN / EARTH MOMN)

ERTH Curr Mon/

Fan Curr Mon

Current CT Ratio

(CT RATIO) 0 – 8000 / 5

High Current Action

(HIGH CURR ACTION)


High Current Threshold

(HIGH CURR THRESH) 0.1 – 10.0 A

Current Delay

(CURR DELAY) 5 – 60 sec

Low Current Action

(LOW CURR ACTION)


Low Current Threshold

(LOW CURR THRESH) 0.1 – 9.9 A

Load Monitoring

(LOAD MONITOR)

Generator Rating

(GEN RATING) 0 – 8000 kW

Over-load Action

(OVERLOAD ACTION)


Over-load Threshold (OVERLOAD THRESHOLD)

50 – 150 %

Over-load Monitoring Delay (OVERLOAD MON DELAY)

1 – 600 sec

Unbalanced Load Action (UNBAL LOAD ACTION)


Unbalanced Load Threshold (UNBAL LOAD THRESHOLD)

5 – 200 %

Unbalanced Load Delay (UNBAL LOAD DELAY)

1 – 600 sec

Mains

(Mains)

Configuration

(MAINS CONFIG)

Mains Monitoring

(MAINS MONITORING) Enable/Disable

Mains AC System

(MAINS AC SYSTEM) 1 Phase/3 Phase

Phase Reversal Detection (PHASE REVERSAL

DETECT) Enable/Disable

Phase Reversal Action (PHASE REVERSAL

ACTION) None/Notification

Partial Healthy Detection

(MAINS PARTIAL HEALTHY) Enable/Disable

Under Voltage Monitoring

(UNDER VOLT MON)

Under-voltage

(UV ENABLE) Enable/Disable

(UV) Trip

(UV TRIP) 50 – 298 V Ph - N

GC2100 SEDEMAC

Page | 27

Level 0 Level 1 (On


(UV) Return

(UV RETURN) 52 – 300 V Ph - N

Over Voltage Monitoring

(OVER VOLT MON)

Over-voltage

(OV ENABLE) Enable/Disable

(OV) Trip

(OV TRIP) 102 – 350 V Ph - N

(OV) Return

(OV RETURN) 100 – 348 V Ph - N

Under Frequency Monitoring

(UNDER FREQ MON)

Under-frequency

(UF ENABLE) Enable/Disable

(UF) Trip

(UF TRIP) 10.0 – 59.0 Hz

(UF) Return

(UF RETURN) 11.0 – 60.0 Hz

Over Frequency Monitoring

(OVER FREQ MON)

Over-frequency

(OF ENABLE) Enable/Disable

(OF) Trip

(OF TRIP) 26.0 – 75.0 Hz

(OF) Return

(OF RETURN) 25.0 – 74.0 Hz

Engine

(ENGINE)

Crank Disconnect

(CRANK DISCONN)

Start Attempts

(START ATTEMPTS) 1 – 9

Disconnect on Oil Pressure Sensor

(DISCONN ON LOP SENS)

Enable/Disable

Pressure Sensor Monitoring Threshold

(DISCONN LOP SENS)

0.5 – 10.0 bar

Monitor Pressure Sensor Before Crank

(MON LLOP BEF CRANK)

Enable/Disable

Monitor Pressure Switch Before Crank

(MON LOP BEF CRANK)

Enable/Disable

Disconnect on Oil Pressure Switch

(DISCONN ON LLOP SW)

Enable/Disable

Pressure Switch Transient Time

(LLOP SW TRANS TIME)

0.0 – 3.0 Sec

Crank Disconnect At Alt Frequency

(ALT FREQUENCY)

10 – 70 Hz

Crank Disconnect At Engine Speed

(ENGINE SPEED)

150 – 4000 RPM

GC2100 SEDEMAC

Page | 28

Level 0 Level 1 (On


Disconnect On Charging Alt Voltage

(DISC ON CHG ALT VOLT)

Enable/Disable

Charging Alt Disconnect Volt Threshold

(CHG ALT THRESHOLD)

5.0 – 30.0 V

Speed Monitoring (SPEED

MONITOR)

Engine Speed Sense Source (SPEED SENSE SOURCE)

Alternator frequency

Under-speed Shutdown (UNDER SPEED

SHUTDOWN) Enable/Disable

Under-speed Threshold (UNDER SPEED THRESH)

0 – 3600 RPM

Under-speed Delay

(UNDER SPEED DELAY) 1 – 60 Sec

Over-speed Threshold

(OVER SPEED THRESH) 700 – 4000 RPM

Over-speed Delay

(OVER SPEED DELAY) 1 – 20 Sec

Gross Over-speed Threshold (GROSS OS THRESHOLD)

100% – 200%

Battery Monitoring

(BATTERY MONITOR)

Low Battery Voltage Action (LOW VOLT ACTION)


Low Battery Voltage Threshold

(LOW VOLT THRESHOLD)

8.0 – 31.0 V

Low Battery Voltage Delay (LOW VOLT DELAY)

5 – 1800 Sec

High Battery Voltage Action (HIGH VOLT ACTION)


High Battery Voltage Threshold

(HIGH VOLT THRESHOLD)

9.0 – 32.0 V

High Battery Voltage Delay (HIGH VOLT DELAY)

5 – 1800 Sec

Charging Alternator Monitoring

(CHARGE ALT MON)

Charging Alternator Fail Action

(FAIL ACTION)


Charging Alternator Fail Threshold

(FAIL THRESHOLD)

0.0 – 35.0 V

Charging Alternator Fail Delay

(FAIL DELAY)

5 – 60 sec

Preheating

(PREHEAT)

Preheat Timer

(PREHEAT TIMER) 1 – 900 sec

GC2100 SEDEMAC

Page | 29

Level 0 Level 1 (On


Engine Temperature

(ENG TEMP EN) Enable/Disable

Engine Temperature Threshold

(ENG TEMP LIMIT)

10 – 300 °C

Maintenance (MAINTENANCE)

Maint Alarm

(MAINT ALARM)

Alarm Action

(ACTION) Notification/Warning

Due At Engine Hours

(DUE AT ENGINE HOURS) 10 – 65000 Hrs

Alarm Due Date

(ALARM DUE DATE)

Alarm Due Date

(ALARM DUE DATE) 1-31/Jan-Dec/2016-75

Id

(ID)

(ENG SR NO) ############ 0 – 9 for each digit and A – Z

for each alphabet

(PASSWORD 1) #### 0 – 9 for each digit

(PASSWORD 2) #### 0 – 9 for each digit

RESET PARAMETERS

(GENERATOR)

(RUN HOURS) (In Numbers) Hrs

(NO OF STARTS) (In Numbers)

NO OF TRIPS (In Numbers)

kWh (In Numbers) kWh

kVAh (In Numbers) kVAh

kVArh (In Numbers) kVArh

(MAINS)

(RUN HOURS) (In Numbers) Hrs

kWh (In Numbers) kWh

kVAh (In Numbers) kVAh

kVArh (In Numbers) kVArh

Table 18: Digital input source selection

# Source (On screen)

1 Not used

2 User Configured

3 Low fuel level switch (Low Fuel LVL switch)

4 Low Lube Oil Pressure Switch

5 High engine temperature switch (High Engine Temp Switch)

6 Low water level switch (Low Water LVL Switch)

7 Emergency Stop

8 Remote Start / Stop

9 Simulate Start

10 Simulate Stop

11 Simulate Auto

12 Close genset/open mains contactor (Close Gen/Open Mains Switch)

13 Close mains/ open genset contactor (Close Mains/Open Gen Switch)

14 Simulate Mains

GC2100 SEDEMAC

Page | 30

# Source (On screen)

15 V-Belt Broken Switch

16 Mains Contactor Latched

17 Genset Contactor Latched

18 Battery Charger Fail

19 Smoke Fire

20 Remote Alarm Mute

21 Remote Alarm Acknowledge

22 Stop and Panel Lock

23 External Panel Lock

24 Generator Load Inhibit

25 Mains Load Inhibit

Table 19: LOP (Resistive) sensor calibration

Resistance(Ω) Pressure (Bar)

0 – 5000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)

Table 20: Fuel level sensor calibration

Resistance(Ω) Fuel level (%)

0 – 5000 (R1 - R10) 0 - 100% (L1-L10)

Table 21: Engine / shelter temperature sensor calibration

Resistance(Ω) Temperature° C

0 – 5000 (R1 - R10) -25 - 300° C (T1-T10)

Table 22: Auxiliary (S1/S2) resistive sensor calibration

Resistance(Ω) Monitoring Parameter (User configuration)

0 – 5000 (R1 - R10) 0 – 1000 (V1-V10)

Table 23: Auxiliary (S3/S4) current sensor calibration

Current(mA) Monitoring Parameter (User configuration)

4 – 20 (I1 - I10) 0 – 1000 (V1 – V10)

Table 24: LOP sensor calibration

Current(mA) Pressure (Bar)

4 – 20 (I1 - I10) 0.0 – 10.0 Bar (V1-V10)

Table 25: Auxiliary (S3/S4) (0 – 5V) voltage sensor calibration

Voltage(V) Monitoring Parameter (User configuration)

0 – 5 V (V1 - V10) 0 – 1000 (V1 – V10)

Table 26: Digital output source selection

# Output source (On screen)

1 Disable

2 Sounder Alarm

3 Battery Over Voltage (Battery Over Volt)

GC2100 SEDEMAC

Page | 31


4 Battery Under Voltage (Battery Under Volt)

5 Charging Alternator Shutdown (Charge Alt Shutdown)

6 Charging Alternator Warning (Charge Alt Warning)

7 Close Genset Contactor (Close Gen Contactor)

8 Close Mains Contactor (Close Mains Contactor)

9 Mains Failure

10 Common Alarm

11 Common Electrical Trip

12 Common Shutdown

13 Common Warning

14 Cooling Down

15 Digital Input A (Dig In A)

16 Digital Input B (Dig In B)

17 Digital Input C (Dig In C)

18 Digital Input D (Dig In D)

19 Digital Input E ((Dig In E)

20 Digital Input F (Dig In F)

21 Digital Input G (Dig In G)

22 Digital Input H (Dig In H)

23 Digital Input I (Dig In I)

24 Digital Input J (LOP Resistive)

25 Digital Input K (Anlg In Fuel LVL)

26 Digital Input L (Anlg In Eng Temp)

27 Digital Input M (Aux Sensor 1)

28 Digital Input N (Aux Sensor 2)

29 Digital Input O (Aux Sensor 3)

30 Digital Input P (Aux Sensor 4)

31 Emergency Stop

32 Stop Solenoid

33 Fail To Start

34 Fail To Stop

35 Fuel Relay

36 Generator Available (Gen Available)

37 R Phase Over Voltage Shutdown (R Phase OV Shutdown)

38 R Phase Under Voltage Shutdown (R Phase UV Shutdown)

39 Y Phase Over Voltage Shutdown (Y Phase OV Shutdown)

40 Y Phase Under Voltage Shutdown (Y Phase UV Shutdown)

41 B Phase Over Voltage Shutdown (B Phase OV Shutdown)

42 B Phase Under Voltage Shutdown (B Phase UV Shutdown)

43 Gen Over Current

44 High Temperature (High Engine Temp)

45 Low Fuel Level (Low Fuel LVL)

GC2100 SEDEMAC

Page | 32


46 Low Lube Oil Pressure (Low LOP)

47 Main High Voltage (Mains High Volt)

48 Mains Low Voltage (Mains Low Volt)

49 Oil Pressure Open Circuit

50 Open Generator Contactor (Open Gen Contactor)

51 Open Mains Contactor

52 Over Frequency Shutdown (Over Freq Shutdown)

53 Over Speed Shutdown

54 Gross Over Speed Shutdown

55 Start Relay

56 Temp Sensor Open Circuit

57 Under Frequency Shutdown (Under Freq Shutdown)

58 Under Speed Shutdown

59 Maintenance Due

60 Stop Mode

61 Auto Mode

62 Manual Mode

63 Preheat Output

64 Calling For Scheduler Run

65 Stop and Panel Lock

66 External Panel Lock

67 Fail To Close Generator

68 Fail To Close Mains

69 Loading Volt Not Reached

70 Loading Freq Not Reached

71 MPU Loss

GC2100 SEDEMAC

Page | 33

Modes selection in GC2100

Figure 14: Mode selection screen

GC2100 SEDEMAC

Page | 34

Start and Stop Sequence

The following is the mechanism which explains the behaviour of the controller when it receives start

and stop command.

Start Sequence

Figure 15: Flow chart of start sequence

Once the start command is received by the controller/controller enters Start Wait State. After Start Delay (Manual or Auto Start Delay) is over, if Preheat Output is configured then controller will enter Preheating State. If Preheat output is not configured, then controller will directly enter Crank Hold State and will activate Start Relay output. In case of Preheat output configured, controller will enter Crank Hold State after Preheat time is over or Preheat temperature threshold is reached. If Crank is not disconnected and Crank Hold time is over, then controller enters Crank Rest State. In Crank Rest, also if Crank is not disconnected and Crank Rest time is over, then controller enters Crank Hold State for next cranking attempt. If Crank is disconnected by any means in the Crank Hold OR Crank Rest States, then controller will enter ENGINE ON state. If Maximum cranking attempts are done, then controller will raise the Fail to Start alarm.

GC2100 SEDEMAC

Page | 35

Stop Sequence

Figure 16: Flow chart of stop sequence

Once the Stop command is received, controller enters Stopping State where it starts the Stop Action Time and activates Stop Solenoid output. If controller detects engine OFF by all the means even before Stop action time is over, then controller will enter by skipping stop action time. Once Additional Stopping Time is over, controller will enter ENGINE OFF State and will deactivate Stop Solenoid output. If Engine is not detected OFF before Stop Action Time, then Fail to Stop alarm will be raised.

GC2100 SEDEMAC

Page | 36

Operation modes

• Auto mode

• Manual mode

• Test mode

Auto mode

To enter Auto mode press “AUTO” key.

• Site Battery Monitoring mode (fuel saving mode)

• Cyclic mode

• Auto Mains Failure (AMF)

• Remote start/stop

• Exerciser mode

Site Battery Monitoring mode

Figure 17: Flow chart of Site monitoring mode

This mode enables the controller to monitor the health of the Site battery and Shelter temperature and accordingly control the power sources (Mains / Genset) to keep the battery charge within the specified threshold.

In this mode if the Site battery condition is healthy, Shelter temperature is below “High Shelter Temp threshold” and mains is unhealthy, the controller keeps both the contactors (Genset and Mains) open

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and waits till the Site battery gets discharged. Once the Site battery becomes unhealthy or Shelter temp is detected high, the controller then gives a start command to the genset. Then Genset will Start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. Then genset will run for DG run Duration. According to the factor which triggered DG start (Site battery voltage Low OR Shelter Temp High), Run duration (Site low Run duration OR High Shelter Temp run duration) will be taken. After the duration is over or mains becomes healthy during the DG Run duration, controller will open genset contactor. If shelter temp run duration is over and the temp is not below Low Temp Threshold, then genset will continue to run for the set duration. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving Stop command.

This mode also supports partial healthy condition of mains source. Partial healthy is a state in which mains is not considered as failed even if one or two-phases are unhealthy. The mains keep supplying power through the available phase/s. Mains failure occurs only when all the three phases fail. Upon Mains failure genset shall receive start command only if either of following conditions occur

a) Site Battery voltage level has reached below its lower limits. b) Shelter temperature has exceeded its upper threshold limits. c) If either of a) or b) occur when source is partially healthy.

It is recommended to keep mains monitoring enable in this mode. Also, it is recommended to use shelter temperature only when Site monitoring is enabled.

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Cyclic mode

Figure 18: Flow chart of cyclic mode

This mode is used for running the genset for a pre-specified time for a cycle of max 12 hours each. The time of genset to be kept ON & OFF is configurable.

Mains is being monitored in this mode. Load is on mains when mains is healthy. If mains is detected unhealthy, controller gives a start command to the genset. Then Genset will Start according to Start sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. After completion of the ON time or if mains become healthy during ON time, controller will open the genset contactor. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving Stop command. When genset is off, controller will start DG off time.

After completion of DG OFF time, DG ON time will start and this cycle will continue until mains is detected healthy. During any of the times, if mains is detected healthy both the timers are reset to zero and load will shift to mains after taking return delay. This process continues in cyclic mode.

If genset is shut down or is unable to start because of any alarm present, then after clearing alarms if mains is unhealthy, DG ON time will be taken first followed by DG OFF time.

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Auto Mains Failure (AMF)

Figure 19: Flow chart of Auto Mains Failure (AMF) mode

The AMF mode is activated when Site monitoring, Cyclic and exerciser modes are disabled, and Mains Monitoring is enabled.

In this mode, if the mains is healthy then the genset remains in Stop condition. If after the Mains Detect Delay, mains is found unhealthy, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. During genset running condition, if the mains is found healthy, Return To Mains Delay timer starts. If mains is found unhealthy during the Return To Mains Delay, then Genset continues to run. At the end of this delay if mains is still healthy, then genset contactor gets opened and mains contactor gets latched after the completion of Load Transfer Delay. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping sequence by giving Stop command.

During start sequence, if the mains voltage recovers or any stop command or shutdown / warning alarm occurs controller will not issue start command to genset. To start the genset it is necessary to clear all the alarms manually and put the controller in Auto mode.

The AMF mode is only valid when site monitoring, Cyclic and exercise modes are disabled, and Mains Monitoring is enabled.

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Remote start/stop

Figure 20: Flow chart of remote start/stop mode

To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote start/stop (Latched type input) and put the controller in the Auto mode. Also disable both Site monitoring and Cyclic mode.

In this mode, the genset can be commanded to start and stop by activating the preconfigured Remote start/stop input. If Remote Start command is received, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. When Remote Stop command is received the controller will open the genset contactor. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping sequence by giving Stop command.

It is recommended not to enable Mains Monitoring and Remote Start/Stop configuration simultaneously.

The Remote start/stop mode is only valid when Site monitoring, Cyclic, exerciser modes and Mains Monitoring are disabled.

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Exercise Mode

The GC2100 allows to configure two scheduled sequences to start and stop the genset on preconfigured time.

The Exercise will occur when the controller is in the Auto mode with no shutdown or warning alarms. The genset will run for pre-set duration. In this mode, load transfer on mains/genset is configurable. Scheduled sequences can be configured to repeat daily, weekly or monthly.

• If the controller is in Auto mode, Exercise will run at scheduled time for pre-set duration. Controller will exit from Exercise mode, if the pre-set duration is expired or if Stop key is pressed while scheduled sequence is running.

• If the controller is in Manual mode when the scheduled sequence begins, genset will not be started. If the controller is switched to Auto mode during Exercise is running, genset will start and run for remaining scheduled duration.

• The genset controller will not respond to Remote start command in Exercise mode.

• In AMF mode, if the mains is unhealthy or cut off or when the genset is running in Exercise mode, genset will first run Exercise and then genset will continues to run in AMF mode. Load will be transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF mode when the mains become healthy.

• If both exercises are scheduled at the same time, then Start time for second exercise will be incremented by 1 min.

The Exerciser mode is only valid when Site monitoring and Cyclic modes are disabled, and Mains Monitoring is enabled.

Manual mode

Module Operation in Manual Mode

Figure 21: Flow chart of manual mode

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Starting the Engine

Figure 22: Pictorial reference for starting the engine

If Start Key is pressed in this mode, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched if Auto Load Transfer is enabled. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received.

When Stop key is pressed, controller will open genset contactor. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving Stop command. If Stop key is pressed during Engine Cooling Time, controller skips the Cooling Time and issues the stop command immediately.

Stopping the Engine

Figure 23: Pictorial reference for stopping the engine

Test mode

In manual mode (while genset is OFF) if auto key is long pressed then controller goes in Test mode. Test mode is almost same as manual mode. Only in test mode, irrespective of auto load transfer option enabled or disabled, Genset contactor will not get latched. If Genset contactor latching key is pressed, then only genset contactor will get latched. Once the genset starts in test mode, Test mode timer starts. After Stop key is pressed or this timer is over, controller will send the Stop command and genset will stop according to stop sequence.

Then, press the START key

to crank the engine.

While engine is running, press STOP key to stop engine. To stop engine

immediately press STOP key twice.

First press STOP key

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Acknowledging & Clearing the Alarms

Press the “Ack” key to acknowledge the alarm in any mode.

Figure 24: Pictorial reference to acknowledge the alarm in any mode

In case, if engine ON is detected without any start command given to GCU, it will allow engine to stay ON and further act according to operating mode and configuration.

Ack

key

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Load sensing

Load Sensing in Manual mode

In Manual mode, the load sensing is done with following configuration:

The GCU senses the load (on Mains / Genset) depending upon “Generator Contactor Latched” and “Mains Contactor latched” inputs (if configured) and their real-time status. In case if the inputs are not configured, the GCU will sense the load depending upon the outputs ‘’Close Genset Contactor’’ and ‘’Close Mains Contactor’’ or ‘’Open Mains Contactor’’ and ‘’Open Genset Contactor” being configured and depending upon their real-time status. These outputs are set through facial keys or Contactor controlling inputs (such as ‘’Close Genset/Open Mains’’ or ‘’Close Mains/Open Genset’’).

In case of MCP Panels, since the “Genset & Mains” contactors are not configured, the load sensed will be treated as load on the genset only

Load Sensing in Auto mode

The GCU will sense the load (on Mains / Genset) when contactors outputs, i.e. ‘’Close Genset Contactor’’ and ‘’Close Mains Contactor’’ or ‘’Open Mains Contactor’’ and ‘’Open Genset Contactor” are being configured and depending upon their real-time status. These outputs will intelligently be set considering different types of Auto operating modes and configuration.

Contactor Status inputs are not considered for load sensing in any type of auto modes.

For Mains load sensing, two configurations are mandatory.

1. Mains monitoring must be enabled. 2. CT location in panel and in GCU configuration must be “On Load

Cable”.

Features

There are some silent features that helps in saving power and other monitoring purpose.

Auto Config Exit Mode

In this mode, the controller comes out of Configuration Mode automatically when there is no user interaction for the pre-set Auto Config Exit Mode Delay.

Controller saves all configuration parameter changes and exit the configuration mode.

Load Histogram

Load Histogram displays an engine run hour spent in different regimes. This mode helps user to monitor the duration of genset running on specific percentage of load. The load percentage is calculated based on following parameters:

1. Generator rating 2. CT ratio

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Alarms

When Shutdown alarm occurs controller commands genset to stop. The controller will not issue the start command if the Shutdown alarm left unacknowledged.

When an electrical trip alarm occurs, the controller opens the genset contactor first and then it commands the genset to stop. The controller will not issue the start command if the Electrical trip alarm left unacknowledged.

If the warning alarm occurs in between the genset running condition, then the controller will not issue the stop command. But if the warning alarm left unacknowledged when the genset is in stop condition, then the genset cannot be started. Warning alarm gets auto cleared when condition gets cleared only if auto warning clear is enabled in config file or through UI.

Notification alarms get auto cleared.

Table 27: Types of alarms actions and their descriptions

# Alarm

Actions Description

1 Shutdown Load is taken off from the genset and the genset is immediately stopped by skipping Engine Cooling Time.

2 Electrical

trip Load is taken off from the genset, engine cooling timer begins, after which genset is stopped.

3 Warning

Warning alarms serves to draw operator's attention to an undesirable condition without affecting genset's operation.

The genset cannot be started without acknowledging the warning alarms

4 Notification Controller will display message on the display screen and will not affect genset start stop operation.

Table 28: Alarms and their causes

Sr. No.

Alarms Causes / Indication Actions

1 Low Oil Pressure (Sensor)

Indicates that the oil pressure measured is below the pre-set threshold

None/

Shutdown/

Warning

Low Oil Pressure (Switch)

Indicates that the oil pressure measured is low through switch

None/

Shutdown/

Warning/

Electrical Trip/

Notification

2 LOP Res Sensor- Ckt Open

The oil pressure sensor is detected as not being present

None/

Shutdown/

Warning/

Electrical Trip/

Notification

3 High Eng Temp (sensor)

Indicates that the engine temperature is above the pre-set threshold. This condition is detected only when engine is on.

None/

Shutdown/

Warning

High Eng Temp (Switch)

Indicates that the engine temperature measured is high through switch

None/

Shutdown/

Warning/

Electrical Trip/

Notification

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Sr. No.


4 Eng Temp - Ckt Opn The temperature sensor is detected as not being present

None/

Shutdown/

Warning/

Electrical Trip/

Notification

5 Low Fuel level (Sensor)

Indicates that the amount of fuel level is below the pre-set threshold. This condition is detected only when engine is on.

None/

Shutdown/

Warning

Low Fuel level (Switch)

Indicates that the amount of fuel level measured is low through switch

None/

Shutdown/

Warning/

Electrical Trip/

Notification

Fuel level - Ckt Open

Fuel level sensor is detected as not being present None/

Shutdown/

Warning/

Electrical Trip/

Notification

6 Fuel Theft The fuel consumption has exceeded the pre-set threshold

Warning

7 Low Water Level Switch

Indicates that radiator water level is below the pre-set threshold

None/

Shutdown/

Warning/

Electrical Trip/

Notification

8 Shelter Temp - Ckt Open

Shelter Temperature sensor is detected as not being present

Notification

9 Aux S2 - Ckt Open Auxiliary sensor S2 is detected as not being present

None/

Shutdown/

Warning/

Electrical Trip/

Notification

10 Auxiliary Input (for e.g. Aux_A - P) /user defined name

Configured auxiliary input has triggered longer than pre-set duration

None/

Shutdown/

Warning/

Electrical Trip/

Notification

11 Emergency Stop When emergency stop switch is pressed and immediate shutdown is required.

Shutdown

12 Fail To Stop It is detected that genset is still running after sending stop command

Shutdown

13 Fail To Start Indicates that genset has not started after the pre-set number of Start Attempts

Shutdown

14 R Phase Over Voltage

Indicates that genset (R) Phase voltage has exceeded the pre-set over voltage threshold.

Warning/

Shutdown

15 Y Phase Over Voltage

Indicates that genset (Y) Phase voltage has exceeded the pre-set over voltage threshold

Warning/

Shutdown

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Sr. No.


16 B Phase Over Voltage

Indicates that genset (B) Phase voltage has exceeded the pre-set over voltage threshold

Warning/

Shutdown

17 R Phase Under Voltage

Indicates that genset (R) Phase voltage has fallen below pre-set under voltage threshold.

Warning/

Shutdown

18 Y Phase Under Voltage

Indicates that genset (Y) Phase voltage has fallen below pre-set under voltage threshold

Warning/

Shutdown

19 B Phase Under Voltage

Indicates that genset (B) Phase voltage has fallen below pre-set under voltage threshold

Warning/

Shutdown

20 DG Phase Reversed

Alternator phase sequence (R-Y-B) is not correct None/

Warning/

Electric trip/

Shutdown/

Notification

21 Mains Phase Reversed

Mains is in unhealthy condition None/

Notification

22 Over Frequency Indicates that genset output frequency has exceeded the pre-set threshold

Warning/

Shutdown

23 Under Frequency Indicates that genset output frequency has fallen below the pre-set threshold

Warning/

Shutdown

24 Over Current Indicates that genset current has exceeded the pre-set shutdown threshold

None/

Shutdown/

Warning/

Electrical Trip/

Notification

25 Over Load Indicates that the measured kW load rating has exceeded the pre-set threshold

None/

Shutdown/

Warning/

Electrical Trip/

Notification

26 Unbalanced Load Load on any phase is greater or less than other phases by a threshold value

None/

Shutdown/

Warning/

Electrical Trip/

Notification

27 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay.

Shutdown

28 Gross Over Speed Indicates that genset speed has exceeded the pre-set Gross Over Speed Threshold. Genset will shut down immediately without any delay.

Shutdown

29 Under Speed The engine speed has fallen below the pre-set RPM

Shutdown

30 Charge Fail The charge alternator voltage has dropped below the pre-set threshold

None/

Shutdown/

Warning/

Electrical Trip/

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Sr. No.


Notification

31 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay.

Shutdown

32 Gross Over Speed Indicates that genset speed has exceeded the pre-set Gross Over Speed Threshold. Genset will shut down immediately without any delay.

Shutdown

33 Under Speed The engine speed has fallen below the pre-set RPM

Shutdown

34 Charge Fail The charge alternator voltage has dropped below the pre-set threshold

Warning/

Electrical Trip/

Shutdown

35 Battery Under Voltage

The battery voltage has fallen below the pre-set threshold

None/

Shutdown/

Warning/

Electrical Trip/

Notification

36 Battery Over Voltage

The battery voltage has exceeded the pre-set threshold

None/

Shutdown/

Warning/

Electrical Trip/

Notification

37 High Oil Press Detected

Lube oil pressure is detected above the crank disconnect threshold when the engine is off.

Warning

38 Maintenance Due Indicates that engine running hours has exceeded the pre-set hours limit or maintenance due date has occurred and filter servicing is required.

Notification/

Warning

39 Battery Charger Fail Indicates the battery is not getting charged by the charger

None/

Shutdown/

Warning/

Electrical Trip/

Notification

40 Smoke Fire Controller has detected smoke / fire through its digital input

None/

Shutdown/

Warning/

Electrical Trip/

Notification

41 Aux S2 / user defined name

Auxiliary sensor S2’s threshold being crossed None/

Warning/

Electrical Trip/

Shutdown

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Troubleshooting

This section explains the common faults, their possible causes and remedial actions.

Table 29: Troubleshooting

Sr. No. Fault Possible Causes / Remedial Actions

1 The controller does not power ON.

• Check the battery voltage.

• Check the fuse on the battery supply.

• Check continuity between battery +ve and controller terminal # 2.

• Check continuity between battery ground and controller terminal # 1.

2 The controller screen freezes or hangs up.

• Reset the controller power.

3 The controller fails to crank-start the engine.

• Check the battery voltage.

• Enter the “configuration mode” in controller and verify the configuration for the “START” output. Also, check that “START” output is working correctly by measuring its voltage o/p.

• Enter the “configuration mode” in controller and verify the configuration of “CRANK DISCONNECT” method. Verify the configuration of “LLOP SWITCH” polarity. Also, ensure that the lube oil pressure switch & sensor are working OK. Check their wiring.

4 The “Emergency Stop” alarm comes up even when the “Emergency Stop” is not pressed.

• Check if the “Emergency Stop” switch is working OK. Check its wiring also.

• Enter the “configuration mode” in controller and verify the configuration of “EMERGENCY STOP” polarity.

5 The controller generates unnecessary “Shutdown Alarms” or “Warning Alarms”

• Check the respective switch/sensor and wiring.

• Enter the “configuration mode” in the controller and verify the respective threshold configuration.

6 The controller reports “Charging Alt Fail” alarm.

• To check if the controller's charging alternator terminal is working or not: disconnect the charging alternator wiring to the controller's terminal # 10. Short the terminal # 10 to the ground through a DC ammeter. Crank-start the engine. The DC ammeter should indicate the current in the range 200 - 400 mA for ~30 seconds. If yes, the controller's chg alternator terminal is working OK.

• Disconnect and re-connect the charging alternator ind connection to the controller's terminal # 10.

• Check if the charging alternator is working OK or not.

7 A) The controller shows genset “ON” while genset is at rest.

B) “Fail To Stop” alarm when genset is at rest.

• Enter the “configuration mode” in the controller and verify the configuration for the LLOP and LOP. Check their wiring also.

• Ensure that the mains voltage wiring is not connected by mistake to the controller's genset voltage terminals.

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8 The controller issues unnecessary “crank-start” command immediately after power on.

• Ensure that the controller's o/p terminal is not directly connected to the starter relay. The controller's o/p should be given to an intermediate relay which should in-turn power the starter relay. The controller can get permanently damaged and will need to be replaced if this precaution is not taken.

• Check start-relay connection with the suitable controller terminal.

• Enter the “configuration mode” in the controller and verify the configuration for “START MODE” and the “START RELAY” o/p polarity.

9 The engine runs, but the controller shows genset to be “OFF”.

• Check for alternator voltage signal (R phase) is received by the controller terminal.

• Check if the LOP and LLOP are working OK. Also check their wiring to the controller.

10 The controller displays incorrect PF value or kW or load current.

• Check wiring of the respective alternator phase voltage and the CT to the controller.

• Check the CT ratio (if kW or current reading is faulty).

11 The controller displays incorrect mains voltage or incorrect main alternator voltage.

• Check the wiring of the respective phase to the controller.

12 Controller displays incorrect reading for any of LOP, Fuel Level, Engine Temp sensors.

• Check respective sensor and its wiring.

• Check SCP wiring.

• Enter the “configuration mode” in the controller and verify the calibration for the respective

• sensor in configuration.

• Possible Issues in AUTO Mode

13 The controller displays incorrect engine RPM.

• Check wiring of the main alternator’s R-phase and neutral to the controller.

14 The controller does not start the engine even when a “Remote Start” command is sent from an external device such as a telecom PIU.

• Check the wiring of the “Remote Start” signal to the controller's respective digital i/p terminal.

• Enter the “configuration mode” in the controller and verify the configuration for the “Remote Start” digital i/p terminal.

• Check that the controller is in “Auto” mode.

• check for mains monitoring disabled & Site mode disabled.

15 Controller does not stop engine even when a “Remote Stop” command is sent from an external device such as a telecom PIU.

• Check the wiring of the “Remote Stop” signal to the controller's respective digital i/p terminal.

• Enter the “configuration mode” in the controller and verify the configuration for the “Remote Stop” digital i/p terminal.

• Check that the controller is in “Auto” mode.

16 While in Auto mode, controller issues “Start” command even if the mains present.

• Check the wiring of the mains R, Y and B phase to the controller's respective i/p terminal.

• Enter the “configuration mode” in the controller and verify the configuration for the “MAINS MONITORING”.

• Possible issues with Site monitoring

17 Site voltage is observed continuously varying

• Check if earthing is proper for panel and Site

• Check if the connections are done properly for the differential input (pin # 24 & 25)

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• Possible issues with MODBUS communication

18 GCU is not sending data over MODBUS communication

• Check if the MODBUS communication is enabled in GCU

• Check if the MODBUS communication settings of slave (GCU) match with the master

• Check if the connections are done properly for the MODBUS input (pin # 31 & 32)

• Check if the connections are interchanged

• Check the 120 Ω resistance between terminal A (pin # 31) & terminal B (pin # 32)

Communication protocol

The GC2100 genset controller supports a custom protocol based on MODBUS over a RS485 layer. The GC2100 genset controller implement a custom protocol based on the standard MODBUS protocol. It operates in a slave mode and responds to commands received from an external MODBUS master.

Connection Details

The transmission mode used by GC2100 series genset or Diesel Genset (DG) controllers is MODBUS RTU (not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits, no parity bits and 1 stop bit, Cyclic Redundancy Check (CRC).

The following section describe the connection details of RS485 MODBUS to SMPS MODBUS module. On the GCU Pin 31 is represented as A, Pin 32 is represented as B and Pin 30 is represented as ground.

Figure 25: RS485 MODBUS connection with the help of two core shielded twisted pair cable

Precautions

• Keep the slave ID of the GCU controller and the SMPS controller same, take the slave ID from

the SMPS and configure the same ID in GCU.

• Enable the GCU in the configuration of the SMPS after hardware connections are made, so the

SMPS can communicate with the GCU.

• Connect the Pin # 31 & 32 (A & B) of the GCU to the pin # A & B of the SMPS respectively and

not with any other pin.

• Connect the ground of the RS485 MODBUS module of the controller to the ground of SMPS. If

ground of the SMPS is not present, leave the ground terminal (Pin 30) of the controller open.

• Use two core shielded cable for connection.

• Use different colour wires for Pin # 31 & 32 (A & B) for easy detection and connection.

• Route the Pin # 31 & 32 (A & B) wires properly ensuring they do not get short with any other

wires.

• Do not use multi strand wires for the connection.

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Supported Functions

This genset controller operates as a MODBUS slave that responds to certain commands (or functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate format. Supported functions and respective command-response structure is as shown below. If the command received from the MODBUS master is other than the three functions mentioned below, an exception message is generated.

Table 30: Details of function codes

Function Code MODBUS Name Description

03 Read holding register Reads one or more 16-bit from the slave device of read/write location

04 Read input register Reads one or more 16-bit from the slave device of read/write location

16 Write holding register Writes one or more 16-bit registers to the slave device

Communication settings

Table 31: RS485 MODBUS communication configuration setting

RS485 Communication

Slave ID 1-247

Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/115200

Parity None/Even/Odd

Stop Bit 1, 2

Recommended polling frequency: 50Hz No response timeout: 250ms Function 04 is used to read measurement parameters and status from the GC2100 controller. Function code is a part of MODBUS message that defines the action to be taken by the Slave. SEDEMAC GC2K supports following functions and the command-response format is as shown in the following table.

Table 32: Command from MODBUS master for Function 4

Byte Field Remarks

0 Slave address As configured in GC2100

1 Function code (0x04)

2 First register address – high byte 16-bit register address, register address map is described in Table 34 3 First register address – low byte

4 Number of registers to read – high byte Number of registers to read must be between 1 to 255 5 Number of registers to read – low byte

6/7 Error check CRC

Query response format for Function 4 is as follows:

Table 33: Normal response from GC2100 slave for Function 4

Byte Field Remarks

0 Slave address As configured in GC2100

1 Function code (0x04)

2 Byte count (n) Equals to number of registers to be read times two. 8-bit even number between 2 to 250

3 First register – high byte

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Byte Field Remarks

4 First register – low byte

...

1+n Last register – high byte

2+n Last register – low byte

3+n/4+n Error check CRC

Table 34: Register map

Parameter Register Address

Scale Factor

Unit / Interpretation

Bits/ Sign

Protocol revision 0 - - Unsigned

Generator L1-N voltage 1 0.1 V Unsigned



Generator L1-L2 voltage 4 0.1 V Unsigned



Generator R frequency 7 0.1 Hz Unsigned

Generator Y frequency 8 0.1 Hz Unsigned

Generator B frequency 9 0.1 Hz Unsigned

Generator power factor L1 10 0.01 -- Unsigned



Generator average power factor 13 0.01 -- Unsigned

Mains L1-N voltage 14 0.1 V Unsigned



Mains L1-L2 voltage 17 0.1 V Unsigned



Mains R frequency 20 0.1 Hz Unsigned

Mains Y frequency 21 0.1 Hz Unsigned

Mains B frequency 22 0.1 Hz Unsigned

Load L1 current 23 0.1 A Unsigned



Load L1 watts 26 0.1 kW Unsigned



Load total watts 29 0.1 kW Unsigned

Percentage Load 30 0.1 kW Unsigned

Load L1 VA 31 0.1 kVA Unsigned


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Scale Factor


Bits/ Sign


Load total VA 34 0.1 kVA Unsigned

Load L1 VAR 35 0.1 kVAR Unsigned



Load total VAR 38 0.1 kVAR Unsigned

Generator cumulative energy 39-40 0.1 kW Unsigned

Generator cumulative apparent energy

41-42 0.1 kVA Unsigned

Generator cumulative reactive energy

43-44 0.1 kVAR Unsigned

Mains cumulative energy 45-46 0.1 kW Unsigned

Mains cumulative apparent energy 47-48 0.1 kVA Unsigned

Mains cumulative reactive energy 49-50 0.1 kVAR Unsigned

Oil pressure 51 0.1 Bar Unsigned

Coolant temperature 52 0.1 Deg C Unsigned

Fuel level 53 1 % Unsigned

Fuel Level in lit 54 0.1 lit Unsigned

Charge alternator voltage 55 0.1 V Unsigned

Battery voltage 56 0.1 V Unsigned

Engine speed 57 1 RPM Unsigned

No of starts 58 1 -- Unsigned

No of trips 59 1 -- Unsigned

Eng run hrs 60 1 Hrs Unsigned

Eng run min 61 1 Min Unsigned

Mains run hrs 62 1 Hrs Unsigned

Mains run min 63 1 Min Unsigned

Auxiliary Input S1 value 64 0.1 Unsigned




Site Voltage 68 0.1 Unsigned

Site Run time hrs 69 1 Unsigned

Site Tun time mins 70 1 Unsigned

Alarm Status

Alarm 1 71

Low oil pressure -- -- 13/16-16/16

High coolant temperature -- -- 9/16-12/16

Radiator water level / low fuel level -- -- 5/16-8/16

Reserved / Radiator water level switch

-- -- 1/16-4/16

Alarm 2 72

GC2100 SEDEMAC

Page | 55


Scale Factor


Bits/ Sign

Under speed -- -- 13/16-16/16

Over speed -- -- 9/16-12/16

Fail to start -- -- 5/16-8/16

Fail to stop -- -- 1/16-4/16

Alarm 3 73

Generator low voltage/ reserved -- -- 13/16-16/16

Generator high voltage/ reserved -- -- 9/16-12/16

Generator low frequency -- -- 5/16-8/16

Generator high -- -- 1/16-4/16

Alarm 4 74

Generator high current -- -- 13/16-16/16

Generator overload -- -- 9/16-12/16

Unbalanced load -- -- 5/16-8/16

Emergency stop -- -- 1/16-4/16

Alarm 5 75

Charge alternator failure -- -- 13/16-16/16

Oil filter maintenance / filter maintenance

-- -- 9/16-12/16

Fuel filter maintenance / reserved -- -- 5/16-8/16

Air filter maintenance / reserved -- -- 1/16-4/16

Alarm 6 76

Battery low voltage -- -- 13/16-16/16

Battery high voltage -- -- 9/16-12/16

Oil pressure circuit open engine Temperature Circuit open

-- -- 5/16-8/16

Reserved -- -- 1/16-4/16

Alarm 7 77

Fuel theft -- -- 13/16-16/16

Magnetic pick up fault -- -- 9/16-12/16

Extended over load trip / oil pressure circuit

-- -- 5/16-8/16

Reserved -- -- 1/16-4/16

Alarm 8 78

Digital input A -- -- 13/16-16/16

Digital input B -- -- 9/16-12/16

Digital input C -- -- 5/16-8/16

Digital input D -- -- 1/16-4/16

Alarm 9 79

Digital input E -- -- 13/16-16/16

Digital input F -- -- 9/16-12/16

Digital input G -- -- 5/16-8/16

Digital input H -- -- 1/16-4/16

GC2100 SEDEMAC

Page | 56


Scale Factor


Bits/ Sign

Alarm 10 80

Digital input I -- -- 13/16-16/16

Analog input J -- -- 9/16-12/16

Analog input K -- -- 5/16-8/16

Analog input L -- -- 1/16-4/16

Alarm 11 81

Auxiliary input M -- -- 13/16-16/16

Auxiliary input N -- -- 9/16-12/16

Auxiliary input O -- -- 5/16-8/16

Auxiliary input P -- -- 1/16-4/16

Alarm 12 82

Gen L1 phase low volt -- -- 13/16-16/16

Gen L1 phase high volt -- -- 9/16-12/16



Alarm 13 83



Dg phase rotation -- -- 5/16-8/16

Mains phase rotation -- -- 1/16-4/16

Alarm 14 84 --

Open fuel level -- -- 13/16-16/16

V belt broken -- -- 9/16-12/16

Extended over load trip/Reserved -- -- 5/16-8/16

High oil pressure detected -- -- 1/16-4/16

Alarm 15 85 --

Auxiliary Input S1 13/16-16/16




Alarm 16 86

Auxiliary S1 open ckt alarm 13/16-16/16




Alarm 17 87

Auxiliary S3 overcurrent/overvoltage alarm

13/16-16/16

Auxiliary S4 overcurrent/overvoltage alarm

9/16-12/16

Auxiliary S3 short to ground alarm 5/16-8/16

Auxiliary S4 short to ground alarm 1/16-4/16

GC2100 SEDEMAC

Page | 57


Scale Factor


Bits/ Sign

Input and output status

Input diagnostics 88

Digital input A -- -- 16/16

Digital input B -- -- 15/16

Digital input C -- -- 14/16

Digital input D -- -- 13/16

Digital input E -- -- 12/16

Digital input F -- -- 11/16

Digital input G -- -- 10/16

Digital input H -- -- 9/16

Digital input I -- -- 8/16

Analog input J -- -- 7/16

Analog input K -- -- 6/16

Analog input L -- -- 5/16

Auxiliary input M -- -- 4/16

Auxiliary input N -- -- 3/16

Auxiliary input O -- -- 2/16

Auxiliary input P -- -- 1/16

Output Diagnostic 89

Digital output A -- -- 16/16

Digital output B -- -- 15/16

Digital output C -- -- 14/16

Digital output D -- -- 13/16

Digital output E -- -- 12/16

Digital output F -- -- 11/16

Digital output G -- -- 10/16

Unimplemented -- -- 9/16









Dg status 90

GCU Mode Config /Run 16/16

Mains Healthy / unhealthy -- True (1) / False (0) 15/16

DG operation mode -- Scheduler/cyclic/A

uto / Manual 14-12/16

Load on Mains True (1) / False (0) 11/16

GC2100 SEDEMAC

Page | 58


Scale Factor


Bits/ Sign

Load on DG -- True (1) / False (0) 10/16

Current DG status -- Running / stopped 9/16

DG stopped normally -- True (1) / False (0) 8/16

DG stopped with fault True (1) / False (0) 7/16

DG fail to start -- True (1) / False (0) 6/16

Gen available True (1) / False (0) 5/16

Common shut down -- True (1) / False (0) 4/16

Common electric trip -- True (1) / False (0) 3/16

Common warning -- True (1) / False (0) 2/16

Common notification -- True (1) / False (0) 1/16

Current time stamp 88-89 -- Current EPOCH

time

GC2100 SEDEMAC

Page | 59

Notes

GC2100 SEDEMAC

Page | 60

Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice.

SEDEMAC Mechatronics Pvt Ltd Technical Centre

C9-10, C Block, MIDC Bhosari Pune 411026, India

Manufacturing Plant

G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje

Pune 410501, India

Manufacturing Plant Survey No. 64/5, Off Sinhagad Road

Vadgaon Budruk, Narhe Pune 411041, India

manual for gc2100: genset controllers · • rpm sensing using genset’s output frequency •...

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