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MANUAL FOR
GC2599: GENSET
CONTROLLER Product Manual Version #0.00
ABSTRACT This manual is intended as an information guide for operating SEDEMAC's GC2599 genset controller.
Doc #SED-MAN-GC2599-002
Date: 10-Jul-2018
Copyright
All rights reserved. No part of this publication may be reproduced, distributed or
transmitted by any means (including photocopying or storing in any medium by
electronic means or other) without the prior written permission of the copyright
holder. Any reference to trademarked product names used within this publication
is owned by their respective companies. SEDEMAC Mechatronics Pvt. Ltd.
reserves the right to change the contents of this document without prior notice.
For permission requests and applications to reproduce any part of this publication
should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
SEDEMAC Mechatronics Pvt. Ltd. C9-10, C Block, MIDC Bhosari Pune 411026, INDIA Web Support: Email: [email protected] Website: www.sedemac.com Telephonic Support: +91-20-67313500 +91-8551041888 +91-8551043888 +91-8551933888 +91-8551039888
GC2599 SEDEMAC
Page | i
Safety Instructions General Instructions
This document includes important instructions that should be followed during installation and
maintenance of the generator set controller.
For safety reasons, the manufacturer recommends that this equipment be installed and serviced by
an authorized service personnel. Follow all applicable state and local electrical codes.
Efficient and safe operation of the controller can be acquired only if the equipment is correctly
operated, configured and maintained.
Note: Many accidents arise due to ignorance or illiteracy towards the elemental rules of safety and
precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions
to the operator, service personnel or the equipment.
• Highlights an essential element of a procedure to ensure correctness
• Indicates a procedure or practice, which could result in damage or destruction of equipment, if not followed strictly
• Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly
Electrical safety Electric shock can cause severe personal injury or death.
Ensure the generator set must be grounded before performing any installation or service.
Generators produce high electrical voltages direct contact with it can cause fatal electrical shock.
Prevent contact with terminals, bare wires, connections, etc., while the generator and related
equipment are running. Do not tamper with interlocks.
To handle the maximum electrical current, sizes of wire gauge used for electrical connections and
wirings must be appropriate to which they will be subjected to.
In operation safety Before installing genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.
Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical
shock.
Remove electric power supply before removing controller or touching other electrical parts.
Use extreme caution when working on electrical components. High voltage can cause injury or death.
Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. It may result in severe electrical shock.
GC2599 SEDEMAC
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Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. Avoid direct contact with the
victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live
conductor. If the victim is unconscious, apply first aid and get immediate medical help.
GC2599 SEDEMAC
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List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer their respective description. This List Does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
BTS Base Transceiver Station
CHG Charging
CKT Circuit
CT Current Transformer
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
NC Normally Closed
NO Normally Open
OV Over Voltage
PFC Potential Free Contacts
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
RTC Real Time Clock
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
SMPS Switched Mode Power Supply
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
GC2599 SEDEMAC
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Table of Contents Introduction ......................................................................................................................... 1
Key Highlights of the Product .......................................................................................... 1
Product Features ............................................................................................................ 1
Specifications ...................................................................................................................... 3
Terminals ........................................................................................................................ 3
Power Supply Specifications ........................................................................................... 4
Genset Voltages and Frequency Measurements ............................................................ 4
Genset Current Measurements ....................................................................................... 4
Earth/Fan Leakage Measurements ................................................................................. 5
Mains Voltages and Frequency Measurements .............................................................. 5
Digital Inputs ................................................................................................................... 5
Analog Resistive Sensor Inputs ...................................................................................... 6
Analog Current/Voltage Inputs ........................................................................................ 6
Site Battery Inputs ....................................................................................................... 6
Magnetic Pick Up Inputs .............................................................................................. 7
Digital Outputs ............................................................................................................. 7
Actuator Outputs .......................................................................................................... 7
PFC Outputs ................................................................................................................ 8
D+ CHG ALT ................................................................................................................ 8
Sensor Common Point ................................................................................................. 8
Deep Sleep Mode Feature ........................................................................................... 9
Communication Ports ....................................................................................................... 10
Installation ......................................................................................................................... 11
Dimensions ................................................................................................................... 11
Mounting on Panel ........................................................................................................ 11
Terminal Pin Details ...................................................................................................... 13
Typical Wiring Diagram ................................................................................................. 15
Monitoring Mode................................................................................................................ 16
Description of Control Keys ............................................................................................. 20
Functions of Control Keys ............................................................................................. 20
Configuration Mode ....................................................................................................... 21
Configurable Parameters .............................................................................................. 21
Modes selection in GC2599 .............................................................................................. 38
Start and Stop Sequence .............................................................................................. 39
Operation Modes ............................................................................................................... 41
Auto Mode .................................................................................................................... 41
Manual Mode ................................................................................................................ 48
GC2599 SEDEMAC
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Load Sensing ..................................................................................................................... 52
Features ............................................................................................................................. 52
Auto Config Exit Mode ............................................................................................... 52
Load Histogram ......................................................................................................... 52
Alarms ................................................................................................................................ 53
Troubleshooting ................................................................................................................ 57
Communication Protocol .................................................................................................. 59
Connection Details..................................................................................................... 59
Precautions ................................................................................................................ 59
Supported Functions.................................................................................................. 60
Communication Settings .................................................................................................. 61
Notes ......................................................................................................................................... 68
GC2599 SEDEMAC
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List of Figure Figure 1: GC2599 genset controller's front fascia ........................................................................ 2
Figure 2: Connectors of 5.08 mm pitch ........................................................................................ 3
Figure 3: Connectors of 10.16 mm pitch ...................................................................................... 3
Figure 4: SCP connection ............................................................................................................ 6
Figure 5: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side) ....... 8
Figure 6: Dimensions of the GC2599 genset controller ............................................................. 11
Figure 7: Fixing clip and screw supplied along with controller .................................................... 12
Figure 8: Controller mounting on the panel using the fixing clips ............................................... 12
Figure 9: Rear view of the controller for terminal detail .............................................................. 13
Figure 10: Power circuit when used in the Auto Mains Failure Mode ......................................... 15
Figure 11: Control keys function ................................................................................................. 20
Figure 12: Configuration mode screen ....................................................................................... 21
Figure 13: Configuration mode authentication page screen ....................................................... 21
Figure 14: Saving setting screen ................................................................................................ 21
Figure 15: Mode selection screen .............................................................................................. 38
Figure 16: Flow chart of start sequence ..................................................................................... 39
Figure 17: Flow chart of stop sequence ..................................................................................... 40
Figure 18: SMD of site monitoring mode .................................................................................... 42
Figure 19: SMD of Cyclic mode ................................................................................................. 43
Figure 20: SMD of Auto Mains Failure mode ............................................................................. 44
Figure 21: SMD of Exerciser mode ............................................................................................ 45
Figure 22: Flow chart of remote start/stop mode ........................................................................ 46
Figure 23: SMD for night restriction mode.................................................................................. 47
Figure 24: SMD of Manual mode ............................................................................................... 48
Figure 25: Pictorial reference for starting the engine ................................................................. 49
Figure 26: Pictorial reference for stopping the engine ................................................................ 49
Figure 27: Analog voltage input terminals of GC2599 ................................................................ 50
Figure 28: Pictorial reference for acknowledging & clearing the alarms ..................................... 51
Figure 29: RS485 MODBUS connection with the help of two core shielded twisted pair cable . 59
GC2599 SEDEMAC
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List of Tables Table 1: Features list .................................................................................................................... 2
Table 2: Pitch connector details ................................................................................................... 3
Table 3: Power supply specifications ........................................................................................... 4
Table 4: Genset voltages and frequency measurements ............................................................. 4
Table 5: Genset current measurements ....................................................................................... 4
Table 6: Earth leakage measurements ......................................................................................... 5
Table 7: Mains voltages and frequency measurements ............................................................... 5
Table 8: Digital inputs ................................................................................................................... 5
Table 9: Analog resistive sensor inputs ........................................................................................ 6
Table 10: Analog current/voltage inputs ....................................................................................... 6
Table 11: Site battery inputs ......................................................................................................... 6
Table 12: Magnetic pick-up inputs ................................................................................................ 7
Table 13: Digital outputs ............................................................................................................... 7
Table 14: Actuator outputs ............................................................................................................ 7
Table 15: PFC outputs ................................................................................................................. 8
Table 16: D+ CHG ALT ................................................................................................................. 8
Table 17: Sensor common point ................................................................................................... 9
Table 18: Communication ports .................................................................................................. 10
Table 19: Details of GC2599 terminals ....................................................................................... 13
Table 20: Screens of engine status and operating modes ......................................................... 16
Table 21: Control keys in different modes .................................................................................. 20
Table 22: List of configurable parameters .................................................................................. 21
Table 23: Digital input source selection ...................................................................................... 35
Table 24: LOP (Resistive) sensor calibration ............................................................................. 36
Table 25: Fuel level sensor calibration ....................................................................................... 36
Table 26: Engine / shelter temperature sensor calibration ......................................................... 36
Table 27: Auxiliary (S1/S2) resistive sensor calibration .............................................................. 36
Table 28: Auxiliary (S3/S4) current sensor calibration ................................................................ 36
Table 29: LOP (4-20 mA) sensor calibration .............................................................................. 36
Table 30: Auxiliary (S3/S4) voltage sensor calibration ............................................................... 36
Table 31: Load – RPM calibration .............................................................................................. 36
Table 32: Digital output source selection .................................................................................... 36
Table 33: Types of alarms actions and their descriptions ........................................................... 53
Table 34: Alarms and their causes ............................................................................................. 53
Table 35: Troubleshooting .......................................................................................................... 57
Table 36: Details of function codes ............................................................................................ 60
Table 37: RS485 MODBUS communication configuration setting .............................................. 61
Table 38: Command from MODBUS master for Function 4 ....................................................... 61
Table 39: Normal response from GC2599 slave for Function 4 .................................................. 61
Table 40: Register map .............................................................................................................. 62
GC2599 SEDEMAC
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Introduction
This document presents information necessary for operating SEDEMAC's GC2599 genset controller.
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. A key feature in the GC2599 controller is load-based 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 offers site battery monitoring feature by which there is significant saving in fuel consumption. In the above feature shelter temperature monitoring feature is also supported. Apart from this it also supports auto (AMF, remote start /stop modes, cyclic mode, Site mode and exerciser mode), manual and test modes.
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 (Site battery back up, AMF, remote start /stop, cyclic modes and exerciser mode), Manual
and Test modes
• Site 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
• Night restriction option
• Earth leakage detection
• Auto Exerciser (2 Events)- Scheduler
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.
GC2599 SEDEMAC
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Table 1: Features list
Features Spec / Remark
Digital Switch Input 9
Analog Resistive Inputs 5
Analog Current/Voltage Inputs 2
E-gov actuator output Y
Differential input (±60V DC) for Site battery voltage Y
Mains V-Input (AMF) Y
DG Alt V-Input, D+ CHG ALT I/O Y
Digital HSD including 2 PFCs 9
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
GC2599 SEDEMAC
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Specifications
Terminals
GC2599 controller host two types of terminal blocks as shown in Figure 2 and Figure 3 given below:
Table 2: Pitch connector details
Connector type
Pitch Male (on
controller) SM Part Number
Female (mating part)
SM Part Number
Quantity
3-Pin 5.08 mm 5447366 SM0003213 5441977 SM0003292 1
4-Pin 5.08 mm 5447379 SM0003207 5448637 SM0003451 2
5-Pin 5.08 mm 5447382 SM0003205 5448640 SM0003293 1
6-Pin 5.08 mm 5441919 SM0003203 5441964 SM0003452 1
8-Pin 5.08 mm 5441935 SM0003201 5441951 SM0003294 1
9-Pin 5.08 mm 5447395 SM0003198 5448653 SM0003453 1
10-Pin 5.08 mm 5447405 SM0003196 5448666 SM0003501 1
4-Pin 10.16 mm 5474274 SM0003195 5453499 SM0001163 3
Figure 2: Connectors of 5.08 mm pitch
Figure 3: Connectors of 10.16 mm pitch
GC2599 SEDEMAC
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Power Supply Specifications
Following table gives a brief overview of power supply specifications
Table 3: Power supply specifications
GCU connector terminal # 1 & 2 (Ground & Battery +Ve respectively)
Supply voltage range 8 to 32 V-DC (Suitable for 12/24 V-DC system)
Cranking drop out period 50 mS
Maximum reverse voltage protection -32 V-DC
Measurement accuracy (Battery Voltage) ±1% of full scale
Resolution 0.1 V
Maximum current consumption ~ 0.4 A @ 12 V-DC (Excluding the current load for the high side driver output's)
Standby current consumption ~0.09 A @ 12V or 24V
Genset Voltages and Frequency Measurements
Following table gives a brief overview of genset voltages and frequency measurements
Table 4: Genset voltages and frequency measurements
GCU connector terminal # 54, 55, 56, 57 (N, B, Y, R respectively)
Measurement type True RMS
Phase to Neutral voltage reading limit 20 to 350 V-AC RMS
Phase to Phase voltage reading limit 20 to 606 V-AC RMS
Measurement accuracy (Voltage) (P-P / P-N) ±1% of full scale for Phase to Neutral
±1.5% of full scale for Phase to Phase
Resolution (Voltage) 1 V-AC RMS for Phase to Neutral
2 V-AC RMS for Phase to Phase
Frequency range 5 to 75 Hz
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For 1 phase genset application, it is mandatory to connect the genset phase and Neutral cables to the genset controller's phase R and Neutral terminals respectively.
Genset Current Measurements
Following table gives a brief overview of genset current measurements
Table 5: Genset current measurements
GCU connector terminal # 47 & 46 (for phase B), 45 & 44 (for phase Y), 43 & 42 (for phase R)
Measurement type True RMS
Maximum CT secondary current rating 5 A
Burden 0.25 VA
Measurement accuracy ±1.4% of full scale
GC2599 SEDEMAC
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Earth/Fan Leakage Measurements
Following table gives a brief overview of earth leakage measurements
Table 6: Earth leakage measurements
GCU connector terminal # 48 & 49
Measurement type True RMS
Maximum CT secondary current rating 5A
Burden 0.25 VA
Measurement accuracy ±1.4% of full scale
Mains Voltages and Frequency Measurements
Following table gives a brief overview of Mains voltages and frequency measurements
Table 7: Mains voltages and frequency measurements
GCU connector terminal # 50, 51, 52, 53 (N, B, Y, R respectively)
Measurement type True RMS
Phase to Neutral voltage 20 to 350 V- AC RMS
Phase to Phase voltage 20 to 606 V-AC RMS
Measurement accuracy (Voltage) ±2% of full scale for Phase to Neutral
±2.5% of full scale for Phase to Phase
Resolution (Voltage) 1 V-AC RMS for Phase to Neutral
2 V-AC RMS for Phase to Phase
Frequency range 3 to 75 Hz
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For 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 Negative sensing (connect to ground for activation)
Low level threshold 0.8 V-DC maximum (measured at the genset controller’s terminals and battery ground terminal)
High level threshold 8 V-DC minimum (measured at the genset controller’s terminals and battery ground terminal)
Software configurable options Emergency stop, Remote start/ stop, etc. Please refer Table 23 for more details.
Follow the recommended phase sequence while connecting the Current Transformer.
GC2599 SEDEMAC
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Analog Resistive Sensor Inputs
Following table gives a brief overview of analog resistive sensor inputs
Table 9: Analog resistive sensor inputs
GCU connector terminal # 11, 12, 13, 14, 15 (LOP, Fuel, Temp, Aux1, Aux2)
Number of inputs 5
Type Ratio-metric sensing
Range 10 to 5000Ω
Open circuit detection Above 5.5 KΩ
Measurement accuracy ±2% of full scale (for range 50 to 1000Ω)
Figure 4: SCP connection
Analog Current/Voltage Inputs
Following table gives a brief overview of analog voltage/current inputs
Table 10: Analog current/voltage inputs
GCU connector terminal # 21, 23 (Aux3, Aux4)
Type Current/Voltage
Range 4mA to 20mA/0 to 5 V-DC
Accuracy ± 1.25% 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)
Site Battery Inputs
Following table gives a brief overview of Site Battery inputs
Table 11: Site battery inputs
GCU connector terminal # 24, 25
Number of inputs 2
Type Differential
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Range ±60V
Resolution 0.1V
Accuracy ±2% of full scale (0 to +Ve max/ 0 to -Ve max)
Site battery run hours: In this feature, controller calculates the run hours for which the site runs on the battery backup. Site battery run hours are incremented only when both the mains and genset contactors are not latched and when site battery voltage is greater than low battery voltage threshold.
Magnetic Pick Up Inputs
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The output of MPU is a sine-wave signal.
Table 12: Magnetic pick-up inputs
GCU connector terminal # 22
Type Single ended
Frequency range 10 to 10000 Hz
Input voltage range 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.
Digital Outputs
Following table gives a brief overview of digital outputs
Table 13: Digital outputs
GCU connector terminal # 3, 4, 5, 6, 7, 8, 9
Number of outputs 7
Type High side driver
Maximum current rating 5A (3 & 4), 1A (5, 6, 7, 8, 9)
Software configurable options Start relay, Fuel relay, Close genset contactor, close mains contactor, Stop solenoid and many more. Please refer Table 32 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-61000-4-5 standard.
Actuator Outputs
Following table gives a brief overview of actuator outputs
Table 14: Actuator outputs
GCU connector terminal # 17, 18, 19, 20
Type Stepper motor drive
Maximum current 1A each coil
GC2599 SEDEMAC
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Figure 5: 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.
PFC Outputs
Following table gives a brief overview of PFC outputs
Table 15: PFC outputs
GCU connector terminal # 26, 27, 28, 29
Number of outputs 2
Type Potential free
Maximum current rating 8A
Software configurable options Start relay, Fuel relay, Close genset contactor, close mains contactor, Stop solenoid and many more. Please refer Table 32 for more details.
• Recommended for genset contactor and mains contactor
D+ CHG ALT
Following table gives a brief overview of D+ CHG ALT
Table 16: D+ CHG ALT
GCU connector terminal # 10
Voltage range 0 to VBATT; VBATT = 8 to 30 V-DC
Excitation PWM (Current limited to 250mA)
Accuracy ±2% of full scale
*The charge fail is a combined input and output terminal. When the genset starts, the terminal provides the excitation current to the charge alternator field winding. After the excitation is successfully done, the controller reads the charging alternator's output voltage for monitoring its health. The action for charge fail is configurable.
Sensor Common Point
The sensor common point (SCP) terminal (Pin # 16) of the controller should be directly connected to an electrically sound point on the engine body. This point on the engine body should serve as a common reference point for all analog sensors such as those for measuring lube oil pressure, engine temperature and fuel level. The electrical cable used for the connection should not be shared with any
GC2599 SEDEMAC
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other electrical connection. Such a wiring practice is strongly recommended to ensure that there is negligible potential difference, if any, between the engine body and the controller's SCP terminal, and, predictable and accurate analog sensor measurements are always available in a wide variety of field conditions.
Table 17: Sensor common point
GCU connector terminal # 16
Range ±2V
Accuracy ±2% of full scale
Resolution 0.1 V
Deep Sleep Mode Feature
Deep Sleep Mode is a useful feature to prolong the battery life.
In this mode, normal functions of the controller are suspended, and controller is placed into its lowest power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode. When the controller wakes up, normal operations are resumed automatically.
The controller goes in Deep Sleep Mode when there is no user interaction for the pre-set Deep Sleep Mode Delay.
GCU does not go to Deep sleep mode in following conditions:
• In auto (Site, cyclic, exercise and remote start/stop) modes
• Mains monitoring is enabled, and mains contactor configured as output
• MODBUS communication is enabled
Comes out of deep sleep mode by pressing either of following keys (not press & hold):
• Stop key
• Start key
• Auto key
• Ack key
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Communication Ports
Following table gives a brief overview of communication ports
Table 18: Communication ports
USB USB 2.0 Type B used for connection to PC running SEDEMAC Smart config.
RS485 Serial Port
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
Termination resistor of 120Ω is provided between output pin A & B
Common-mode operating range
Maximum distance of line is 1200m
GCU connector terminal # 30, 31, 32 (GND, A, B respectively)
CAN
Baud rate used is 250 kbps
Packet size used is 8 bytes
Termination resistor of 120Ω is provided
Controller's terminal number for CAN 58, 59
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
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Installation
Dimensions
Figure 6: Dimensions of the GC2599 genset controller
Recommended mounting panel cut-out dimensions: 189 mm X 143 mm.
Mounting on Panel
To mount the controller into the panel, use the fixing clips provided along with the controller.
Follow the given steps:
GC2599 SEDEMAC
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Figure 7: Fixing clip and screw supplied along with controller
Figure 8: Controller mounting on the panel using the fixing clips
• Insert the fixing clip into the slot provided on the side of the controller.
• Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is properly fitted inside the slot provided on the controller.
• Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum tightening torque is 0.19 N-m.
Over tightening of the screws may damage the controller casing.
GC2599 SEDEMAC
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Terminal Pin Details
Following figure shows rear view of the GCU which has terminal details printed on it.
Figure 9: Rear view of the controller for terminal detail
Table 19: Details of GC2599 terminals
Pin # Name Description Mating connector
part #
1 GND Power ground
BCP-508-10GN
2 BATT + Power supply positive
3 OUT A High side driver output – A
4 OUT B High side driver output – B
5 OUT C High side driver output – C
6 OUT D High side driver output – D
7 OUT E High side driver output – E
8 OUT F High side driver output – F
9 OUT G High side driver output – G
10 D+ CHG ALT Input for charging alternator control
11 ANLG LOP / DIG J Analog input from Lube Oil Pressure Sensor/Digital Input J
BCP-508-6GN
12 ANLG FUEL LEVEL / DIG K Analog input from Fuel Level Sensor / Digital Input K
13 ANLG ENG TEMP / DIG L Analog input from Engine Temperature Sensor / Digital Input L
14 ANLG AUX 1 / DIG M Analog input auxiliary/Analog input from Shelter Temperature Sensor/Digital Input M
GC2599 SEDEMAC
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Pin # Name Description Mating connector
part #
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
BCP-508-4GN 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 Analog input auxiliary /0-5V/4-20 mA (LOP) / Digital Input O
BCP-508-5GN
22 MPU Input from engine speed sensor (Inductive)
23 ANLG AUX 4 / DIG P Analog input auxiliary / 0-5V (Paralleling) / 4-20 mA/ Digital Input P
24 SITE ATT I/P Input 1 from Site battery
25 SITE BATT I/P Input 2 from Site battery
26 PFC OUT A Potential free output A (NC) BCP-508-7GN-4PA
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
30 RS485- GND RS485 – GND BCP-508-3GN
31 RS485- A RS485 – A
32 RS485- B RS485 – B
33 DIG IN A Input from switch – A
BCP-508-9GN
34 DIG IN B Input from switch – B
35 DIG IN C Input from switch – C
36 DIG IN D Input from switch – D
37 DIG IN E Input from switch – E
38 DIG IN F Input from switch – F
39 DIG IN G Input from switch – G
40 DIG IN H Input from switch – H
41 DIG IN I Input from switch – I
42 GEN CT IN R2 CT input 2 from Phase R
BCP-508-8GN
43 GEN CT IN R1 CT input 1 from Phase R
44 GEN CT IN Y2 CT input 2 from Phase Y
45 GEN CT IN Y1 CT input 1 from Phase Y
46 GEN CT IN B2 CT input 2 from Phase B
47 GEN CT IN B1 CT input 1 from Phase B
48 GEN CT IN EL2 CT input 2 from Earth Leakage
49 GEN CT IN EL1 CT input 1 from Earth Leakage
50 MAINS V N Voltage input from Mains Neutral BCP-508-7GN-4PA
51 MAINS V B Voltage input from Mains Phase B
52 MAINS V Y Voltage input from Mains Phase Y
GC2599 SEDEMAC
Page | 15
Pin # Name Description Mating connector
part #
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
BCP-508-4GN 59 CAN H CAN High
60 RESERVED RESERVED
61 RESERVED RESERVED
Typical Wiring Diagram
The typical wiring diagram of GC2599 for Auto Mains Failure application
Figure 10: Power circuit when used in the Auto Mains Failure Mode
1) Genset & mains contactor latching relays should be compiled against 4kV surge as per IEC-61000-4-5 standard.
2) Wiring drawing is for representation purpose only. Please refer wiring as per given genset application drawing.
3) Relay cards that used with controller should have protection against reverse battery voltages.
GC2599 SEDEMAC
Page | 16
Monitoring Mode
In monitoring mode, the screen will scroll automatically after a predefined time which can be configured in configuration menu or one can use the “Navigation UP/DOWN Keys” to scroll/browse the screens.
Table 20: Screens of engine status and operating modes
Product Info Manual mode
Auto mode Auto - SITE 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)
GC2599 SEDEMAC
Page | 17
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)
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
Load Current 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
Cumulative energy screens
Generator energy Mains energy
GC2599 SEDEMAC
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Engine screens
Engine lube oil pressure Engine fuel level
Engine temperature Shelter temperature
Auxiliary sensor
Engine Run Time SITE Run Time
GC2599 SEDEMAC
Page | 19
Engine Battery & Site battery voltage Engine speed
Alarm Histogram
GC2599 SEDEMAC
Page | 20
Description of Control Keys
Figure 11: 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
Functions of Control Keys
Following table gives a brief overview of different functions of control keys
Table 21: Control keys in different modes
# Mode Key input Function
1 Manual
Start Starts the engine
Auto Enters Auto mode
Stop Stops the engine when engine is running
Stop (long pressed) Enters configuration mode
Stop + Down (long pressed) 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
Configuration
Start Selects/saves the parameter
6 Up + Down (long pressed) Enters on event log page
7 Stop (long pressed) Back to Manual mode
8 Deep sleep Stop/Start/Auto/Ack
9 Event log Up + Down (long pressed) Back to configuration mode
10 Programming Up + Down (long pressed) Controller enters in Manual mode
1
2
3
4
8
7
6
5
GC2599 SEDEMAC
Page | 21
Configuration Mode
To configure the controller please follow the below mentioned instructions:
• To enter the configuration mode press and hold “STOP” key, at least for 3 seconds. Following screen will appear on the GCU
Figure 12: Configuration mode screen
• If you want to only view the configuration, press “STOP” key of the GCU. If you wish to change the configuration, press “START” key of the GCU
Figure 13: Configuration mode authentication page screen
• The GCU will ask for password (4 digit). Enter the password by using up & down arrow key for digit and “START” key for entering the digit. The 4 digits will start blinking individually as go on selecting. Press “START” button as mentioned earlier to enter the right digit.
• After completion of parameter configuration, press and hold “STOP” key to exit from configuration mode. Before existing from configuration mode controller will show the following screen.
Figure 14: Saving setting screen
Configurable Parameters
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 22: List of configurable parameters
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Module (MODULE)
General (GENERAL)
Power On Mode
(POWER ON MODE) Manual/Auto
Power On Lamp Test
(POWER ON LAMP TEST) Enable/Disable
GC2599 SEDEMAC
Page | 22
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Deep Sleep Mode
(DEEP SLEEP MODE) Enable/Disable
Load Histogram
(LOAD HISTOGRAM) Enable/Disable
Auto-Clear Warning Alarm
(AUTO CLEAR WARNINGS) Enable/Disable
Language
(LANGUAGE SUPPORT) English/Chinese
Display
(DISPLAY)
Contrast
(CONTRAST) 0 – 100 %
Power Save Mode
(POWER SAVE MODE) Enable/Disable
Communication
(COMMUNICATION)
Communication Mode
(COMM MODE) None/MODBUS-SEDEMAC
Slave ID
(MODBUS SLAVE ID) 1 – 247
Baudrate
(BAUDRATE)
1200/2400/4800/9600/19200/38400/57600/115200
Parity Bit
(PARITY) None/Even/Odd
Site Battery Monitoring
(SITE BAT CONFIG)
Battery Monitoring
(BATTERY MON) Yes/No
Low Voltage Threshold
(LOW BATT THRESHOLD) 15.0 – 60.0 V
Battery Monitoring Delay
(LOW BATT MON DELAY) 5 – 300 sec
Genset Run Duration
(GEN RUN DURATION) 1 – 720 Mins
Cyclic Mode
(CYCLIC CONFIG)
Cyclic Mode
(CYCLIC MODE) Enable/Disable
Genset Off Time
(GEN OFF DURATION) 1 – 720 Mins
Genset On Time
(GEN ON DURATION) 1 – 720 Mins
Auto Exercise - Event 1
(AUTO EXERCISE – 1)
Auto Exercise
(EVENT 1) Enable/Disable
Event Occurrence
(EVENT OCCURENCE) Daily/Weekly/Monthly
Event Day
(EVENT DAY)
Runs Every day/Week Days/1-28
Start Time
(START TIME)
00 hr 00 Mins – 23 hr 59 Mins
Duration
(GEN ON DURATION)
00 hr 01 Mins – 99 hr 59 Mins
GC2599 SEDEMAC
Page | 23
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Load Transfer
(LOAD TRANSFER) Enable/Disable
Auto Exercise – Event 2
(AUTO EXERCISE – 2)
Auto Exercise
(EVENT 2) Enable/Disable
Event Occurrence
(EVENT OCCURENCE) Daily/Weekly/Monthly
Event Day
(EVENT DAY)
Runs Every Day/ Week Days/1-28
Start Time
(START TIME)
00 hr 00 Mins – 23 hr 59 Mins
Duration
(GEN ON DURATION)
00 hr 01 Mins – 99 hr 59 Mins
Load Transfer
(LOAD TRANSFER) Enable/Disable
(NIGHT MODE)
Night Mode
(NIGHT MODE RESTRICT) Enable/Disable
Night Mode Start Time
(START TIME)
00 hr 00 Mins – 23 hr 59 Mins
Night Mode Off Duration
(GEN OFF DURATION) 1 – 1140 Mins
Inputs
(INPUTS)
Digital Input X
(DIG IN X)
X= A/B/C/D/E/F/G/H
/I
Source
(SOURCE) Refer Table 23
Polarity
(POLARITY)
Close to Activate/Open to Activate
Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
Activation Delay
(ACTIVATION DELAY) 1 – 180 Sec
Analog Inputs
(INPUTS)
Analog Input 1
(LOP RES / DIG J)
Use Input As
(SENSOR SELECTION)
Not used/Dig In J/LOP Sensor
(Dig In J) Source
(SOURCE) Refer Table 23
(Dig In J) Polarity
(POLARITY)
Close to Activate/Open to Activate
(Dig In J) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In J) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In J) Activation Delay (ACTIVATION DELAY)
1 – 180 Sec
(LOP) Low Level Shutdown (SHUTDOWN)
Enable/Disable
(LOP) Low Level Shutdown 0 – 9.8 Bar
GC2599 SEDEMAC
Page | 24
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Threshold
(SHUTDOWN THRESHOLD)
(LOP) Low Level Warning (WARNING)
Enable/Disable
(LOP) Low Level Warning Threshold
(WARNING THRESHOLD)
0.2 – 10 Bar
(LOP) Circuit Fault Action (OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(LOP) Calibration Table for Lube Oil Pressure
Refer Table 24
Analog Input 2
(FUEL LVL / DIG K)
Use Input As
(SENSOR SELECTION)
Not used/Dig In K/Anlg In Fuel LVL
(Dig In K) Source
(SOURCE) Refer Table 23
(Dig In K) Polarity
(POLARITY)
Close to Activate/Open to Activate
(Dig In K) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In K) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In K) Activation Delay
(ACTIVATION DELAY) 1 – 180 Sec
(FLS) Low Fuel Level Shutdown
(SHUTDOWN) Enable/Disable
(FLS) Shutdown Threshold (SHUTDOWN THRESHOLD)
0 – 78 %
(FLS) Low Fuel Level Warning
(WARNING) Enable/Disable
(FLS) Warning Threshold (WARNING THRESHOLD)
2 – 80 %
(FLS) Fuel Tank Capacity
(FUEL TANK SIZE) 2 – 1000 Litres
(FLS) Fuel Theft Warning
(FUEL THEFT ALARM) Enable/Disable
(FLS) Fuel Theft Alarm Threshold
(FUEL LVL THRESH)
1 – 100 % per hour
(FLS) Circuit Fault Action (OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(FLS) Fuel Sensor Reference
(FUEL LVL REF)
Battery Negative/Engine Body
(FLS) Calibration Table for Fuel Level Sensor
Refer Table 25
Analog Input 3
(ENG TEMP /
Use Input As
(SENSOR SELECTION)
Not used/Dig In L/Anlg In Eng Temp
GC2599 SEDEMAC
Page | 25
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
DIG L)
(Dig In L) Source
(SOURCE) Refer Table 23
(Dig In L) Polarity
(POLARITY)
Close to Activate/Open to Activate
(Dig In L) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In L) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In L) Activation Delay
(ACTIVATION DELAY) 1– 180 Sec
(ETS) High Level Shutdown
(SHUTDOWN) Enable/Disable
(ETS) Shutdown Threshold (SHUTDOWN THRESHOLD)
27 – 300 deg C
(ETS) High Level Warning (WARNING)
Enable/Disable
(ETS) Warning Threshold (WARNING THRESHOLD)
25-298 deg C
(ETS) Circuit Fault Action (OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(ETS) Calibration Table for Engine Temperature Sensor
Refer Table 26
S1 Sensor
(AUX S1 RES/DIG M)
Use Input As
(SENSOR SELECTION)
Not used/Dig In M/Auxiliary Sensor/Shelter Temperature
(Dig In M) Source
(SOURCE) Refer Table 23
(Dig In M) Polarity
(POLARITY)
Close to Activate/Open to Activate
(Dig In M) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In M) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In M) Activation Delay (ACTIVATION DELAY)
1 – 180 Sec
(S1) Threshold Type (THRESHOLD TYPE)
Greater Than Threshold / Less Than Threshold
(S1) Shutdown
(SHUTDOWN) Enable/Disable
(S1) Shutdown Threshold (SHUTDOWN THRESHOLD)
0 – 1000 units
(S1) Warning
(WARNING) Enable/Disable
(S1) Warning Threshold (WARNING THRESHOLD)
0 - 1000 units
GC2599 SEDEMAC
Page | 26
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
(S1) Circuit Fault Action
(OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(STS) High Temp Threshold (SHELT TEMP THRESH)
25-300 deg C
(STS) Shelter temp hysteresis
(SHELT TEMP HYST) 1-100 deg C
(STS) Shelt Temp Monitoring Delay
(SHELT TEMP DELAY)
5 – 300 sec
(STS) Shelt Temp Run Duration
(GEN RUN DURATION) 1 – 720 sec
(STS) Calibration Table (Resistive)
Refer Table 27
S2 Sensor
(AUX S2 RES / DIG N)
Use Input As
(SENSOR SELECTION)
Not used/Dig In N/Auxiliary Sensor
(Dig In N) Source
(SOURCE) Refer Table 23
(Dig In N) Polarity
(POLARITY)
Close to Activate/Open to Activate
(Dig In N) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In N) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In N) Activation Delay
(ACTIVATION DELAY) 1 – 180 Sec
(S2) Threshold Type (THRESHOLD TYPE)
Greater Than Threshold/ Less Than Threshold
(S2) Shutdown
(SHUTDOWN) Enable/Disable
(S2) Shutdown Threshold (SHUTDOWN THRESHOLD)
0 –1000 units
(S2) Warning
(WARNING) Enable/Disable
(S2) Warning Threshold (WARNING THRESHOLD)
0 –1000 units
(S2) Circuit Fault Action
(OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(S2) Calibration Table (Resistive)
Refer Table 27
S3 Sensor/ Digital Input O
(AUX S3 RES / DIG O/*LOP)
And
S4 Current Sensor/ Digital
Use Input As
(SENSOR SELECTION)
Not used/Dig In O/ Dig In P/S3 Sensor/ S4 Sensor/0
– 5V Sensor/*LOP
(Dig In O/ Dig In P) Source
(SOURCE) Refer Table 23
(Dig In O/ Dig In P) Polarity
(POLARITY)
Close to Activate/Open to Activate
GC2599 SEDEMAC
Page | 27
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Input P
(AUX S4 RES / DIG P)
(Dig In O/ Dig In P) Action
(ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
(Dig In O/ Dig In P) Activation
(ACTIVATION)
Never/From Engine Start/ From Monitoring On/Always
(Dig In O/ Dig In P) Activation Delay (ACTIVATION DELAY)
1 – 180 Sec
(S3/S4) Threshold Type (THRESHOLD TYPE)
Greater Than Threshold/ Less Than Threshold
(S3/S4/LOP) Shutdown
(SHUTDOWN) Enable/Disable
(S3/S4/LOP) Shutdown Threshold
(SHUTDOWN THRESHOLD)
0 –1000 units
(S3/S4/LOP) Warning
(WARNING) Enable/Disable
(S3/S4/LOP) Warning Threshold (WARNING THRESHOLD)
0 –1000 units
(S3/S4/LOP) Circuit Fault Action
(OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(S3/S4/LOP) Calibration Table (Current)
Refer Table 28 for S3/S4 & Refer Table 29 for LOP
(0-5 V Sensor) Threshold Type (THRESHOLD TYPE)
Greater Than Threshold/ Less Than Threshold
(0-5 V Sensor) Shutdown (SHUTDOWN)
Enable/Disable
(0-5 V Sensor) Shutdown Threshold
(SHUTDOWN THRESHOLD)
0 –1000 units
(0-5 V Sensor) Warning (WARNING)
Enable/Disable
(0-5 V Sensor) Warning Threshold
(WARNING THRESHOLD)
0 –1000 units
(0-5 V Sensor) Circuit Fault Action
(OPEN CKT ALARM)
None/Warning/Electrical Trip/Shutdown/Notification
(0-5 V Sensor) Calibration Table (Voltage)
Refer Table 30
Outputs (OUTPUTS)
Output X
(OUTPUT X) X=A/B/C/D/E/F/
G
Source
(SOURCE) Refer Table 32
On Activation
(ON ACTIVATION) Energise/De-energise
Output PFC-X
(PFC X)
X=A/B
Source
(SOURCE) Refer Table 32
On Activation
(ON ACTIVATION) Energise/De-energise
GC2599 SEDEMAC
Page | 28
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Timers
(TIMERS)
Cranking
(CRANKING TIMER)
Crank Hold Time
(CRANK HOLD TIME) 1 – 15 sec
Crank Rest Time
(CRANK REST TIME) 2 – 60 sec
Manual Start Delay
(MANUAL START DELAY) 0 – 300 sec
Auto Start Delay
(AUTO START DELAY) 0 – 300 sec
Start / Stop
(START / STOP TIMER)
Safety Monitoring Delay (SAFETY MONITOR DELAY)
10 – 60 sec
Mains Detect Delay
(MAINS DETECT DELAY) 1 – 300 sec
Alternator Detect Delay
(ALT DETECT DELAY) 1 – 30 sec
Warm-Up Delay
(WARM-UP DELAY) 0 – 60 sec
Return To Mains Delay
(RETN-TO-MAINS DELAY) 0 – 600 sec
Engine Cooling Time
(ENG COOL TIME) 0 – 300 sec
Stop Action Time
(STOP ACTION TIME) 10 – 120 sec
Additional Stopping Time (ADDN STOPPING TIME)
0 – 120 sec
Load Transfer Delay
(LOAD TRANSFER DELAY) 1 – 60 sec
General
(GENERAL TIMER)
Power Save Mode Delay
(PWR SAVE MODE DELAY) 5 – 1800 sec
Screen Changeover Time (SCRN CHNGOVER TIME)
1 – 1800 sec
Deep Sleep Mode Delay
(DEEP SLP MODE DELAY) 5 – 1800 sec
Sounder Alarm Time (SOUNDER ALARM TIMER)
1 – 300 sec
Test Mode Timer
(TEST MODE TIMER) 1 – 720 min
Auto Exit Config Mode
(AUTO EXIT CNFG MODE) 10 – 1800 sec
Generator (GENERATOR)
Alternator Configuration
(ALT CONFIG)
Alternator Present
(ALT PRESENT) Yes/No
Number of Poles
(NUMBER OF POLES) 2/4/6/8 Poles
AC system
(ALT AC SYSTEM) 1 Phase/3 Phase
Min Healthy Voltage 50 – 350 V Ph - N
GC2599 SEDEMAC
Page | 29
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
(MIN HEALTHY VOLT)
Min Healthy Frequency
(MIN HEALTHY FREQ) 10 – 75 Hz
Phase Reversal Detection (PHASE REVERSAL DETECT)
Enable/Disable
Phase Reversal Action
(PHASE REVERSAL ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Auto Load Transfer
(AUTO LOAD TRANSFER) Enable/Disable
Alternator Wave Detection
(WAVEFORM DETECT) Enable/Disable
Voltage Monitoring
(VOLT MONITOR)
Under-voltage Shutdown
(UNDER VOLT SHUTDOWN) Enable/Disable
Under-voltage Shutdown Threshold
(UV SHUTDOWN THRESH)
50 – 295 V Ph-N
Under-voltage Warning
(UNDER VOLT WARNING) Enable/Disable
Under-voltage Warning Threshold
(UV WARNING THRESHOLD)
55 – 300 V Ph - N
Over-voltage Shutdown
(OVER VOLT SHUTDOWN) Enable/Disable
Over-voltage Shutdown Threshold
(OV SHUTDOWN THRESH)
105 – 350 V Ph - N
Over-voltage Warning
(OVER VOLT WARNING) Enable/Disable
Over-voltage Warning Threshold (OV WARNING THRESHOLD)
100 – 345 V Ph - N
Frequency Monitoring
(FREQ MONITOR)
Under-frequency Shutdown
(UNDER FREQ SHUTDOWN) Enable/Disable
Under-frequency Shutdown Threshold
(UF SHUTDOWN THRESH)
10.0 – 59.0 Hz
Under-frequency Warning
(UNDER FREQ WARNING) Enable/Disable
Under-frequency Warning Threshold
(UF WARNING THRESHOLD)
11.0 – 60.0 Hz
Over-frequency Shutdown
(OVER FREQ SHUTDOWN) Enable/Disable
Over-frequency Shutdown Threshold
(OF SHUTDOWN THRESH)
26.0 – 75.0 Hz
GC2599 SEDEMAC
Page | 30
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Over-frequency Warning
(OVER FREQ WARNING) Enable/Disable
Over-frequency Warning Threshold
(OF WARNING THRESHOLD)
25.0 – 74.0 Hz
Current Monitoring
(CURRENT MONITOR)
CT Ratio
(LOAD CT RATIO) 0 – 8000 / 5
Over-current Action
(OVER CURR ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Over-current Threshold
(OVER CURR THRESHOLD) 5 – 10000 Amp
Over-current Delay
(OVER CURR DELAY) 1 – 600 sec
CT Correction Factor 0.900 – 1.100
CT Location
(CT LOCATION)
On Alt Output Cable/On Load Cable
Earth/Fan Current
Monitoring (EARTH CURR
MON)
Current Monitoring
(FAN / EARTH MON)
ERTH Curr Mon/
FAN Curr Mon
Current CT Ratio
(CT RATIO) 0 – 8000 / 5
High Current Action
(HIGH CURR ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
High Current Threshold
(HIGH CURR THRESH) 0.1 – 10.0 A
Current Delay
(CURR DELAY) 5 – 60 sec
Low Current Action
(LOW CURR ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Low Current Threshold
(LOW CURR THRESH) 0.0 – 9.9 A
Load Monitoring
(LOAD MONITOR)
Generator Rating
(GEN RATING) 0 – 8000 kW
Over-load Action
(OVERLOAD ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Over-load Threshold (OVERLOAD THRESHOLD)
50 – 150 %
Over-load Monitoring Delay (OVERLOAD MON DELAY)
1 – 600 sec
Unbalanced Load Action (UNBAL LOAD ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Unbalanced Load Threshold (UNBAL LOAD THRESHOLD)
5 - 200 %
Unbalanced Load Delay (UNBAL LOAD DELAY)
1 - 600 sec
Mains Configuration Mains Monitoring Enable/Disable
GC2599 SEDEMAC
Page | 31
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
(Mains) (MAINS CONFIG)
(MAINS MONITORING)
Mains AC System
(MAINS AC SYSTEM) 1 Phase/3 Phase
Phase Reversal Detection (PHASE REVERSAL DETECT)
Enable/Disable
Phase Reversal Action
(PHASE REVERSAL ACTION) None/Notification
Partial Healthy Detection
(MAINS PARTIAL HEALTHY) Enable/Disable
Voltage Monitoring
(VOLTAGE MON)
Under-voltage
(UV ENABLE) Enable/Disable
(UV) Trip
(UV TRIP) 50 – 298 V Ph - N
(UV) Return
(UV RETURN) 52 – 300 V Ph - N
Over-voltage
(OV ENABLE) Enable/Disable
(OV) Trip
(OV TRIP) 102 – 350 V Ph - N
(OV) Return
(OV RETURN) 100 – 348 V Ph - N
Frequency Monitoring
(FREQUENCY MON)
Under-frequency
(UF ENABLE) Enable/Disable
(UF) Trip
(UF TRIP) 10.0 – 59.0 Hz
(UF) Return
(UF RETURN) 11.0 – 60.0 Hz
Over-frequency
(OF ENABLE) Enable/Disable
(OF) Trip
(OF TRIP) 26.0 - 75.0 Hz
(OF) Return
(OF RETURN) 25.0 - 74.0 Hz
Engine
(ENGINE)
Crank Disconnect
(CRANK DISCONN)
Start Attempts
(START ATTEMPTS) 1 – 9
Disconnect on Oil Pressure Sensor
(DISCONN ON LOP SENS)
Enable/Disable
Pressure Sensor Monitoring Threshold
(DISCONN LOP SENS)
0.5 – 10.0 bar
Monitor Pressure Sensor Before Crank
(MON LLOP BEF CRANK)
Enable/Disable
GC2599 SEDEMAC
Page | 32
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
Monitor Pressure Switch Before Crank
(MON LOP BEF CRANK)
Enable/Disable
Disconnect on Oil Pressure Switch
(DISCONN ON LLOP SW)
Enable/Disable
Pressure Switch Transient Time
(LLOP SW TRANS TIME) 0.0 – 3.0 Sec
Crank Disconnect At Alt Frequency
(ALT FREQUENCY)
10 – 70 Hz
Crank Disconnect At Engine Speed
(ENGINE SPEED)
150 – 4000 RPM
Disconnect On Charging Alt Voltage
(DISC ON CHG ALT VOLT)
Enable/Disable
Charging Alt Disconnect Volt Threshold
(CHG ALT THRESHOLD)
5.0 – 30.0 V
Speed Monitoring
(SPEED MONITOR)
Engine Speed Sense Source
(SPEED SENSE SOURCE) Alternator frequency/MPU
Flywheel Teeth
(FLYWHEEL TEETH) 1 – 300
Under-speed Shutdown (UNDER SPEED SHUTDOWN)
Enable/Disable
Under-speed Threshold (UNDER SPEED THRESH)
0 - 3600 RPM
Under-speed Delay
(UNDER SPEED DELAY) 1 - 60 Sec
Over-speed Threshold
(OVER SPEED THRESH) 700 - 4000 RPM
Over-speed Delay
(OVER SPEED DELAY) 1 - 20 Sec
Gross Over-speed Threshold
(GROSS OS THRESHOLD) 100% - 200%
Battery Monitoring
(BATTERY MONITOR)
Low Battery Voltage Action (LOW VOLT ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Low Battery Voltage Threshold
(LOW VOLT THRESHOLD) 8.0 – 31.0 V
Low Battery Voltage Delay (LOW VOLT DELAY)
5 – 1800 Sec
High Battery Voltage Action (HIGH VOLT ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
High Battery Voltage Threshold
(HIGH VOLT THRESHOLD) 9.0 – 32.0 V
GC2599 SEDEMAC
Page | 33
Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
High Battery Voltage Delay (HIGH VOLT DELAY)
5 – 1800 Sec
Charging Alternator Monitoring
(CHARGE ALT MON)
Charging Alternator Fail Action
(FAIL ACTION)
None/Warning/Electrical Trip/Shutdown/Notification
Charging Alternator Fail Threshold
(FAIL THRESHOLD)
0.0 - 35.0 V
Charging Alternator Fail Delay
(FAIL DELAY) 5 – 60 sec
Preheating
(PREHEAT)
Preheat Timer
(PREHEAT TIMER) 1 – 900 sec
Engine Temperature
(ENG TEMP EN) Enable/Disable
Engine Temperature Threshold
(ENG TEMP LIMIT) 10 – 300 °C
Maintenance (MAINTENANCE)
Maint Alarm
(MAINT ALARM)
Alarm Action
(ACTION) Notification/Warning
Due At Engine Hours
(DUE AT ENGINE HOURS) 10 – 65000 Hrs
Alarm Due Date
(ALARM DUE DATE)
Alarm Due Date
(ALARM DUE DATE) 1-31/Jan-Dec/2016-75
Rotary Actuator
(ROTARY ACTUATOR)
General
(GENERAL)
Actuator Application
(ACTUATOR APPLICATION)
As E-Governor/As Start/Stop Device
Actuator Speed
(ACTUATOR SPEED) 1 – 10 * 25 Hz
Actuator Direction
(ACTUATOR DIRECTION)
Clockwise/Anti clockwise to Stop
Governing Mode
(GOVERNING MODE)
Fixed Speed/Variable Speed
Variable Speed
(ECONOSEEK)
Recovery Mode
(RECOVERY THRESHOLD) 600 – 3000 RPM
Low Voltage Recovery
(LOW VOLTAGE REC) 0 – 300 Volt Ph-N
Low Load Entry Limit
(LOW LOAD ENTRY LMT) 0 – 100 %
Low Load Exit Limit
(LOW LOAD EXIT LIMIT) 0 – 100 %
Recovery Time
(RECOVERY TIME) 10 – 300 sec
Low Saturation Voltage
(LOW SATURATION VOLT) 0 – 300 Volt Ph-N
RPM Stepup Rate
(RPM STEP UP RATE) 1 – 50 RPM/sec
RPM Stepdown Rate 1 – 50 RPM/sec
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Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
(RPM STEP DOWN RATE)
RPM vs Load Calibration Table Refer Table 31
Generator EGov Configuration
(GEN EGOV CONFIG)
Set Speed Selection
(SET SPEED SELECTION)
Fixed Speed (0% Droop)/Speed Bias Inp (0-5
V)/Load Based Droop
Droop
(LOAD DROOP) 0 – 4 %
Target Speed
(TARGET/RECOVERY SPD) 500 – 4000 RPM
Proportional Gain (Kp)
(PROPORTIONAL GAIN) 0 – 1000
Integral Gain(Ki)
(INTEGRAL GAIN) 0 – 2000
Derivative Gain(Kd)
(DERIVATIVE GAIN) 0 – 1000
Friction Setoff
(FRICTION SETOFF) 0 – 1000
Gain Schedule Trigger
(GAIN SCHEDULE TRIGER) 0.0 – 100.0 %
Loading Factor
(LOADING FACTOR) 0 – 1000
Unloading Factor
(UNLOADING FACTOR) 0 – 1000
Engine EGov Configuration
(ENGINE GOV CFG)
Target Speed (TARGET/RECOVERY SPD)
500 – 4000 RPM
Proportional Gain (Kp)
(PROPORTIONAL GAIN) 0 – 1000
Integral Gain(Ki)
(INTEGRAL GAIN) 0 – 2000
Derivative Gain(Kd)
(DERIVATIVE GAIN) 0 – 1000
Friction Setoff
(FRICTION SETOFF) 0 – 1000
Gain Schedule Trigger (GAIN SCHEDULE TRIGER)
0.0 – 100.0 %
Loading Factor
(LOADING FACTOR) 0 – 1000
Unloading Factor
(UNLOADING FACTOR) 0 – 1000
Engine Start Strategy
(ENG START STRGY)
Cranking Steps
(CRANKING STEPS) 50 – 5000
Initial Low Speed Delay
(INIT LOW SPEED DELAY) 0 – 180 sec
Initial Low Speed
(INIT LOW SPEED) 500 – 1800 RPM
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Level 0 Level 1 (On
screen) Level 2 (On screen) * Possible Value
PID Trigger Speed
(PID TRIGGER SPEED) 20 – 2800 RPM
Ramp Up Time
(RAMP UP TIME) 1 – 180 sec
PID On Time
(PID ON TIME) 1 – 180 sec
Start Stop Device
Configuration
(START STOP DEVICE)
Running Steps
(RUNNING STEPS) 0 – 500
Id
(ID)
(ENG SR NO) ############ 0 – 9 for each digit and A –
Z for each alphabet
(PASSWORD 1) #### 0 – 9 for each digit
(PASSWORD 2) #### 0 – 9 for each digit
Table 23: Digital input source selection
# Source (On screen)
1 Not used
2 User Configured
3 Low Fuel Level Switch (Low Fuel LVL switch)
4 Low Lube Oil Pressure Switch
5 High engine temperature switch (High Engine Temp Switch)
6 Low Water Level Switch (Low Water LVL Switch)
7 Emergency Stop
8 Remote Start / Stop
9 Simulate Start
10 Simulate Stop
11 Simulate Auto
12 Close genset/open mains contactor (Close Gen/Open Mains Switch)
13 Close mains/ open genset contactor (Close Mains/Open Gen Switch)
14 Simulate Mains
15 V-Belt Broken Switch
16 Mains Contactor Latched
17 Genset Contactor Latched
18 Battery Charger Fail
19 Smoke Fire
20 Remote Alarm Mute
21 Remote Alarm Acknowledge
22 Stop and Panel Lock
23 External Panel Lock
24 Generator Load Inhibit
25 Mains Load Inhibit
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Table 24: LOP (Resistive) sensor calibration
Resistance(Ω) Pressure (Bar)
0 – 5000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)
Table 25: Fuel level sensor calibration
Resistance(Ω) Fuel level (%)
0 – 5000 (R1 - R10) 0 - 100% (V1-V10)
Table 26: Engine / shelter temperature sensor calibration
Resistance(Ω) Temperature° C
0 – 5000 (R1 - R10) -25 - 300° C (V1-V10)
Table 27: Auxiliary (S1/S2) resistive sensor calibration
Resistance(Ω) Monitoring Parameter (User configuration)
0 – 5000 (R1 - R10) 0.0 – 1000.0 (V1-V10)
Table 28: Auxiliary (S3/S4) current sensor calibration
Current(mA) Monitoring Parameter (User configuration)
4 – 20 (I1 - I10) 0 – 1000 (V1 – V10)
Table 29: LOP (4-20 mA) sensor calibration
Current(mA) Bar (Bar)
4 – 20 (I1 - I10) 0 – 10 (V1 – V10)
Table 30: Auxiliary (S3/S4) voltage sensor calibration
Voltage(V) Monitoring Parameter (User configuration)
0-5 (I1 - I10) 0 – 1000 (V1 – V10)
Table 31: Load – RPM calibration
Load (%) RPM
0 – 130 (L1 - L11) 400 – 4000 (R1 – R11)
Table 32: 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 Shutdown (Charge Alt Shutdown)
6 Charging Alternator Warning (Charge Alt Warning)
7 Close Genset Contactor (Close Gen Contactor)
8 Close Mains Contactor (Close Mains Contactor)
9 Mains Failure
10 Common Alarm
11 Common Electrical Trip
12 Common Shutdown
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# Output source (On screen)
13 Common Warning
14 Cooling Down
15 Digital Input A (Dig In A)
16 Digital Input B (Dig In B)
17 Digital Input C (Dig In C)
18 Digital Input D (Dig In D)
19 Digital Input E ((Dig In E)
20 Digital Input F (Dig In F)
21 Digital Input G (Dig In G)
22 Digital Input H (Dig In H)
23 Digital Input I (Dig In I)
24 Digital Input J (LOP Resistive)
25 Digital Input K (Anlg In Fuel LVL)
26 Digital Input L (Anlg In Eng Temp)
27 Digital Input M (Aux Sensor 1)
28 Digital Input N (Aux Sensor 2)
29 Digital Input O (Aux Sensor 3)
30 Digital Input P (Aux Sensor 4)
31 Emergency stop
32 Stop Solenoid
33 Fail To Start
34 Fail To Stop
35 Fuel Relay
36 Generator Available (Gen Available)
37 R Phase Over Voltage Shutdown (R Phase OV Shutdown)
38 R Phase Under Voltage Shutdown (R Phase UV Shutdown)
39 Y Phase Over Voltage Shutdown (Y Phase OV Shutdown)
40 Y Phase Under Voltage Shutdown (Y Phase UV Shutdown)
41 B Phase Over Voltage Shutdown (B Phase OV Shutdown)
42 B Phase Under Voltage Shutdown (B Phase UV Shutdown)
43 Gen Over Current
44 High 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 Shutdown (Over Freq Shutdown)
53 Over Speed Shutdown
54 Gross Over Speed Shutdown
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# Output source (On screen)
55 Start Relay
56 Temp Sensor Open Circuit
57 Under Frequency Shutdown (Under Freq Shutdown)
58 Under Speed Shutdown
59 Maintenance Due
60 Stop Mode
61 Auto Mode
62 Manual Mode
63 Preheat Output
64 Calling For Scheduler Run
65 Stop and Panel Lock
66 External Panel Lock
67 Fail To Close Generator
68 Fail To Close Mains
69 Loading Volt Not Reached
70 Loading Freq Not Reached
71 MPU Loss
Modes selection in GC2599
Figure 15: Mode selection screen
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Start and Stop Sequence
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 16: 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.
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Stop Sequence
Figure 17: 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.
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Operation Modes
• Auto mode
• Manual mode
• Test mode
• Paralleling mode
Auto Mode
To enter Auto mode press “AUTO” key.
• Site Battery monitoring mode (fuel saving mode)
• Cyclic mode
• Auto Mains Failure (AMF)
• Remote start/stop
• Exerciser mode
Site Battery Monitoring Mode
This mode enables the controller to monitor the health of the Site battery and Shelter temperature and accordingly control the power sources (Mains / Genset) to keep the battery charge within the specified threshold.
This mode also supports partial healthy condition of mains source. Partial healthy is a state in which mains is not considered as failed even if one or two-phases are unhealthy. The mains keep supplying power through the available phase/s. Mains failure occurs only when all the three phases fail. Upon Mains failure genset shall receive start command only if either of following conditions occur
a) Site Battery voltage level has reached below its lower limits. b) Shelter temperature has exceeded its upper threshold limits. c) If either of a) or b) occur when source is partially healthy.
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Figure 18: SMD of site monitoring 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
In this mode if the Site battery condition is healthy, Shelter temperature is below “High Shelter Temp threshold” and mains is unhealthy, the controller keeps both the contactors (Genset and Mains) open and waits till the Site battery gets discharged. Once the Site battery becomes unhealthy or Shelter temp is detected high, the controller then gives a start command to the genset. Then Genset will Start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. Then genset will run for DG run Duration. According to the factor which triggered DG start (Site battery voltage Low OR Shelter Temp High), Run duration (Site low Run duration OR High Shelter Temp run duration) will be taken. After the duration is over or mains becomes healthy during the DG Run duration, controller will open genset contactor. If shelter temp run duration is over and the temp is not below Low Temp Threshold, then genset will continue to run for the set duration. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving Stop command.
It is recommended to keep mains monitoring enable in this mode. Also, it is recommended to use shelter temperature only when site monitoring is enabled.
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Cyclic Mode
Figure 19: 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.
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Auto Mains Failure (AMF)
Figure 20: 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 Site monitoring, Cyclic and exerciser modes are disabled, and Mains Monitoring is enabled.
In this mode, if the mains is healthy then the genset remains in Stop condition. If after the Mains Detect Delay, mains is found unhealthy, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. During genset running condition, if the mains is found healthy, Return To Mains Delay timer starts. If mains is found unhealthy during the Return To Mains Delay, then Genset continues to run. At the end of this delay if mains is still healthy, then genset contactor gets opened and mains contactor gets latched after the completion of Load Transfer Delay. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping sequence by giving Stop command.
During start sequence, if the mains voltage recovers or any stop command or shutdown / warning alarm occurs controller will not issue start command to genset. To start the genset it is necessary to clear all the alarms manually and put the controller in Auto mode.
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The AMF mode is only valid when site monitoring, Cyclic and exercise modes are disabled, and Mains Monitoring is enabled.
Exercise Mode
Figure 21: 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. If the controller is switched to Auto mode during Exercise is running, genset will start and run for remaining scheduled duration.
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• The genset controller will not respond to Remote start command in Exercise mode.
• In AMF mode, if the mains is unhealthy or cut off or when the genset is running in Exercise mode, genset will first run Exercise and then genset will continues to run in AMF mode. Load will be transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF mode when the mains become healthy.
• If both exercises are scheduled at the same time, then Start time for second exercise will be incremented by 1 min.
The Exerciser mode is only valid when site monitoring and cyclic modes are disabled, and Mains Monitoring is enabled.
Remote Start/Stop
Figure 22: Flow chart of remote start/stop mode
To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote start/stop (Latched type input) and put the controller in the Auto mode. Also disable both Site monitoring and Cyclic mode.
In this mode, the genset can be commanded to start and stop by activating the preconfigured Remote start/stop input. If Remote Start command is received, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received. When Remote Stop command is received the controller will open the genset contactor. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping sequence by giving Stop command.
It is recommended not to enable Mains Monitoring and Remote Start/Stop configuration simultaneously.
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The Remote start/stop mode is only valid when site monitoring, cyclic, exerciser modes and mains monitoring are disabled.
Night Restriction Mode
In night restriction mode, user can set a particular time in 24 – hour cycle, and then select the time duration for which you want to restrict DG run in any circumstances. Night restriction mode commands to turn off the genset at preconfigured time. This time is of 24 – hour cycle and repeated on daily basis. It also keeps the genset in OFF state for the preconfigured time duration. Genset is restricted to start if start command is received by any means during “Night Mode OFF Duration”. If genset needs to start in night restriction mode, then follow the below instructions:
• Press and hold “STOP” key for minimum three seconds and enter in edit mode of configuration
of genset controller.
• Select the “Module” and navigate to “Night Mode” parameter.
• Enter in Night mode and disable the ‘Night Mode” or change the “Night Mode OFF Duration”
time period.
• Save the parameters and come out of configuration mode.
• Start the genset in Auto/Manual mode
Figure 23: SMD for night restriction mode
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Manual Mode
Module Operation in Manual Mode
Figure 24: 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
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Starting the Engine
Figure 25: Pictorial reference for starting the engine
If Start Key is pressed in this mode, then controller will issue Start command and Genset will start according to Start Sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched if Auto Load Transfer is enabled. Engine run hours will start incrementing as long as the genset is in running condition till the stop command is received.
When Stop key is pressed, controller will open genset contactor. After opening genset contactor, Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving Stop command. If Stop key is pressed during Engine Cooling Time, controller skips the Cooling Time and issues the stop command immediately.
Stopping the Engine
Figure 26: Pictorial reference for stopping the engine
Press the START key to crank the engine.
While engine is running, press STOP key to stop engine. To stop engine
immediately press STOP key twice.
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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 27)
Figure 27: Analog voltage input terminals of GC2599
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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.
Figure 28: 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.
Press the Ack key
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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”.
Features
There are some silent features that helps in saving power and other monitoring purpose.
Auto Config Exit Mode
In this mode, the controller comes out of Configuration Mode automatically when there is no user interaction for the pre-set Auto Config Exit Mode Delay.
Controller saves all configuration parameter changes and exit the configuration mode.
Load Histogram
Load Histogram displays an engine run hour spent in different regimes. This mode helps user to monitor the duration of genset running on specific percentage of load. The load percentage is calculated based on following parameters:
1. Generator rating 2. CT ratio
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Alarms
When Shutdown alarm occurs controller commands genset to stop. The controller will not issue the start command if the Shutdown alarm left unacknowledged.
When an electrical trip alarm occurs, the controller opens the genset contactor first and then it commands the genset to stop. The controller will not issue the start command if the Electrical trip alarm left unacknowledged.
If the warning alarm occurs in between the genset running condition, then the controller will not issue the stop command. But if the warning alarm left unacknowledged when the genset is in stop condition, then the genset cannot be started. Warning alarm gets auto cleared when condition gets cleared only if auto warning clear is enabled in config file or through UI.
Notification alarms get auto cleared.
Table 33: Types of alarms actions and their descriptions
# Alarm
Actions Description
1 Shutdown Load is taken off from the genset and the genset is immediately stopped by skipping Engine Cooling Time.
2 Electrical trip Load is taken off from the genset, engine cooling timer begins, after which genset is stopped.
3 Warning
Warning alarms serves to draw operator's attention to an undesirable condition without affecting genset's operation.
The genset cannot be started without acknowledging the warning alarms
4 Notification Controller will display message on the display screen and will not affect genset start stop operation.
Table 34: Alarms and their causes
Sr. No.
Alarms Causes / Indication Actions
1
Low Oil Pressure (Sensor)
Indicates that the oil pressure measured is below the pre-set threshold
None/
Shutdown/
Warning
Low Oil Pressure (Switch)
Indicates that the oil pressure measured is low through switch
None/
Shutdown/
Warning/
Electrical Trip/
Notification
2 LOP Res Sensor- Ckt Open
The oil pressure sensor is detected as not being present
None/
Shutdown/
Warning/
Electrical Trip/
Notification
3
High Eng Temp (sensor) Indicates that the engine temperature is above the pre-set threshold. This condition is detected only when engine is on.
None/
Shutdown/
Warning
High Eng Temp (Switch) Indicates that the engine temperature measured is high through switch
None/
Shutdown/
Warning/
Electrical Trip/
Notification
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Sr. No.
Alarms Causes / Indication Actions
4 Eng Temp - Ckt Open The temperature sensor is detected as not being present
None/
Shutdown/
Warning/
Electrical Trip/
Notification
5
Low Fuel level (Sensor) Indicates that the amount of fuel level is below the pre-set threshold. This condition is detected only when engine is on.
None/
Shutdown/
Warning
Low Fuel level (Switch) Indicates that the amount of fuel level measured is low through switch
None/
Shutdown/
Warning/
Electrical Trip/
Notification
Fuel level - Ckt Open Fuel level sensor is detected as not being present
None/
Shutdown/
Warning/
Electrical Trip/
Notification
6 Fuel Theft The fuel consumption has exceeded the pre-set threshold
Warning
7 Low Water Level Switch Indicates that radiator water level is below the pre-set threshold
None/
Shutdown/
Warning/
Electrical Trip/
Notification
8 Shelter Temp - Ckt Open
Shelter Temperature sensor is detected as not being present
Notification
9 Aux S2 - Ckt Open Auxiliary sensor S2 is detected as not being present
None/
Shutdown/
Warning/
Electrical Trip/
Notification
10 Auxiliary Input (for e.g. Aux_A - P) /user defined name
Configured auxiliary input has triggered longer than pre-set duration
None/
Shutdown/
Warning/
Electrical Trip/
Notification
11 Emergency Stop When emergency stop switch is pressed and immediate shutdown is required.
Shutdown
12 Fail To Stop It is detected that genset is still running after sending stop command
Shutdown
13 Fail To Start Indicates that genset has not started after the pre-set number of Start Attempts
Shutdown
14 R Phase Over Voltage Indicates that genset (R) Phase voltage has exceeded the pre-set over voltage threshold.
Warning/
Shutdown
15 Y Phase Over Voltage Indicates that genset (Y) Phase voltage has exceeded the pre-set over voltage threshold
Warning/
Shutdown
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Sr. No.
Alarms Causes / Indication Actions
16 B Phase Over Voltage Indicates that genset (B) Phase voltage has exceeded the pre-set over voltage threshold
Warning/
Shutdown
17 R Phase Under Voltage Indicates that genset (R) Phase voltage has fallen below pre-set under voltage threshold.
Warning/
Shutdown
18 Y Phase Under Voltage Indicates that genset (Y) Phase voltage has fallen below pre-set under voltage threshold
Warning/
Shutdown
19 B Phase Under Voltage Indicates that genset (B) Phase voltage has fallen below pre-set under voltage threshold
Warning/
Shutdown
20 DG Phase Reversed Alternator phase sequence (R-Y-B) is not correct
None/
Warning/
Electric trip/
Shutdown/
Notification
21 Mains Phase Reversed Mains is in unhealthy condition None/
Notification
22 Over Frequency Indicates that genset output frequency has exceeded the pre-set threshold
Warning/
Shutdown
23 Under Frequency Indicates that genset output frequency has fallen below the pre-set threshold
Warning/
Shutdown
24 Over Current Indicates that genset current has exceeded the pre-set shutdown threshold
None/
Shutdown/
Warning/
Electrical Trip/
Notification
25 Over Load Indicates that the measured kW load rating has exceeded the pre-set threshold
None/
Shutdown/
Warning//
Electrical Trip
Notification
26 Unbalanced Load Load on any phase is greater or less than other phases by a threshold value
None/
Shutdown/
Warning/
Electrical Trip/
Notification
27 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay.
Shutdown
28 Gross Over Speed Indicates that genset speed has exceeded the pre-set Gross Over Speed Threshold. Genset will shut down immediately without any delay.
Shutdown
29 Under Speed The engine speed has fallen below the pre-set RPM
Shutdown
30 Charge Fail The charge alternator voltage has dropped below the pre-set threshold
None/
Shutdown/
Warning/
Electrical Trip/
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Sr. No.
Alarms Causes / Indication Actions
Notification
31 Over Speed Indicates that genset speed has exceeded the pre-set over speed threshold. Genset will shut down after Over Speed Delay.
Shutdown
32 Gross Over Speed Indicates that genset speed has exceeded the pre-set Gross Over Speed Threshold. Genset will shut down immediately without any delay.
Shutdown
33 Under Speed The engine speed has fallen below the pre-set RPM
Shutdown
34 Charge Fail The charge alternator voltage has dropped below the pre-set threshold
Warning/
Electrical Trip/
Shutdown
35 Battery Under Voltage The battery voltage has fallen below the pre-set threshold
None/
Shutdown/
Warning/
Electrical Trip/
Notification
36 Battery Over Voltage The battery voltage has exceeded the pre-set threshold
None/
Shutdown/
Warning//
Electrical Trip
Notification
37 High Oil Press Detected Lube oil pressure is detected above the crank disconnect threshold when the engine is off.
Warning
38 Maintenance Due Indicates that engine running hours has exceeded the pre-set hours limit or maintenance due date has occurred and filter servicing is required.
Notification/
Warning
39 Battery Charger Fail Indicates the battery is not getting charged by the charger
None/
Shutdown/
Warning/
Electrical Trip/
Notification
40 Smoke Fire Controller has detected smoke / fire through its digital input
None/
Shutdown/
Warning/
Electrical Trip/
Notification
41 Aux S2 / user defined name
Auxiliary sensor S2’s threshold being crossed
None/
Warning/
Electrical Trip/
Shutdown
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Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Table 35: Troubleshooting
Sr. No.
Fault Possible Causes / Remedial Actions
1 The controller does not power ON.
• Check the battery voltage.
• Check the fuse on the battery supply.
• Check continuity between battery +ve and controller terminal # 2.
• Check continuity between battery ground and controller terminal # 1.
2 The controller screen freezes or hangs up.
• Reset the controller power.
3 The controller fails to crank-start the engine.
• Check the battery voltage.
• Enter the “configuration mode” in controller and verify the configuration for the “START” output. Also, check that “START” output is working correctly by measuring its voltage o/p.
• Enter the “configuration mode” in controller and verify the configuration of “CRANK DISCONNECT” method. Verify the configuration of “LLOP SWITCH” polarity. Also, ensure that the lube oil pressure switch & sensor are working OK. Check their wiring.
4
The “Emergency Stop” alarm comes up even when the “Emergency Stop” is not pressed.
• Check if the “Emergency Stop” switch is working OK. Check its wiring also.
• Enter the “configuration mode” in controller and verify the configuration of “EMERGENCY STOP” polarity.
5
The controller generates unnecessary “Shutdown Alarms” or “Warning Alarms”
• Check the respective switch/sensor and wiring.
• Enter the “configuration mode” in the controller and verify the respective threshold configuration.
6 The controller reports “Charging Alt Fail” alarm.
• To check if the controller's charging alternator terminal is working or not: disconnect the charging alternator wiring to the controller's terminal # 10. Short the terminal # 10 to the ground through a DC ammeter. Crank-start the engine. The DC ammeter should indicate the current in the range 200 - 400 mA for ~30 seconds. If yes, the controller's chg alternator terminal is working OK.
• Disconnect and re-connect the charging alternator ind connection to the controller's terminal # 10.
• Check if the charging alternator is working OK or not.
7
A) The controller shows genset “ON” while genset is at rest.
B) “Fail To Stop” alarm when genset is at rest.
• Enter the “configuration mode” in the controller and verify the configuration for the LLOP and LOP. Check their wiring also.
• Ensure that the mains voltage wiring is not connected by mistake to the controller's genset voltage terminals.
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Sr. No.
Fault Possible Causes / Remedial Actions
8
The controller issues unnecessary “crank-start” command immediately after power on.
• Ensure that the controller's o/p terminal is not directly connected to the starter relay. The controller's o/p should be given to an intermediate relay which should in-turn power the starter relay. The controller can get permanently damaged and will need to be replaced if this precaution is not taken.
• Check start-relay connection with the suitable controller terminal.
• Enter the “configuration mode” in the controller and verify the configuration for “START MODE” and the “START RELAY” o/p polarity.
9 The engine runs, but the controller shows genset to be “OFF”.
• Check for alternator voltage signal (R phase) is received by the controller terminal.
• Check if the LOP and LLOP are working OK. Also check their wiring to the controller.
10 The controller displays incorrect PF value or kW or load current.
• Check wiring of the respective alternator phase voltage and the CT to the controller.
• Check the CT ratio (if kW or current reading is faulty).
11
The controller displays incorrect mains voltage or incorrect main alternator voltage.
• Check the wiring of the respective phase to the controller.
12
Controller displays incorrect reading for any of LOP, Fuel Level, Engine Temp sensors.
• Check respective sensor and its wiring.
• Check SCP wiring.
• Enter the “configuration mode” in the controller and verify the calibration for the respective
• sensor in configuration.
Possible Issues in AUTO Mode
13 The controller displays incorrect engine RPM.
• Check wiring of the main alternator’s R-phase and neutral to the controller.
14
The controller does not start the engine even when a “Remote Start” command is sent from an external device such as a telecom PIU.
• Check the wiring of the “Remote Start” signal to the controller's respective digital i/p terminal.
• Enter the “configuration mode” in the controller and verify the configuration for the “Remote Start” digital i/p terminal.
• Check that the controller is in “Auto” mode.
• check for mains monitoring disabled & Site mode disabled.
15
Controller does not stop engine even when a “Remote Stop” command is sent from an external device such as a telecom PIU.
• Check the wiring of the “Remote Stop” signal to the controller's respective digital i/p terminal.
• Enter the “configuration mode” in the controller and verify the configuration for the “Remote Stop” digital i/p terminal.
• Check that the controller is in “Auto” mode.
16
While in Auto mode, controller issues “Start” command even if the mains present.
• Check the wiring of the mains R, Y and B phase to the controller's respective i/p terminal.
• Enter the “configuration mode” in the controller and verify the configuration for the “MAINS MONITORING”.
Possible issues with Site monitoring
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Sr. No.
Fault Possible Causes / Remedial Actions
17 Site voltage is observed continuously varying
• Check if earthing is proper for panel
and Site
• Check if the connections are done properly for the differential input (pin # 24 & 25)
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.
Figure 29: 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.
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• 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 36: Details of function codes
Function Code MODBUS Name Description
03 Read holding register Reads one or more 16-bit from the slave device of read/write location
04 Read input register Reads one or more 16-bit from the slave device of read/write location
16 Write holding register Writes one or more 16-bit registers to the slave device
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Communication Settings
Table 37: RS485 MODBUS communication configuration setting
RS485 Communication
Slave ID 1-247
Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/115200
Parity None/Even/Odd
Stop Bit 1, 2
Recommended polling frequency: 50Hz No response timeout: 250ms Function 04 is used to read measurement parameters and status from the 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 38: Command from MODBUS master for Function 4
Byte Field Remarks
0 Slave address As configured in GC2599
1 Function code (0x04)
2 First register address – high byte 16-bit register address, register address map is described in section 8 3 First register address – low byte
4 Number of registers to read – high byte Number of registers to read must be between 1 to 255 5 Number of registers to read – low byte
6/7 Error check CRC
Query response format for Function 4 is as follows:
Table 39: Normal response from GC2599 slave for Function 4
Byte Field Remarks
0 Slave address As configured in GC2599
1 Function code (0x04)
2 Byte count (n) Equals to number of registers to be read times two. 8-bit even number between 2 to 250
3 First register – high byte
4 First register – low byte
...
1+n Last register – high byte
2+n Last register – low byte
3+n/4+n Error check CRC
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Table 40: Register map
Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
Protocol revision 0 - - Unsigned
Generator L1-N voltage 1 0.1 V Unsigned
Generator L2-N voltage 2 0.1 V Unsigned
Generator L3-N voltage 3 0.1 V Unsigned
Generator L1-L2 voltage 4 0.1 V Unsigned
Generator L2-L3 voltage 5 0.1 V Unsigned
Generator L3-L1 voltage 6 0.1 V Unsigned
Generator R frequency 7 0.1 Hz Unsigned
Generator Y frequency 8 0.1 Hz Unsigned
Generator B frequency 9 0.1 Hz Unsigned
Generator power factor L1 10 0.01 -- Unsigned
Generator power factor L2 11 0.01 -- Unsigned
Generator power factor L3 12 0.01 -- Unsigned
Generator average power factor 13 0.01 -- Unsigned
Mains L1-N voltage 14 0.1 V Unsigned
Mains L2-N voltage 15 0.1 V Unsigned
Mains L3-N voltage 16 0.1 V Unsigned
Mains L1-L2 voltage 17 0.1 V Unsigned
Mains L2-L3 voltage 18 0.1 V Unsigned
Mains L3-L1 voltage 19 0.1 V Unsigned
Mains R frequency 20 0.1 Hz Unsigned
Mains Y frequency 21 0.1 Hz Unsigned
Mains B frequency 22 0.1 Hz Unsigned
Load L1 current 23 0.1 A Unsigned
Load L2 current 24 0.1 A Unsigned
Load L3 current 25 0.1 A Unsigned
Load L1 watts 26 0.1 kW Unsigned
Load L2 watts 27 0.1 kW Unsigned
Load L3 watts 28 0.1 kW Unsigned
Load total watts 29 0.1 kW Unsigned
Percentage Load 30 1 kW Unsigned
Load L1 VA 31 0.1 kVA Unsigned
Load L2 VA 32 0.1 kVA Unsigned
Load L3 VA 33 0.1 kVA Unsigned
Load total VA 34 0.1 kVA Unsigned
Load L1 VAR 35 0.1 kVAR Unsigned
Load L2 VAR 36 0.1 kVAR Unsigned
Load L3 VAR 37 0.1 kVAR Unsigned
Load total VAR 38 0.1 kVAR Unsigned
Generator cumulative energy 39-40 0.1 kW Unsigned
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Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
Generator cumulative apparent energy
41-42 0.1 kVA Unsigned
Generator cumulative reactive energy
43-44 0.1 kVAR Unsigned
Mains cumulative energy 45-46 0.1 kW Unsigned
Mains cumulative apparent energy 47-48 0.1 kVA Unsigned
Mains cumulative reactive energy 49-50 0.1 kVAR Unsigned
Oil pressure 51 0.1 Bar Unsigned
Coolant temperature 52 0.1 Deg C Unsigned
Fuel level 53 1 % Unsigned
Fuel Level in lit 54 0.1 lit Unsigned
Charge alternator voltage 55 0.1 V Unsigned
Battery voltage 56 0.1 V Unsigned
Engine speed 57 1 RPM Unsigned
No of starts 58 1 -- Unsigned
No of trips 59 1 -- Unsigned
Eng run hrs 60 1 Hrs Unsigned
Eng run min 61 1 Min Unsigned
Mains run hrs 62 1 Hrs Unsigned
Mains run min 63 1 Min Unsigned
Auxiliary Input S1 value 64 0.01 Unsigned
Auxiliary Input S2 value 65 0.01 Unsigned
Auxiliary Input S3 value 66 0.01 Unsigned
Auxiliary Input S4 value 67 0.01 Unsigned
Site Voltage 68 0.1 Unsigned
Site Run time hrs 69 1 Unsigned
Site Tun time mins 70 1 Unsigned
Alarm Status
Alarm 1 71
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Radiator water level / low fuel level -- -- 5/16-8/16
Reserved / Radiator water level switch
-- -- 1/16-4/16
Alarm 2 72
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
Alarm 3 73
Generator low voltage/ reserved -- -- 13/16-16/16
Generator high voltage/ reserved -- -- 9/16-12/16
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Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
Generator low frequency -- -- 5/16-8/16
Generator high frequency -- -- 1/16-4/16
Alarm 4 74
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
Alarm 5 75
Charge alternator failure -- -- 13/16-16/16
Oil filter maintenance / filter maintenance
-- -- 9/16-12/16
Fuel filter maintenance / reserved -- -- 5/16-8/16
Air filter maintenance / reserved -- -- 1/16-4/16
Alarm 6 76
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- -- 9/16-12/16
Oil pressure circuit open engine Temperature Circuit open
-- -- 5/16-8/16
Reserved -- -- 1/16-4/16
Alarm 7 77
Fuel theft -- -- 13/16-16/16
Magnetic pick up fault -- -- 9/16-12/16
Extended over load trip / oil pressure circuit
-- -- 5/16-8/16
Reserved -- -- 1/16-4/16
Alarm 8 78
Digital input A -- -- 13/16-16/16
Digital input B -- -- 9/16-12/16
Digital input C -- -- 5/16-8/16
Digital input D -- -- 1/16-4/16
Alarm 9 79
Digital input E -- -- 13/16-16/16
Digital input F -- -- 9/16-12/16
Digital input G -- -- 5/16-8/16
Digital input H -- -- 1/16-4/16
Alarm 10 80
Digital input I -- -- 13/16-16/16
Analog input J -- -- 9/16-12/16
Analog input K -- -- 5/16-8/16
Analog input L -- -- 1/16-4/16
Alarm 11 81
Auxiliary input M -- -- 13/16-16/16
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Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
Auxiliary input N -- -- 9/16-12/16
Auxiliary input O -- -- 5/16-8/16
Auxiliary input P -- -- 1/16-4/16
Alarm 12 82
Gen L1 phase low volt -- -- 13/16-16/16
Gen L1 phase high volt -- -- 9/16-12/16
Gen L2 phase low volt -- -- 5/16-8/16
Gen L2 phase high volt -- -- 1/16-4/16
Alarm 13 83
Gen L3 phase low volt -- -- 13/16-16/16
Gen L3 phase high volt -- -- 9/16-12/16
Dg phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
Alarm 14 84 --
Open fuel level -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Extended overload trip/Reserved -- -- 5/16-8/16
High oil pressure detected -- -- 1/16-4/16
Alarm 15 85 --
Auxiliary Input S4 13/16-16/16
Auxiliary Input S3 9/16-12/16
Auxiliary Input S2 5/16-8/16
Auxiliary Input S1 1/16-4/16
Alarm 16 86
Auxiliary S4 open ckt alarm 13/16-16/16
Auxiliary S3 open ckt alarm 9/16-12/16
Auxiliary S2 open ckt alarm 5/16-8/16
Auxiliary S1 open ckt alarm 1/16-4/16
Alarm 17 87
Auxiliary S4 overcurrent/overvoltage alarm
13/16-16/16
Auxiliary S3 overcurrent/overvoltage alarm
9/16-12/16
Auxiliary S4 short to ground alarm 5/16-8/16
Auxiliary S3 short to ground alarm 1/16-4/16
Input and output status
Input diagnostics 88
Digital input A -- -- 16/16
Digital input B -- -- 15/16
Digital input C -- -- 14/16
Digital input D -- -- 13/16
Digital input E -- -- 12/16
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Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
Digital input F -- -- 11/16
Digital input G -- -- 10/16
Digital input H -- -- 9/16
Digital input I -- -- 8/16
Analog input J -- -- 7/16
Analog input K -- -- 6/16
Analog input L -- -- 5/16
Auxiliary input M -- -- 4/16
Auxiliary input N -- -- 3/16
Auxiliary input O -- -- 2/16
Auxiliary input P -- -- 1/16
Output Diagnostic 89
Digital output A -- -- 16/16
Digital output B -- -- 15/16
Digital output C -- -- 14/16
Digital output D -- -- 13/16
Digital output E -- -- 12/16
Digital output F -- -- 11/16
Digital output G -- -- 10/16
Unimplemented -- -- 9/16
Unimplemented -- -- 8/16
Unimplemented -- -- 7/16
Unimplemented -- -- 6/16
Unimplemented -- -- 5/16
Unimplemented -- -- 4/16
Unimplemented -- -- 3/16
Unimplemented -- -- 2/16
Unimplemented -- -- 1/16
Dg status 90
GCU Mode Config /Run 16/16
Mains Healthy / unhealthy -- True (1) / False (0) 15/16
DG operation mode -- Scheduler/cyclic/Auto / Manual
14-12/16
Load on DG True (1) / False (0) 11/16
Load on Mains -- 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
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Parameter Register Address
Scale Factor
Unit / Interpretation
Bits/ Sign
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 91-92 -- Current EPOCH time
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Notes
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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 411026, India
Manufacturing Plant
G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje
Pune 410501, India
Manufacturing Plant Survey No. 64/5, Off Sinhagad Road
Vadgaon Budruk, Narhe Pune 411041, India