MANUAL FOR GC2599 CONTROLLER ABSTRACT. This manual is intended as an information guide for operating SEDEMAC's GC2599 genset controller.

Transcription

1 ABSTRACT This manual is intended as an information guide for operating SEDEMAC's GC2599 genset controller. MANUAL FOR GC2599 CONTROLLER Doc #SED-MAN-GC Date: 28-Sep-2017 Product Manual Revision # 1.00

2 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 , INDIA Web Support: support@sedemac.com Website: Telephonic Support:

3 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 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, if not strictly observed, could result in damage or destruction of equipment 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. Page 3 of 80

4 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. 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. Page 4 of 80

5 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 AC ACK ALT AMF AUX BTS CHG CKT CT Ratio DC DG DIG IN ENG TEMP GCU Genset GND HMI HSD HWT LCD LED LLOP LOP LVL MCP MPU NC NO OV PFC PID PWM RMS RPM R-Y-B SCP SMD SMPS TEMP USB UV Description Alternating Current Acknowledge Alternator Auto Mains Failure Auxiliary Base Transceiver Station Charging Circuit Current Transformer Ratio Direct Current Diesel Generator Digital Input Engine Temperature Genset Control Unit Generator Set Ground Human Machine Interface High Side Driver High Water Temperature Liquid Crystal Display Light Emitting Diode Low Lube Oil Pressure Lube Oil Pressure Level Manual Control Panel Magnetic Pickup Unit Normally Closed Normally Open Over Voltage Potential Free Contacts Proportional Integral Derivative Pulse Width Modulation Root Mean Square Revolutions Per Minute Red-Yellow-Blue Sensor Common Point State Machine Diagram Switched Mode Power Supply Temperature Universal Serial Bus Under Voltage Page 5 of 80

6 Table of Contents Introduction Key Highlights of the Product Product Features Specifications Terminals Power Supply Inputs Generator Voltages and Frequency Measurements Generator Current Measurement Earth leak Measurement Mains Voltage and Frequency Measurements Digital Inputs Analog Resistive Sensor Inputs Magnetic Pick Up Input Analog Current/Voltage Input Charge Fail BTS Battery Input Sensor Common Point Outputs Digital Outputs Actuator Outputs PFC Outputs Communication Ports Installation Dimensions Mounting on Panel Terminal Pin Details Typical Wiring Diagram Monitoring Mode Description of Control Keys Functions of Control Keys Configuration Mode Configurable Parameters Modes selection in GC Start and Stop Sequence Operation Modes Page 6 of 80

7 Auto Mode Manual Mode Load Sensing Features Deep Sleep Mode Auto Config Exit Mode Load Histogram Alarms Troubleshooting Communication Protocol Connection Details Precautions Supported Functions Communication Settings Page 7 of 80

8 List of Figure Figure 1: GC2599 genset controller's front fascia Figure 2: Mating connector (make Phoenix Contact) Figure 3: SCP connection Figure 4: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side) Figure 5: Dimensions of the GC2599 genset controller Figure 6: Fixing clip and screw supplied along with controller Figure 7: Rear view of the controller for terminal detail Figure 8: Power circuit when used in the Auto Mains Failure Mode Figure 9: Control keys function Figure 10: Screens of configuration mode Figure 11: Mode selection screen Figure 12: Flow chart of start sequence Figure 13: Flow chart of stop sequence Figure 14: SMD of BTS monitoring mode Figure 15: SMD of Cyclic mode Figure 16: SMD of Auto Mains Failure mode Figure 17: SMD of Exerciser mode Figure 18: Flow chart of remote start/stop mode Figure 19: SMD of Manual mode Figure 20: Pictorial reference for starting the engine Figure 21: Pictorial reference for stopping the engine Figure 22: Analog voltage input terminals of GC Figure 23: Pictorial reference for acknowledging & clearing the alarms Figure 24: RS485 MODBUS connection with the help of two core shielded twisted pair cable. 70 Page 8 of 80

9 List of Tables Table 1: Feature list Table 2: Terminals Table 3: Power supply specification Table 4: Generator voltage and frequency measurement Table 5: Generator current measurement Table 6:Earth leak measurement Table 7: Mains voltage and frequency measurement Table 8: Digital inputs Table 9: Analog resistive sensor inputs Table 10: Magnetic pick-up input Table 11: Analog current/voltage input Table 12: Charge fail Table 13: BTS battery input Table 14: Digital outputs Table 15: Actuator outputs Table 16: PFC outputs Table 17: Communication ports Table 18: Details of GC2599 terminals Table 19: Module display on the genset controller screens Table 20: Control keys in different modes Table 21: List of configurable parameters Table 22: Digital input source selection Table 23: LOP (Resistive) sensor calibration Table 24: Fuel level sensor calibration Table 25: Engine / shelter temperature sensor calibration Table 26: Auxiliary (S1/S2) resistive sensor calibration Table 27: Auxiliary (S3/S4) current sensor calibration Table 28: Auxiliary (S3/S4) voltage sensor calibration Table 29: Load RPM calibration Table 30: Digital output source selection Table 31: Types of alarms actions and their descriptions Table 32: Alarms and their causes Table 33: Troubleshooting Page 9 of 80

10 Table 34: Details of function codes Table 35: RS485 MODBUS communication configuration setting Table 36: Command from MODBUS master for Function Table 37: Normal response from GC2599 slave for Function Table 38: Register map Page 10 of 80

11 Introduction This document presents information necessary for operating SEDEMAC's GC2599 genset controller. SEDEMAC TM SEDEMAC s GC2599 is a modern and feature rich genset controller with user-friendly HMI and full graphics LCD. The GC2599 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. GC2599 controller offers BTS 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, BTS mode and exerciser mode), manual and test modes. A key feature in the GC2599 controller is loadbased variable speed operation for telecom tower gensets. The controller incorporates a built-in governor module that directly drives SEDEMAC s rotary actuators and helps save fuel consumption under part load conditions prevalent in the telecom tower application. The governor module can also be configured to operate in 0% droop fixed speed operation to support non-telecom applications with sensitivity to power quality. GC2599 controller offer unique features such as electronic governing for engines with mechanical fuel systems. With a SEDEMAC's Rotary Actuator as an add-on for air / fuel charge control, these controllers can subsume the electronic governing duty for the engine and offers tight speed governing performance within ISO 8528: G3 class limits. The GC2599 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 MODBUS RS485 based communication Monitoring of engine and alternator parameters Fully configurable inputs and outputs for range of functions Key Highlights of the Product Auto (BTS back up, AMF, remote start /stop, cyclic modes and exerciser mode), Manual and Test modes BTS battery monitoring Shelter Temperature Monitoring Electronic governor controller integration Real time clock Fuel theft alarm Cyclic timer RPM sensing using genset s output frequency and MPU Backlit and full graphics display Product Features GC2599 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 E-gov actuator output Page 11 of 80 Y

12 Features Spec / Remark Differential input (±60V DC) for BTS 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 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: GC2599 genset controller's front fascia Page 12 of 80

13 Specifications Terminals The terminals are listed below Table 2: Terminals Connector type Pitch Male (on controller) Order no. Female (mating part) Order no. 10-Pin 5.08 mm BCH-508VS-10GN BCP GN Pin 5.08 mm BCH-508VS-6GN BCP-508-6GN Pin 5.08 mm BCH-508VS-5GN BCP-508-5GN Pin 5.08 mm BCH-508VS-3GN BCP-508-3GN Pin 5.08 mm BCH-508VS-9GN BCP-508-9GN Pin 5.08 mm BCH-508VS-8GN BCP-508-8GN Pin mm BCH-508VS-7GN- 4PA BCP-508-7GN-4PA Pin 5.08 mm BCH-508VS-4GN BCP-508-4GN Figure 2: Mating connector (make Phoenix Contact) Power Supply Following table gives a brief overview of power supply specification Table 3: Power supply specification GCU connector terminal # Supply voltage range Cranking drop out period Maximum reverse voltage protection Measurement accuracy (Battery Voltage) Resolution Maximum current consumption Standby current consumption 1 & 2 (Ground & Battery +Ve respectively) 8 to 32 V-DC (Suitable for 12/24 V-DC system) 50mS -32 V-DC ±1% of full scale 0.1 V ~ V-DC (Excluding the current load for the high side driver output's) ~ V or 24V Page 13 of 80

14 Inputs Generator Voltages and Frequency Measurements Following table gives a brief overview of generator voltage and frequency measurement Table 4: Generator voltage and frequency measurement SEDEMAC TM GCU connector terminal # Measurement type Phase to Neutral voltage reading limit Phase to Phase voltage reading limit Measurement accuracy (Voltage) (P-P / P-N) Resolution (Voltage) Frequency range Measurement accuracy (Frequency) Resolution (Frequency) 54, 55, 56, 57 (N, B, Y, R respectively) True RMS 20 to 300 V-AC RMS 20 to 520 V-AC RMS ±2% of full scale 1 V-AC RMS for Phase to Neutral 2 V-AC RMS for Phase to Phase 3 to 75 Hz 0.25% of full scale 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. Generator Current Measurement Following table gives a brief overview of generator current measurement Table 5: Generator current measurement GCU connector terminal # Measurement type Maximum CT secondary current rating Burden Measurement accuracy Earth leak Measurement 47 & 46 (for phase B), 45 & 44 (for phase Y), 43 & 42 (for phase R) True RMS 5 A 0.25 VA ±1% of nominal Following table gives a brief overview of earth leak measurement Table 6:Earth leak measurement GCU connector terminal # 48 & 49 Measurement type Maximum CT secondary current rating Burden Measurement accuracy True RMS 5A 0.25 VA ±1% of nominal Page 14 of 80

15 Follow the recommended phase sequence while connecting the Current Transformer (CT). Mains Voltage and Frequency Measurements Following table gives a brief overview of Mains voltage and frequency measurement Table 7: Mains voltage and frequency measurement GCU connector terminal # Measurement type Phase to Neutral voltage Phase to Phase voltage Measurement accuracy (Voltage) Resolution (Voltage) Frequency range Measurement accuracy (Frequency) Resolution (Frequency) 50, 51, 52, 53 (N, B, Y, R respectively) True RMS 20 to 300 V- AC RMS 20 to 520 V-AC RMS ±2% of full scale 1 V-AC RMS for Phase to Neutral 2 V-AC RMS for Phase to Phase 3 to 75 Hz 0.25% of full scale 0.1 Hz For 1 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 Low level threshold High level threshold Software configurable options Negative sensing (connect to ground for activation) 0.8 V-DC maximum (measured at the genset controller s terminals and battery ground terminal) 8 V-DC minimum (measured at the genset controllers terminals and battery ground terminal) Emergency stop, Remote start/ stop, etc. Please refer Table 22 for more details. Page 15 of 80

16 Analog Resistive Sensor Inputs Following table gives a brief overview of analog resistive sensor input 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 0 to 5000Ω Open circuit detection Above 5.5 KΩ Measurement accuracy ±1% of full scale (for range 50 to 1000Ω) Figure 3: SCP connection Magnetic Pick Up Input Table 10: Magnetic pick-up input GCU connector terminal # 22 Type Frequency range Input voltage range Single ended 10 to Hz 200mV to 45 V-AC RMS The MPU (Magnetic Pick-Up) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The output of MPU is a sine wave signal. Page 16 of 80

17 Analog Current/Voltage Input Table 11: Analog current/voltage input GCU connector terminal # Type Range Accuracy 21, 23 (Aux3, Aux4) Current/Voltage 4mA to 20mA/0 to 5 V-DC ± 1% of full scale For genset paralleling application, configure input Aux4 (Pin 23) to accept a 0-5 V-DC speed bias signal generated by a LSM (Load Sharing Module) Charge Fail Table 12: Charge fail GCU connector terminal # 10 Voltage range Excitation Accuracy 0 to VBATT ; VBATT = 8 to 30 V-DC PWM (Current limited to 250mA) ±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. BTS Battery Input Following table gives a brief overview of BTS Battery input Table 13: BTS battery input GCU connector terminal # 24, 25 Number of inputs 2 Type Differential Range ±60V Resolution 0.1V Accuracy 1% of full scale (0 to +Ve max/ 0 to -Ve max) 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. GCU connector terminal # 16 Range ±2V Page 17 of 80

18 Outputs Digital Outputs Following table gives a brief overview of digital outputs Table 14: 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 Actuator Outputs Table 15: Actuator outputs Start relay, Fuel relay, Close genset contactor, close mains contactor, Stop solenoid and many more. Please refer Table 30 for more details. 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 standard. GCU connector terminal # 17, 18, 19, 20 Type Maximum current Stepper motor drive 1A each coil Figure 4: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side) The Actuator outputs are used only for the SEDEMAC's Actuator, if installed. The SEDEMAC's Actuator is a 4-wire Actuator that is used for creating an electronic governing application in case of a mechanical fuel system engine. In diesel engines, the Rotary Actuator's shaft output gets mechanically connected to the stop lever or the throttle lever of an in-line or rotary fuel injection pump. In case of petrol or natural gas engines, the Rotary Actuator's shaft output gets connected to the throttle/charge control valve. Page 18 of 80

19 PFC Outputs Table 16: PFC outputs GCU connector terminal # 26, 27, 28, 29 Number of outputs 2 Type Maximum current rating Software configurable options Potential free 8A Start relay, Fuel relay, Close genset contactor, close mains contactor, Stop solenoid and many more. Please refer Table 30 for more details. Recommended for genset contactor and mains contactor Communication Ports Table 17: Communication ports USB RS485 Serial Port GCU connector terminal # CAN Controller's terminal number for CAN 58, 59 USB 2.0 Type B used for connection to PC running SEDEMAC Smart config. Half Duplex Max Baud Rate 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 30, 31, 32 (GND, A, B respectively) Baud rate used is 250 kbps Packet size used is 8 bytes Termination resistor of 120Ω is provided The RS485 port on GC2599 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 Page 19 of 80

20 Installation Dimensions Figure 5: Dimensions of the GC2599 genset controller Recommended mounting panel cut-out dimensions: 189 mm X 143 mm. Page 20 of 80

21 Mounting on Panel Figure 6: Fixing clip and screw supplied along with controller To mount the controller into the panel, use the fixing clips provided along with the controller. Follow the given steps. 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. Figure 7: Rear view of the controller for terminal detail Page 21 of 80

22 Table 18: Details of GC2599 terminals Pin # Name Description 1 GND Power ground 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 Mating connector part # BCP GN 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 12 ANLG FUEL LEVEL / DIG K 13 ANLG ENG TEMP / DIG L 14 ANLG AUX 1 / DIG M Analog input from Lube Oil Pressure Sensor/Digital Input J Analog input from Fuel Level Sensor / Digital Input K Analog input from Engine Temperature Sensor / Digital Input L 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 GOV_ACT OUT1 Output for the SEDEMAC Actuator 18 GOV_ACT OUT2 Output for the SEDEMAC Actuator 19 GOV_ACT OUT3 Output for the SEDEMAC Actuator 20 GOV_ACT OUT4 Output for the SEDEMAC Actuator 21 ANLG AUX 3/ DIG 0 22 MPU 23 ANLG AUX 4 / DIG P Analog input auxiliary /0-5V/4-20 ma (LOP) / Digital Input O Input from engine speed sensor (Inductive) Analog input auxiliary / 0-5V (Paralleling) / 4-20 ma/ Digital Input P 24 BTS BATT I/P Input 1 from BTS battery 25 BTS BATT I/P Input 2 from BTS battery 26 PFC OUT A Potential free output A (NC) 27 PFC OUT A COMM Potential free output A common 28 PFC OUT B Potential free output B (NO) 29 PFC OUT B COMM Potential free output B common BCP-508-6GN BCP-508-4GN BCP-508-5GN BCP-508-7GN-4PA 30 RS485- GND RS485 GND BCP-508-3GN Page 22 of 80

23 Pin # Name Description 31 RS485- A RS485 A 32 RS485- B RS485 B 33 DIG IN A Input from switch A 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 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 51 MAINS V B Voltage input from Mains Phase B 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 CAN Low 59 CAN H CAN High 60 RESERVED RESERVED 61 RESERVED RESERVED Mating connector part # BCP-508-9GN BCP-508-8GN BCP-508-7GN-4PA BCP-508-4GN Page 23 of 80

24 Typical Wiring Diagram The typical wiring diagram of GC2599 for Auto Mains Failure application Figure 8: Power circuit when used in the Auto Mains Failure Mode Wiring drawing is for representation purpose only. Please refer wiring as per given genset application drawing. Page 24 of 80

25 Monitoring Mode SEDEMAC TM 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 19: Module display on the genset controller screens Product Info Manual mode Auto mode Auto - BTS mode Auto Cyclic mode Auto - Exercise mode Generator Voltage Genset Power Factor (The Y and B phase will be visible only if configured for 3 phase genset) Page 25 of 80

26 Mains Voltage Mains Run Time DG and Mains load status* Load Apparent Power kva Load Power KW (The Y and B phase will be visible only if configured for 3 phase genset) Load Current (The Y and B phase will be visible only if configured for 3 phase genset) Load Reactive Power kvar (The Y and B phase will be visible only if configured for 3 phase genset) (The Y and B phase will be visible only if configured for 3 phase genset) *These 4 screens are common for DG and Mains Page 26 of 80

27 Cumulative energy screens Generator energy Mains energy Engine screens Engine lube oil pressure Engine fuel level Engine temperature Shelter temperature Auxiliary sensor Page 27 of 80

28 Engine Run Time BTS Run Time Engine Battery & BTS battery voltage Engine speed Alarm Histogram Page 28 of 80

29 Description of Control Keys Figure 9: 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 Page 29 of 80

30 Functions of Control Keys Following table gives a brief overview of different functions of control keys Table 20: Control keys in different modes # Mode Key input Function 1 Manual Start Auto Stop Stop (long pressed) Stop + Down (long pressed) Starts the engine Enters Auto mode Stops the engine when engine is running Enters configuration mode Enters Programming mode 2 Auto Stop Stops the engine and enters Manual mode 3 Manual/Auto/ Configuration Up/Down Scrolls the screens/parameter 4 Manual/Auto Ack Acknowledges and clears the alarm 5 Start Selects/saves the parameter 6 Configuration Up + Down (long pressed) Enters on event log page 7 Stop (long pressed) 8 Deep sleep Stop/Start/Auto/Ack Back to Manual mode 9 Event log Up + Down (long pressed) Back to configuration mode 10 Programming Up + Down (long pressed) Controller enters in Manual mode Configuration Mode To configure the controller, follow the below mentioned instructions. To enter the configuration mode press and hold STOP key for minimum three seconds. Following screen will be visible for entering the configuration mode. Press start for configuration edit (write) mode & stop for configuration view (read) mode Enter the 4-digit password with help of up & down navigation keys Configuration Mode Authentication page Figure 10: Screens of configuration mode Page 30 of 80

31 Configurable Parameters SEDEMAC TM Configurable parameters are listed in below table along with the range and value for the GCU configuration. This will help to configure a GCU controller 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 21: List of configurable parameters Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Module (MODULE) General (GENERAL) Display (DISPLAY) Communication (COMMUNICATION) BTS Battery Monitoring (BTS CONFIG) Cyclic Mode (CYCLIC CONFIG) Auto Exercise - Event 1 (AUTO EXERCISE 1) Power On Mode (POWER ON MODE) Power On Lamp Test (POWER ON LAMP TEST) Deep Sleep Mode (DEEP SLEEP MODE) Load Histogram (LOAD HISTOGRAM) Auto-Clear Warning Alarm (AUTO CLEAR WARNINGS) Language (LANGUAGE SUPPORT) Contrast (CONTRAST) Power Save Mode Enable (POWER SAVE MODE) Communication Mode (COMM MODE) Slave ID (MODBUS SLAVE ID) Baudrate (BAUDRATE) Parity Bit (PARITY) Battery Monitoring (BATTERY MON) Low Voltage Threshold (LOW BATT THRESHOLD) Battery Monitoring Delay (LOW BATT MON DELAY) DG Run Duration (DG RUN DURATION) Cyclic Mode Enable (CYCLIC MODE) Cyclic Mode DG Off Time (DG OFF DURATION) Cyclic Mode DG On Time (DG ON DURATION) Auto Exercise Enable (EVENT 1) Event Occurrence (EVENT OCCURENCE) Event Day (EVENT DAY) Manual, Auto Disable, Enable Disable, Enable Disable, Enable Disable, Enable English, Chinese % Disable, Enable None, MODBUS , 2400, 4800, 9600, 19200, 38400, 57600, None, Even, Odd Yes, No V sec min Enable, Disable min min Disable, Enable Daily/Weekly/Monthly Runs Every day/week Days/1-28 Page 31 of 80

32 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Inputs (INPUTS) Auto Exercise Event 2 (AUTO EXERCISE 2) Digital Input X (DIG IN X) X= A, B, C, D, E, F, G, H, I Analog Inputs Analog Input 1 (LOP RES / DIG J) Start Time (START TIME) Duration (DG ON DURATION) Load Transfer (LOAD TRANSFER) Auto Exercise Enable (EVENT 2) Event Occurrence (EVENT OCCURENCE) Event Day (EVENT DAY) Start Time (START TIME) Duration (DG ON DURATION) Load Transfer (LOAD TRANSFER) Source (SOURCE) Polarity (POLARITY) Action (ACTION) Activation (ACTIVATION) Activation Delay (ACTIVATION DELAY) Use Input As (SENSOR SELECTION) (Dig In J) Source (SOURCE) (Dig In J) Polarity (POLARITY) (Dig In J) Action (ACTION) (Dig In J) Activation (ACTIVATION) (Dig In J) Activation Delay (ACTIVATION DELAY) (LOP) Low Level (SHUTDOWN) 00 hr 00mins- 23 hr 59 mins 00 hr 01mins-99 hr 59mins Disable, Enable Disable, Enable Daily/Weekly/Monthly Runs Every Day/ Week Days/ hr 00mins- 23 hr 59 mins 00 hr 01mins-99 hr 59mins Disable, Enable Refer Table 22 Close to Activate, Open to Activate None, Warning, Electrical Trip,, Notification Never, From Engine Start, From Monitoring On, Always Sec Not used, Digital Input J, Lube Oil Pressure Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Sec Enable, Disable Page 32 of 80

33 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Analog Input 2 (FUEL LVL / DIG K) (LOP) Low Level Threshold (SHUTDOWN THRESHOLD) (LOP) Low Level Warning (WARNING) (LOP) Low Level Warning Threshold (WARNING THRESHOLD) (LOP) Circuit Fault Action (OPEN CKT ALARM) (LOP) Calibration Table for Lube Oil Pressure Use Input As (SENSOR SELECTION) (Dig In K) Source (SOURCE) (Dig In K) Polarity (POLARITY) (Dig In K) Action (ACTION) (Dig In K) Activation (ACTIVATION) (Dig In K) Activation Delay (ACTIVATION DELAY) (FLS) Low Fuel Level (SHUTDOWN) (FLS) Threshold (SHUTDOWN THRESHOLD) (FLS) Low Fuel Level Warning (WARNING) (FLS) Warning Threshold (WARNING THRESHOLD) (FLS) Fuel Tank Capacity (FUEL TANK SIZE) (FLS) Fuel Theft Warning (FUEL THEFT ALARM) (FLS) Fuel Theft Alarm Threshold (FUEL LVL THRESH) (FLS) Circuit Fault Action (OPEN CKT ALARM) (FLS) Fuel Sensor Reference Bar Enable, Disable Bar None, Notification, Warning, Electrical Trip, Refer Table 23 Not used, Digital Input K, Fuel Level Sensor Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Sec Enable, Disable 0 78 % Enable, Disable 2 80 % Litres Disable, Enable % per hour None, Notification, Warning, Electrical Trip, Battery Negative, Engine Body Page 33 of 80

34 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value (FUEL LVL REF) Analog Input 3 (ENG TEMP / DIG L) S1 Sensor (AUX S1 RES/DIG M) (FLS) Calibration Table for Fuel Level Sensor Use Input As (SENSOR SELECTION) (Dig In L) Source (SOURCE) (Dig In L) Polarity (POLARITY) (Dig In L) Action (ACTION) (Dig In L) Activation (ACTIVATION) (Dig In L) Activation Delay (ACTIVATION DELAY) (ETS) High Level (SHUTDOWN) (ETS) Threshold (SHUTDOWN THRESHOLD) (ETS) High Level Warning (WARNING) (ETS) Warning Threshold (WARNING THRESHOLD) (ETS) Circuit Fault Action (OPEN CKT ALARM) (ETS) Calibration Table for Engine Temperature Sensor Use Input As (SENSOR SELECTION) (Dig In M) Source (SOURCE) (Dig In M) Polarity (POLARITY) (Dig In M) Action (ACTION) (Dig In M) Activation (ACTIVATION) Refer Table 24 Not used, Digital Input L, Engine Temperature Sensor Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Sec Enable, Disable deg C Enable, Disable deg C None, Notification, Waring, Electrical Trip, Refer Table 25 Not used, Digital Input M, S1 Sensor, Shelter Temperature Sensor Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Page 34 of 80

35 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value (Dig In M) Activation Delay (ACTIVATION DELAY) (S1) Threshold Type (THRESHOLD TYPE) (S1) (SHUTDOWN) (S1) Threshold (SHUTDOWN THRESHOLD) (S1) Warning (WARNING) (S1) Warning Threshold (WARNING THRESHOLD) (S1) Circuit Fault Action (OPEN CKT ALARM) (S1) Sensor/Alarm Name Sec Greater Than Threshold / Less Than Threshold Enable, Disable units Enable, Disable units None, Notification, Electrical Trip, Warning, S1 Sensor S2 Sensor (AUX S2 RES / DIG N) (STS) High Temp Threshold (SHELT TEMP THRESH) (STS) Shelter temp hysteresis (SHELT TEMP HYST) (STS) Shelt Temp Monitoring Delay (SHELT TEMP DELAY) (STS) Shelt Temp Run Duration (DG RUN DURATION) (STS) Calibration Table (Resistive) Use Input As (SENSOR SELECTION) (Dig In N) Source (SOURCE) (Dig In N) Polarity (POLARITY) (Dig In N) Action (ACTION) (Dig In N) Activation (ACTIVATION) (Dig In N) Activation Delay (ACTIVATION DELAY) (S2) Threshold Type (THRESHOLD TYPE) deg C deg C sec sec Refer Table 26 Not used, Digital Input N, S2 Sensor Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Sec Greater Than Threshold, Less Than Threshold Page 35 of 80

36 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value (S2) (SHUTDOWN) (S2) Threshold (SHUTDOWN THRESHOLD) (S2) Warning (WARNING) (S2) Warning Threshold (WARNING THRESHOLD) (S2) Circuit Fault Action (OPEN CKT ALARM) (S2) Sensor/Alarm Name Enable, Disable units Enable, Disable units None, Notification, Warning, Electrical trip, S2 Sensor S3 Sensor/ Digital Input O (AUX S3 RES / DIG O) * And S4 Current Sensor/ Digital Input P (AUX S4 RES / DIG P) (S2) Calibration Table (resistive) Use Input As (SENSOR SELECTION) (Dig In O/ Dig In P) Source (SOURCE) (Dig In O/ Dig In P) Polarity (POLARITY) (Dig In O/ Dig In P) Action (ACTION) (Dig In O/ Dig In P) Activation (ACTIVATION) (Dig In O/ Dig In P) Activation Delay (ACTIVATION DELAY) (S3/S4) Threshold Type (THRESHOLD TYPE) (S3/S4) (SHUTDOWN) (S3/S4) Threshold (SHUTDOWN THRESHOLD) (S3/S4) Warning (WARNING) (S3/S4) Warning Threshold (WARNING THRESHOLD) (S3/S4) Circuit Fault Action (OPEN CKT ALARM) Refer Table 26 Not used, Digital Input O/ Digital Input P, S3 Sensor/ S4 Sensor, 0 5V Sensor, *LOP Refer Table 22 Close to Activate, Open to Activate None, Notification, Warning, Electrical Trip, Never, From Engine Start, From Monitoring On, Always Sec Greater Than Threshold, Less Than Threshold Enable, Disable units Enable, Disable units None, Notification, Warning, Electrical Trip, Page 36 of 80

37 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Outputs (OUTPUTS) Timers (TIMERS) Output X (OUTPUT X) X=A,B,C,D,E,F,G Output PFC-A (PFC A) Output PFC-B (PFC B) Cranking (CRANKING TIMER) Start / Stop (START / STOP TIMER) (S3/S4) Sensor/Alarm Name (S3/S4) Calibration Table (Current) (0-5 V Sensor) Threshold Type (THRESHOLD TYPE) (0-5 V Sensor) (SHUTDOWN) (0-5 V Sensor) Threshold (SHUTDOWN THRESHOLD) (0-5 V Sensor) Warning (WARNING) (0-5 V Sensor) Warning Threshold (WARNING THRESHOLD) (0-5 V Sensor) Circuit Fault Action (OPEN CKT ALARM) (0-5 V Sensor) Sensor/Alarm Name (0-5 V Sensor) Calibration Table (Voltage) S3 Sensor/ S4 Sensor Refer Table 27 Greater Than Threshold, Less Than Threshold Enable, Disable units Enable, Disable units None, Notification, Warning, Electrical Trip, S3 Sensor/ S4 Sensor Refer Table 28 Source (SOURCE) Refer Table 30 On Activation (ON ACTIVATION) Energise, Deenergise Source (SOURCE) Refer Table 30 On Activation (ON ACTIVATION) Energise, Deenergise Source (SOURCE) Refer Table 30 On Activation (ON ACTIVATION) Crank Hold Time (CRANK HOLD TIME) Crank Rest Time (CRANK REST TIME) Manual Start Delay (MANUAL START DELAY) Auto Start Delay (AUTO START DELAY) Safety Monitoring Delay (SAFETY MONITOR DELAY) Energise, Deenergise 1 15 sec 2 60 sec sec sec sec Page 37 of 80

38 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Generator (GENERATOR) General (GENERAL TIMER) Alternator Configuration (ALT CONFIG) Mains Detect Delay (MAINS DETECT DELAY) Alternator Detect Delay (ALT DETECT DELAY) Warm-Up Delay (WARM-UP DELAY) Return To Mains Delay (RETN-TO-MAINS DELAY) Engine Cooling Time (ENG COOL TIME) Stop Action Time (STOP ACTION TIME) Additional Stopping Time (ADDN STOPPING TIME) Load Transfer Delay (LOAD TRANSFER DELAY) Power Save Mode Delay (PWR SAVE MODE DELAY) Screen Changeover Time (SCRN CHNGOVER TIME) Deep Sleep Mode Delay (DEEP SLP MODE DELAY) Sounder Alarm Time (SOUNDER ALARM TIMER) Test Mode Timer (TEST MODE TIMER) Auto Exit Config Mode (AUTO EXIT CNFG MODE) Alternator Present (ALT PRESENT) Number of Poles (NUMBER OF POLES) AC system (ALT AC SYSTEM) Min Healthy Voltage (MIN HEALTHY VOLT) Min Healthy Frequency (MIN HEALTHY FREQ) Phase Reversal Detection (PHASE REVERSAL DETECT) Phase Reversal Action (PHASE REVERSAL ACTION) sec 1 30 sec 0 60 sec sec sec sec sec 1 60 sec sec sec sec sec min sec Yes, No 2, 4, 6, 8 Poles 1, 3 Phase V Ph - N Hz Enable, Disable None, Notification, Warning, Electrical trip, Page 38 of 80

39 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Voltage Monitoring (VOLT MONITOR) Frequency Monitoring (FREQ MONITOR) Auto Load Transfer (AUTO LOAD TRANSFER) Under-voltage Enable (UNDER VOLT SHUTDOWN) Under-voltage Threshold (UV SHUTDOWN THRESH) Under-voltage Warning Enable (UNDER VOLT WARNING) Under-voltage Warning Threshold (UV WARNING THRESHOLD) Over-voltage Enable (OVER VOLT SHUTDOWN) Over-voltage Threshold (OV SHUTDOWN THRESH) Over-voltage Warning Enable (OVER VOLT WARNING) Over-voltage Warning Threshold (OV WARNING THRESHOLD) Under-frequency Enable (UNDER FREQ SHUTDOWN) Under-frequency Threshold (UF SHUTDOWN THRESH) Under-frequency Warning Enable (UNDER FREQ WARNING) Under-frequency Warning Threshold (UF WARNING THRESHOLD) Over-frequency Enable (OVER FREQ SHUTDOWN) Over-frequency Threshold (OF SHUTDOWN THRESH) Enable, Disable Enable, Disable V Ph-N Enable, Disable V Ph - N Enable, Disable V Ph - N Enable, Disable V Ph - N Enable, Disable Hz Enable, Disable Hz Enable, Disable Hz Page 39 of 80

40 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Mains (Mains) Current Monitoring (CURRENT MONITOR) Earth Current Monitoring (EARTH CURR MON) Load Monitoring (LOAD MONITOR) Configuration (MAINS CONFIG) Over-frequency Warning Enable (OVER FREQ WARNING) Over-frequency Warning Threshold (OF WARNING THRESHOLD) CT Ratio (LOAD CT RATIO) Over-current Action (OVER CURR ACTION) Over-current Threshold (OVER CURR THRESHOLD) Over-current Delay (OVER CURR DELAY) Enable, Disable Hz / 5 None, Notification, Warning, Electrical Trip, Amp sec CT Correction Factor CT Location (CT LOCATION) Earth CT Ratio (EARTH CT RATIO) Leak Current Action (LEAK CURR ACTION) Leak Current Threshold (LEAK CURR THRESH) Leak Current Delay (LEAK CURR DELAY) Generator Rating (GEN RATING) Over-load Action (OVERLOAD ACTION) Over-load Threshold (OVERLOAD THRESHOLD) Over-load Monitoring Delay (OVERLOAD MON DELAY) Unbalanced Load Action (UNBAL LOAD ACTION) Unbalanced Load Threshold (UNBAL LOAD THRESHOLD) Unbalanced Load Delay (UNBAL LOAD DELAY) Mains Monitoring Enable (MAINS MONITORING) Mains AC System (MAINS AC SYSTEM) On Alt Output Cable, On Load Cable / 5 None, Notification, Warning,, Electrical Trip A 5 60 sec kw None, Notification, Warning, Electrical Trip, % sec None, Notification, Warning, Electrical Trip, % sec Enable, Disable 1 Phase, 3 Phase Page 40 of 80

41 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Engine (ENGINE) Voltage Monitoring (VOLTAGE MON) Frequency Monitoring (FREQUENCY MON) Crank Disconnect (CRANK DISCONN) Phase Reversal Detection (PHASE REVERSAL DETECT) Phase Reversal Action (PHASE REVERSAL ACTION) Under-voltage Enable (UV ENABLE) (UV) Trip (UV TRIP) (UV) Return (UV RETURN) Over-voltage Enable (OV ENABLE) (OV) Trip (OV TRIP) (OV) Return (OV RETURN) Under-frequency Enable (UF ENABLE) (UF) Trip (UF TRIP) (UF) Return (UF RETURN) Over-frequency Enable (OF ENABLE) (OF) Trip (OF TRIP) (OF) Return (OF RETURN) Start Attempts (START ATTEMPTS) Disconnect on Oil Pressure Sensor (DISCONN ON LOP SENS) Pressure Sensor Monitoring Threshold (DISCONN LOP SENS) Monitor Pressure Sensor Before Crank (MON LLOP BEF CRANK) Monitor Pressure Switch Before Crank (MON LOP BEF CRANK) Disconnect on Oil Pressure Switch (DISCONN ON LLOP SW) Enable, Disable None, Notification Enable, Disable V Ph - N V Ph - N Enable, Disable V Ph - N V Ph - N Enable, Disable Hz Hz Enable, Disable Hz Hz 1 9 Enable, Disable bar Enable, Disable Enable, Disable Enable, Disable Page 41 of 80

42 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Speed Monitoring (SPEED MONITOR) Battery Monitoring (BATTERY MONITOR) Pressure Switch Transient Time (LLOP SW TRANS TIME) Crank Disconnect At Alt Frequency (ALT FREQUENCY) Crank Disconnect At Engine Speed (ENGINE SPEED) Disconnect On Charging Alt Voltage (DISC ON CHG ALT VOLT) Charging Alt Disconnect Volt Threshold (CHG ALT THRESHOLD) Engine Speed Sense Source (SPEED SENSE SOURCE) Flywheel Teeth (FLYWHEEL TEETH) Under-speed (UNDER SPEED SHUTDOWN) Under-speed Threshold (UNDER SPEED THRESH) Under-speed Delay (UNDER SPEED DELAY) Over-speed Threshold (OVER SPEED THRESH) Over-speed Delay (OVER SPEED DELAY) Gross Over-speed Threshold (GROSS OS THRESHOLD) Low Battery Voltage Action (LOW VOLT ACTION) Low Battery Voltage Threshold (LOW VOLT THRESHOLD) Low Battery Voltage Delay (LOW VOLT DELAY) High Battery Voltage Action (HIGH VOLT ACTION) High Battery Voltage Threshold (HIGH VOLT THRESHOLD) Sec Hz RPM Enable, Disable V Alternator frequency, MPU Enable, Disable RPM 1-60 Sec RPM 1-20 Sec 100% - 200% None, Notification, Warning, Electrical Trip, V Sec None, Notification, Warning, Electrical Trip, V Page 42 of 80

43 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Maintenance (MAINTENANCE) (ROTARY ACTUATOR) Charging Alternator Monitoring (CHARGE ALT MON) Preheating (PREHEAT) Mains Alarm (MAINT ALARM) Alarm Due Date (ALARM DUE DATE) General (GENERAL) Variable Speed (ECONOSEEK) High Battery Voltage Delay (HIGH VOLT DELAY) Charging Alternator Fail Action (FAIL ACTION) Charging Alternator Fail Threshold (FAIL THRESHOLD) Charging Alternator Fail Delay (FAIL DELAY) Preheat Timer (PREHEAT TIMER) Engine Temperature (ENG TEMP EN) Engine Temperature Threshold (ENG TEMP LIMIT) Alarm Action (ACTION) Due At Engine Hours (DUE AT ENGINE HOURS) Alarm Due Date (ALARM DUE DATE) Actuator Application (ACTUATOR APPLICATION) Actuator Speed (ACTUATOR SPEED) Actuator Direction (ACTUATOR DIRECTION) Governing Mode (GOVERNING MODE) Recovery Mode (RECOVERY THRESHOLD) Recovery Time (RECOVERY TIME) Low Voltage Recovery (LOW VOLTAGE REC) Low Load Entry Limit (LOW LOAD ENTRY LMT) Low Load Exit Limit (LOW LOAD EXIT LIMIT) Low Saturation Voltage (LOW SATURATION VOLT) RPM Stepup Rate (RPM STEP UP RATE) Sec None, Notification, Warning, Electrical Trip, V 5 60 sec sec Enable, Disable C Notification, Warning Hrs 1-31/Jan-Dec/ As E-Governor, As Start/Stop Device 1 10 * 25 Hz Clockwise/Anti clockwise to Stop Fixed Speed, Variable Speed RPM sec Volt Ph-N % % Volt Ph-N 1 50 RPM/sec Page 43 of 80

44 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Generator EGov Configuration (GEN EGOV CONFIG) Engine EGov Configuration (ENGINE GOV CFG) Engine Start Strategy (ENG START STRGY) RPM Stepdown Rate (RPM STEP DOWN RATE) RPM vs Load Calibration Table Set Speed Selection (SET SPEED SELECTION) Droop (LOAD DROOP) Target Speed (TARGET/RECOVERY SPD) Proportional Gain (Kp) (PROPORTIONAL GAIN) Integral Gain(Ki) (INTEGRAL GAIN) Derivative Gain(Kd) (DERIVATIVE GAIN) Friction Setoff (FRICTION SETOFF) Gain Schedule Trigger (GAIN SCHEDULE TRIGER) Loading Factor (LOADING FACTOR) Unloading Factor (UNLOADING FACTOR) Target Speed (TARGET/RECOVERY SPD) Proportional Gain (Kp) (PROPORTIONAL GAIN) Integral Gain(Ki) (INTEGRAL GAIN) Derivative Gain(Kd) (DERIVATIVE GAIN) Friction Setoff (FRICTION SETOFF) Gain Schedule Trigger (GAIN SCHEDULE TRIGER) Loading Factor (LOADING FACTOR) Unloading Factor (UNLOADING FACTOR) Cranking Steps (CRANKING STEPS) 1 50 RPM/sec Refer Table 29 Fixed Speed (0% Droop), Speed Bias Input (0-5 V), Load Based Droop 0 4 % RPM % RPM % Page 44 of 80

45 Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value Id (ID) (SELECT PROFILE) Start Stop Device Configuration Engine Sr Number (ENG SR NO) Password 1 (PASSWORD 1) Password 2 (PASSWORD 2) (SELECT PROFILE) Table 22: 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 Initial Low Speed Delay (INIT LOW SPEED DELAY) Initial Low Speed (INIT LOW SPEED) PID Trigger Speed (PID TRIGGER SPEED) Ramp Up Time (RAMP UP TIME) sec RPM RPM sec Running Steps ############ 0 9 for each digit and A Z for each alphabet #### 0 9 for each digit #### 0 9 for each digit Profile 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 15 V-Belt Broken Switch 16 Mains Contactor Latched 17 Genset Contactor Latched 18 Battery Charger Fail Page 45 of 80

46 # Source (On screen) 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 23: LOP (Resistive) sensor calibration Resistance(Ω) Pressure (Bar) (R1-R10) Bar (V1-V10) Table 24: Fuel level sensor calibration Resistance(Ω) Fuel level (%) (R1 - R10) 0-100% (V1-V10) Table 25: Engine / shelter temperature sensor calibration Resistance(Ω) Temperature C (R1 - R10) C (V1-V10) Table 26: Auxiliary (S1/S2) resistive sensor calibration Resistance(Ω) Monitoring Parameter (User configuration) (R1 - R10) (V1-V10) Table 27: Auxiliary (S3/S4) current sensor calibration Current(mA) Monitoring Parameter (User configuration) 4 20 (I1 - I10) (V1 V10) Table 28: Auxiliary (S3/S4) voltage sensor calibration Voltage(V) Monitoring Parameter (User configuration) 0-5 (I1 - I10) (V1 V10) Table 29: Load RPM calibration Load (%) RPM (L1 - L11) (R1 R11) Page 46 of 80

47 Table 30: Digital output source selection # Output source (On screen) 1 Disable 2 Sounder Alarm 3 Battery Over Voltage (Battery Over Volt) 4 Battery Under Voltage (Battery Under Volt) 5 Charging Alternator (Charge Alt ) 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 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 Page 47 of 80

48 # Output source (On screen) 34 Fail to stop 35 Fuel relay 36 Generator Available (Gen Available) 37 R Phase Over Voltage (R Phase OV ) 38 R Phase Under Voltage (R Phase UV ) 39 Y Phase Over Voltage (Y Phase OV ) 40 Y Phase Under Voltage (Y Phase UV ) 41 B Phase Over Voltage (B Phase OV ) 42 B Phase Under Voltage (B Phase UV ) 43 Gen Over Current 44 High Engine Temperature (High Engine Temp) 45 Low Fuel Level (Low Fuel LVL) 46 Low Lube Oil Pressure (Low LOP) 47 Mains High Voltage (Mains High Volt) 48 Mains Low Voltage (Mains Low Volt) 49 (Res) Oil Pressure Open Circuit 50 Open Generator Contactor (Open Gen Contactor) 51 Open Mains Contactor 52 Over Frequency (Over Freq ) 53 Over Speed 54 Gross Over Speed 55 Start Relay 56 Temp Sensor Open Circuit 57 Under Frequency (Under Freq ) 58 Under Speed 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 Page 48 of 80

49 # Output source (On screen) 68 Fail To Close Mains 69 Loading Volt Not Reached 70 Loading Freq Not Reached 71 MPU Loss Modes selection in GC2599 Figure 11: Mode selection screen Page 49 of 80

50 Start and Stop Sequence SEDEMAC TM Start and stop sequence is described below with flow chart. It explains the behaviour of the controller when it receives start and stop command. Start Sequence Figure 12: 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. Page 50 of 80

51 Stop Sequence Figure 13: 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. Page 51 of 80

52 Operation Modes Auto mode Manual mode Test mode Paralleling mode Auto Mode To enter Auto mode press AUTO key. BTS Monitoring mode (fuel saving mode) Cyclic mode Auto Mains Failure (AMF) Remote start/stop Exerciser mode BTS Monitoring Mode This mode enables the controller to monitor the health of the BTS battery and Shelter temperature and accordingly control the power sources (Mains / Genset) to keep the battery charge within the specified threshold. Figure 14: SMD of BTS monitoring mode Page 52 of 80

53 Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit represents mains contactor status and second digit represents genset contactor status, whereas 0 Contactor unlatched 1 Contactor latched In this mode if the BTS 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 and waits till the BTS battery gets discharged. Once the BTS 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 (BTS battery voltage Low OR Shelter Temp High), Run duration (BTS 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. It is recommended to keep mains monitoring enable in this mode. Also, it is recommended to use shelter temperature only when BTS monitoring is enabled. Page 53 of 80

54 Cyclic Mode Figure 15: SMD of Cyclic mode Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit represents mains contactor status and second digit represents genset contactor status, whereas 0 Contactor unlatched 1 Contactor latched 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 if 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. Page 54 of 80

55 Auto Mains Failure (AMF) Figure 16: SMD of Auto Mains Failure mode Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit represents mains contactor status and second digit represents genset contactor status, whereas 0 Contactor unlatched 1 Contactor latched The AMF mode is activated when BTS 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. Page 55 of 80

56 The AMF mode is only valid when BTS monitoring, Cyclic and exercise modes are disabled and Mains Monitoring is enabled. Exercise Mode Figure 17: SMD of Exerciser mode Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit represents mains contactor status and second digit represents genset contactor status, whereas 0 Contactor unlatched 1 Contactor latched The GC2599 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. Page 56 of 80

57 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 BTS monitoring and Cyclic modes are disabled and Mains Monitoring is enabled. Remote Start/Stop Figure 18: 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 BTS 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 Page 57 of 80

58 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 BTS monitoring, Cyclic, exerciser modes and Mains Monitoring are disabled. Manual Mode Module Operation in Manual Mode Figure 19: SMD of Manual mode Genset contactor latching status is represented by a digit in all the states of this SMD. Whereas 0 Contactor unlatched 1 Contactor latched Page 58 of 80

59 Starting the Engine Press the START key to crank the engine. Figure 20: 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 While engine is running, press STOP key to stop engine. To stop engine immediately press STOP key twice. Figure 21: Pictorial reference for stopping the engine Page 59 of 80

60 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. Paralleling Mode The GC2599 controller offers the feature of electronic governing for engines with mechanical fuel systems. In conjunction with the external Load Sharing Module, GC2599 controller can control speed of engine and supports genset synchronisation and paralleling feature. The Electronic speed governing (E-governor) system is especially applicable to engines used in genset. This system provides precise, fast-acting control of engine speed. This system can be configured in Isochronous mode or Paralleling mode. In paralleling mode of operation, the system maintains the speed in accordance to the speed reference signal provided by supervisory control/load Sharing Module (LSM). Concept Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset must match within prescribed limits before they can be paralleled. By considering linear relation between speed of the engine and frequency of the alternator output, the speed must be controlled until the genset is paralleled with the grid or other genset with the help of electronic governor. A Load Sharing Module controls the speed and the voltage of the genset by controlling the AVR and E-governor of the genset. To control these two devices the LSM provides the DC analog voltage signal to the both devices. The analog voltage signal is generally in the range of 0-5 V. Mode Description In case of paralleling mode operation of the genset, the E-governor module present in the GC2599 controller accepts speed reference (speed bias) signal in terms of 0-5 V analog DC voltage from the supervisory LSM (Load sharing module). Following is the stepwise procedure for configuring the GC2599 for paralleling operation. Select the Governing Mode as Fixed speed. Select Set Speed Selection as Speed Bias Provide 0-5 V analog signal from the LSM to GC2599 controller at terminal no. 23, as a speed reference signal (Refer figure 22) Page 60 of 80

61 Figure 22: Analog voltage input terminals of GC2599 Configure Analog Aux4 Sensor as Not Used for paralleling mode. Acknowledging & Clearing the Alarms Press the Ack key to acknowledge the alarm in any mode. Press the Ack key Figure 23: Pictorial reference for acknowledging & clearing the alarms 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. Page 61 of 80

62 Load Sensing In Manual and Auto 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 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. Page 62 of 80

63 Features There are some silent features that helps in saving power and other monitoring purpose. Deep Sleep Mode Deep Sleep Mode is a useful feature to prolong the battery life. SEDEMAC TM 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. 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 (BTS, 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 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 Page 63 of 80

64 Alarms SEDEMAC TM When alarm occurs controller commands genset to stop. The controller will not issue the start command if the 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 31: Types of alarms actions and their descriptions # Alarm Actions Description 1 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 32: 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 Warning Low Oil Pressure (Switch) Indicates that the oil pressure measured is low through switch None Warning Electrical Trip 2 LOP Res Sensor- Ckt Open The oil pressure sensor is detected as not being present 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. High Eng Temp (Switch) Indicates that the engine temperature measured is high through switch 4 Eng Temp - Ckt Open The temperature sensor is detected as not being present Notification None Warning Electrical Trip Notification None Warning None Warning Electrical Trip Notification None Warning Electrical Trip Notification Page 64 of 80

65 Sr. No. Alarms Causes / Indication Actions 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 Warning Low Fuel level (Switch) Indicates that the amount of fuel level measured is low through switch None Warning Electrical Trip Fuel level - Ckt Open Fuel level sensor is detected as not being present 6 Fuel Theft The fuel consumption has exceeded the pre-set threshold 7 Low Water Level Switch Indicates that radiator water level is below the pre-set threshold 8 Shelter Temp - Ckt Open Shelter Temperature sensor is detected as not being present 9 Aux S2 - Ckt Open Auxiliary sensor S2 is detected as not being present 10 Auxiliary Input (for e.g. Aux_A - P) /user defined name Configured auxiliary input has triggered longer than pre-set duration 11 Emergency Stop When emergency stop switch is pressed and immediate shutdown is required. 12 Fail To Stop It is detected that genset is still running after sending stop command 13 Fail To Start Indicates that genset has not started after the pre-set number of Start Attempts 14 R Phase Over Voltage Indicates that genset (R) Phase voltage has exceeded the pre-set over voltage threshold. 15 Y Phase Over Voltage Indicates that genset (Y) Phase voltage has exceeded the pre-set over voltage threshold 16 B Phase Over Voltage Indicates that genset (B) Phase voltage has exceeded the pre-set over voltage threshold 17 R Phase Under Voltage Indicates that genset (R) Phase voltage has fallen below pre-set under voltage threshold. 18 Y Phase Under Voltage Indicates that genset (Y) Phase voltage has fallen below pre-set under voltage threshold 19 B Phase Under Voltage Indicates that genset (B) Phase voltage has fallen below pre-set under voltage threshold Notification None Warning Electrical Trip Notification Warning None Warning Electrical Trip Notification Notification None Warning Electrical Trip Notification None Warning Electrical Trip Notification Warning Warning Warning Warning Warning Warning Page 65 of 80

66 Sr. No. Alarms Causes / Indication Actions 20 DG Phase Reversed Alternator phase sequence (R-Y-B) is not correct None Warning Electric trip 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 23 Under Frequency Indicates that genset output frequency has fallen below the pre-set threshold Warning 24 Over Current Indicates that genset current has exceeded the pre-set shutdown threshold None Warning Electrical Trip 25 Over Load Indicates that the measured kw load rating has exceeded the pre-set threshold 26 Unbalanced Load Load on any phase is greater or less than other phases by a threshold value 27 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay. 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. 29 Under Speed The engine speed has fallen below the preset RPM 30 Charge Fail The charge alternator voltage has dropped below the pre-set threshold 31 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay. 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. 33 Under Speed The engine speed has fallen below the preset RPM 34 Charge Fail The charge alternator voltage has dropped below the pre-set threshold 35 Battery Under Voltage The battery voltage has fallen below the pre-set threshold Notification None Warning Electrical Trip Notification None Warning Electrical Trip Notification None Warning Electrical Trip Notification Warning Electrical Trip None Warning Electrical Trip Page 66 of 80

67 Sr. No. Alarms Causes / Indication Actions 36 Battery Over Voltage The battery voltage has exceeded the preset threshold Notification None Warning Electrical Trip Notification 37 High Oil Press Detected Lube oil pressure is detected above the crank disconnect threshold when the engine is off. 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. 39 Battery Charger Fail Indicates the battery is not getting charged by the charger 40 Smoke Fire Controller has detected smoke / fire through its digital input 41 Aux S2 / user defined name Auxiliary sensor S2 s threshold being crossed Warning Notification Warning None Warning Electrical Trip Notification None Warning Electrical Trip Notification None Warning Electrical Trip Troubleshooting This section explains the common faults, their possible causes and remedial actions. Table 33: Troubleshooting Sr. Fault No. 1 The controller does not power ON. 2 The controller screen freezes or hangs up. 3 The controller fails to crankstart the engine. Possible Causes / Remedial Actions 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. Reset the controller power. 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 Check if the Emergency Stop switch is working OK. Page 67 of 80

68 Sr. No. Fault alarm comes up even when the Emergency Stop is not pressed. 5 The controller generates unnecessary Alarms or Warning Alarms 6 The controller reports Charging Alt Fail alarm. 7 A) The controller shows genset ON while genset is at rest. B) Fail To Stop alarm when genset is at rest. 8 The controller issues unnecessary crank-start command immediately after power on. Possible Causes / Remedial Actions Check its wiring also. Enter the configuration mode in controller and verify the configuration of EMERGENCY STOP polarity. Check the respective switch/sensor and wiring. Enter the configuration mode in the controller and verify the respective threshold configuration. 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 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. 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. 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. 10 The controller displays incorrect PF value or kw or load current. 11 The controller displays incorrect mains voltage or incorrect main alternator voltage. 12 Controller displays incorrect reading for any of LOP, Fuel Level, Engine Temp sensors. 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. 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). Check the wiring of the respective phase to the controller. 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. Page 68 of 80

69 Sr. Fault No. 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. 15 Controller does not stop engine even when a Remote Stop command is sent from an external device such as a telecom PIU. 16 While in Auto mode, controller issues Start command even if the mains present. 17 BTS voltage is observed continuously varying Possible Causes / Remedial Actions 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 & BTS mode disabled. 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. 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 BTS monitoring Check if earthing is proper for panel and BTS Check if the connections are done properly for the differential input (pin # 24 & 25) 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 GC2599 genset controller supports a custom protocol based on MODBUS over a RS485 layer. The GC2599 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. The transmission mode used by GC2599 controller 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). Connection Details 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. Page 69 of 80

70 Figure 24: 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. 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 34: Details of function codes Function Code MODBUS Name Description 03 Read holding register 04 Read input register Reads one or more 16-bit from the slave device of read/write location 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 Page 70 of 80

71 Communication Settings Table 35: RS485 MODBUS communication configuration setting RS485 Communication Slave ID Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/ 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 GC2599 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 36: Command from MODBUS master for Function 4 Byte Field Remarks 0 Slave address As configured in GC Function code (0x04) 2 First register address high byte 16-bit register address, register address map 3 First register address low byte is described in section 8 4 Number of registers to read high byte Number of registers to read must be between 5 Number of registers to read low byte 1 to 255 6/7 Error check CRC Query response format for Function 4 is as follows: Table 37: Normal response from GC2599 slave for Function 4 Byte Field Remarks 0 Slave address As configured in GC Function code (0x04) 2 Byte count (n) 3 First register high byte 4 First register low byte... 1+n Last register high byte 2+n Last register low byte 3+n/4+n Error check CRC Equals to number of registers to be read times two. 8-bit even number between 2 to 250 Page 71 of 80

72 Table 38: Register map Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Protocol revision Unsigned Generator L1-N voltage V Unsigned Generator L2-N voltage V Unsigned Generator L3-N voltage V Unsigned Generator L1-L2 voltage V Unsigned Generator L2-L3 voltage V Unsigned Generator L3-L1 voltage V Unsigned Generator R frequency Hz Unsigned Generator Y frequency Hz Unsigned Generator B frequency Hz Unsigned Generator power factor L Unsigned Generator power factor L Unsigned Generator power factor L Unsigned Generator average power factor Unsigned Mains L1-N voltage V Unsigned Mains L2-N voltage V Unsigned Mains L3-N voltage V Unsigned Mains L1-L2 voltage V Unsigned Mains L2-L3 voltage V Unsigned Mains L3-L1 voltage V Unsigned Mains R frequency Hz Unsigned Mains Y frequency Hz Unsigned Mains B frequency Hz Unsigned Load L1 current A Unsigned Load L2 current A Unsigned Load L3 current A Unsigned Load L1 watts KW Unsigned Load L2 watts KW Unsigned Load L3 watts KW Unsigned Page 72 of 80

73 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Load total watts KW Unsigned Percentage Load KW Unsigned Load L1 VA KVA Unsigned Load L2 VA KVA Unsigned Load L3 VA KVA Unsigned Load total VA KVA Unsigned Load L1 VAR KVAR Unsigned Load L2 VAR KVAR Unsigned Load L3 VAR KVAR Unsigned Load total VAR KVAR Unsigned Generator cumulative energy KW Unsigned Generator cumulative apparent energy Generator cumulative reactive energy KVA Unsigned KVAR Unsigned Mains cumulative energy KW Unsigned Mains cumulative apparent energy KVA Unsigned Mains cumulative reactive energy KVAR Unsigned Oil pressure Bar Unsigned Coolant temperature Deg C Unsigned Fuel level 53 1 % Unsigned Fuel Level in lit lit Unsigned Charge alternator voltage V Unsigned Battery voltage V Unsigned Engine speed 57 1 RPM Unsigned No of starts Unsigned No of trips 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 Page 73 of 80

74 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Auxiliary Input S1 value Unsigned Auxiliary Input S2 value Unsigned Auxiliary Input S3 value Unsigned Auxiliary Input S4 value Unsigned BTS Voltage Unsigned BTS Run time hrs 69 1 Unsigned BTS Tun time mins 70 1 Unsigned Alarm Status Alarm 1 71 Low oil pressure /16-16/16 High coolant temperature /16-12/16 Radiator water level / low fuel level /16-8/16 Reserved / Radiator water level switch /16-4/16 Alarm 2 72 Under speed /16-16/16 Over speed /16-12/16 Fail to start /16-8/16 Fail to stop /16-4/16 Alarm 3 73 Generator low voltage/ reserved /16-16/16 Generator high voltage/ reserved /16-12/16 Generator low frequency /16-8/16 Generator high /16-4/16 Alarm 4 74 Generator high current /16-16/16 Generator overload /16-12/16 Unbalanced load /16-8/16 Emergency stop /16-4/16 Alarm 5 75 Charge alternator failure /16-16/16 Page 74 of 80

75 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Oil filter maintenance / filter maintenance /16-12/16 Fuel filter maintenance / reserved /16-8/16 Air filter maintenance / reserved /16-4/16 Alarm 6 76 Battery low voltage /16-16/16 Battery high voltage /16-12/16 Oil pressure circuit open engine Temperature Circuit open /16-8/16 Reserved /16-4/16 Alarm 7 77 Fuel theft /16-16/16 Magnetic pick up fault /16-12/16 Extended over load trip / oil pressure circuit /16-8/16 Reserved /16-4/16 Alarm 8 78 Digital input A /16-16/16 Digital input B /16-12/16 Digital input C /16-8/16 Digital input D /16-4/16 Alarm 9 79 Digital input E /16-16/16 Digital input F /16-12/16 Digital input G /16-8/16 Digital input H /16-4/16 Alarm Digital input I /16-16/16 Analog input J /16-12/16 Analog input K /16-8/16 Analog input L /16-4/16 Page 75 of 80

76 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Alarm Auxiliary input M /16-16/16 Auxiliary input N /16-12/16 Auxiliary input O /16-8/16 Auxiliary input P /16-4/16 Alarm Gen L1 phase low volt /16-16/16 Gen L1 phase high volt /16-12/16 Gen L2 phase low volt /16-8/16 Gen L2 phase high volt /16-4/16 Alarm Gen L3 phase low volt /16-16/16 Gen L3 phase high volt /16-12/16 Dg phase rotation /16-8/16 Mains phase rotation /16-4/16 Alarm Open fuel level /16-16/16 V belt broken /16-12/16 Extended over load trip /16-8/16 High oil pressure detected /16-4/16 Alarm Auxiliary Input S1 13/16-16/16 Auxiliary Input S2 9/16-12/16 Auxiliary Input S3 5/16-8/16 Auxiliary Input S4 1/16-4/16 Alarm Auxiliary S1 open ckt alarm 13/16-16/16 Auxiliary S2 open ckt alarm 9/16-12/16 Auxiliary S3 open ckt alarm 5/16-8/16 Auxiliary S4 open ckt alarm 1/16-4/16 Page 76 of 80

77 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Alarm Auxiliary S3 overcurrent/overvoltage alarm Auxiliary S4 overcurrent/overvoltage alarm 13/16-16/16 9/16-12/16 Auxiliary S3 short to ground alarm 5/16-8/16 Auxiliary S4 short to ground alarm 1/16-4/16 Input and output status Input diagnostics 88 Digital input A /16 Digital input B /16 Digital input C /16 Digital input D /16 Digital input E /16 Digital input F /16 Digital input G /16 Digital input H /16 Digital input I /16 Analog input J /16 Analog input K /16 Analog input L /16 Auxiliary input M /16 Auxiliary input N /16 Auxiliary input O /16 Auxiliary input P /16 Output Diagnostic 89 Digital output A /16 Digital output B /16 Digital output C /16 Digital output D /16 Digital output E /16 Page 77 of 80

78 Parameter Register Address Scale Factor Unit / Interpretation Bits/ Sign Digital output F /16 Digital output G /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /16 Unimplemented /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 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 Current EPOCH time Page 78 of 80

79 Notes Page 79 of 80

80 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 C 9-10, C Block, MIDC Bhosari Pune , India Manufacturing Plant G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje Pune , India Manufacturing Plant Survey No. 64/5, Off Sinhagad Road Vadgaon Budruk, Narhe Pune , India Page 80 of 80