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engine
gOVerning
systeM
gns2500 seriesaMF generator set controller
governors america corp., 720 silver street agawam, Ma 01001phone: 413.786.5600 fax: 413.789.7736
1
gac’s Generator Set Controller Series (GNS2500 Series) is a family of highly-fl exible generator set controllers for AMF applications. The GNS2500 Series, designed for both electronically and mechanically controlled engines, is ruggedly constructed with simple-to-use microprocessor technology. gac’s new controller series provides superior generator set control, protection, and metering all at a reasonable cost.
The GNS2500 Series monitors the mains voltage and frequency, to detect loss of mains power. Once one of these mains protections is tripped the GNS will automatically start the generator, open the MCB, then close the GCB. The MCB can be confi gured to open at the immediate loss of mains or at “generator ready to load”. Upon the return of a stable mains, the GNS2500, using user confi gurable timing, will open the GCB then close the MCB. The GNS is also programmed to provide warnings of impending loss of mains and a test function
Programming the GNS2500 Series is easily accomplished by utilizing either the front panel navigation keys and the large LCD display or with gac’s enhanced smartVu™ confi guration software. The controller senses engine parameters directly via 4 analog inputs and it can communicate with the engine’s electronic control unit via J1939 CAN bus protocol. The programmable inputs and outputs are engineered to allow the user to easily customize the operation as desired.
The GNS2500 Series has been designed to provide maximum functionality at a minimum price. Standard features include: 9 programmable inputs and 9 programmable outputs; 4 analog inputs that support a wide range of senders; 2 Form A and 2 Form C relays; robust electronic protection; remote control and monitoring; one built in RS-232/485 port (with an additional RS232 Port on GNS2504B and GNS2504BE units); Modbus and J1939 CAN bus interface; multiple, memory-resident languages; and an industrial temperature range operation of -40° to +85°C. To reduce costs, gac offers within the GNS2500 Series a no display, black-box version and an optional operating temperature range (-20° to +85°C) version.
Added features are easily incorporated in the unit without adding on high additional costs. Optional features include: remote displays, relay modules; and expandable I/O capabilities via J1939 CANbus.
As with all gac products, the GNS2500 Series can be easily and cost effectively adapted to provide customized solutions for OEMs.
advanced control & Monitoring • Engine Start/Stop Control• Engine & Generator Monitoring & Protection• Remote Monitoring & Alerts• Comprehensive Metering • Auto Generator Start at Loss of Mains
Expanded off ering of I/o• 9 Binary Inputs & 9 Outputs• 2 Form A and 2 Form C Relays• 4 Versatile Analog Inputs that Support:
VDO, 5VDC, 0-20 mA, Resistive & Thermocouple
Intuitive, Adaptable user Interface • Simultaneous Multi-Lingual Support• Local, Remote & No Display Support• Multiple Security Levels & Panel Lock• User-friendly smartVu Configuration Software
high degree of Connectivity & Compatibility
• SAE J1939 • MODBUS• RS-232/485• Ethernet (via serial to ethernet converter)
highly developed design • Robust 600V Design
(min. 25% over voltage allowed)• UL Approved*, CSA Compliant*, CE Compliant• NFPA110 Level 2 Compatible• Industrial Temperature Range• Resistant to salt fog, humidity, dust, dirt, and
chemical contaminants• Audible & Tactile F/B on Buttons for Gloved
Fingers
* non-e Versions
gns2502 genset controller
gns2504b black box genset controller
gns2504b black box
OVERNORS
MERICA
ORP.CAG
™
ISO 9001CERTIFIED
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item.
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Operating MOdesThe GNS2500 Series can be operated in Manual, Auto, Test or Off modes, and has a full suite of engine and generator protections. When in Manual mode, the GNS will start and stop the engine based on user inputs. In Auto mode, the GNS will start and stop the engine when a mains failure is detected. Test mode allows the user to test the genset without changing breaker status.
alarMs, Warnings, and prOtectiOnsThe GNS alarms and warnings alert the user while protecting the generator and engine. Virtually all protections can be individually enabled or disabled. Shutdown conditions include low oil pressure, low fuel level, high coolant temperature, under/over speed, under/over voltage, over current, over frequency, sensor failures, over crank, and generator voltage unbalanced.
EnginE COnTrOl
• Cranking control provides pre-lube, up to 4 pre-start stages, adjustable number of crank attempts, duration, pause delay and crank disconnect. Also provided is an engine start counter.
• Enginetimersincludeservice,pre-crank,crank,idle,cool down and after cool.
• Adjustable protection thresholds and delays forspeed, oil pressure, coolant temperature, and fuel level.
METEring
• Meteredgeneratorparametersincludelinevoltage,line to line voltage, current, frequency, reactive power, power factor and actual power.
• Metered engine parameters include RPM, oilpressure, coolant temperature, battery voltage, fuel level, service hours, run hours, and number of starts. RPM, oil pressure, and coolant temperature can be integrated via J1939.
inputsThe GNS is equipped with dedicated inputs for mains and generator voltage, generator current, and a speed sensor. The unit is also equipped with 4 configurable analog inputs and 9 configurable binary inputs. The analog inputs allow a wide range of sensors including voltage, current, and resistive senders. Though easily reconfigured, three of the analog inputs are configured for Fuel level, Engine Temperature, and Oil Pressure. The GNS2500 Series can use J1939 messages for oil pressure, engine speed, and coolant temperature in combination with the analog inputs for control and protection operations, thereby, freeing up analog inputs for other sensors.
OutputsThe GNS2500 Series is equipped with 5 discrete binary outputs and four relays. The discrete outputs can sink up to 500mA of current to battery ground and support up to 32VDC. The GNS2500 Series has four relays, two Form C and two Form A. Though reconfigurable, one Form C relay is configured to control the fuel solenoid, the other is configured to control the starter. By adding a jumper (located on the back of the GNS), the fuel relay can be configured to be directly controlled by the emergency stop input – when the emergency stop input is activated, power to the fuel solenoid is removed, thereby depriving the engine of fuel.
All GNS2500 Series analog inputs, binary inputs, relays and binary outputs assignments can be configured by the user.
RS232/485, SAE J1939, EthERnEt, ModbuSThe standard GNS is equipped with a SAE J1939 port and one serial port. The serial port can be configured for RS232 or RS485 operation. The RS232 can connect the GNS to an external modem, external I/O, remote display, Ethernet converter or PC using the industry standard MODBUS protocol. A factory installed modem can be provided for dial in and dial out remote monitoring.** An external cell modem can support SMS functions. Note: the GNS2504B and GNS2504BE is a stand-alone controller equipped with one RS232/485 port and one RS232 and can be operated without a display.
reMOte annunciatOr, Output relays, & prOgraMMable lOgic
The optional gac Remote Annuciator (RA20) and Contact Relay Module (CRM20) provide external programmable logic and annunciation for the GNS2500 Series. The RA20 is equipped with 20 LEDs and can be panel mounted. The CRM20 is similar to the RA20 with the inclusion 20 Form C relays. Both of these devices have 30 blocks for programming and can source data via Modbus over two RS-232/485 ports and J1939 over CAN bus.
gns2500 displayThe GNS2500 Series is equipped with a 64 x 128 graphical display, status LEDs, and buttons (with the exception of GNS2504B and GNS2504BE). Depending on the configuration the display can support mulitple languages simultaneously. The user can switch between the languages on the fly.
** coming soon
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item.
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GnS display Real time Information
• OperatingMode• LineVoltage• LinetoLineVoltage• Current• Frequency• OilPressure
• EngineTemperature• GeneratorState• ActiveAlarmsand
Warnings• BinaryInputs• BinaryOutputs
• AnalogMetering• PowerMetering• GeneratorMetering• History• Power(RealPower,Apparent
Power, Power Factor)• MainsVoltage
System Settings
Password LoginChange PasswordGen ConfigZero LegHighLegNom VoltNom AmpsNom Pwr 3 PhNom Pwr 1 Ph Gen ConfigNom Freq CT RatioPT RatioGear TeethGCB DelayHornPeriodD+Speed Inputs MasterSpeed Inputs Second Speed Inputs TertiaryEngine Speed
Engine Parameters
RPM DisconnectOil Disconnect Prelube Period Prelube PauseIdle/CoolingAfter Cool PeriodPrestart Period 1Prestart Period 2 Prestart Period 3 Prestart Period 4Crank PeriodCrank PauseCrank AttempsEngine Type Gas RPM DelayGas RPM PauseVent Period Idle PeriodStop PeriodCooling Period
Setpoints Accessible from the GnS display protections
Generator Under Frequency Generator Over Frequency Generator Under Volt Generator Over Volt Generator Unbalanced Volt Mains Under Frequency Mains Over Frequency Mains Under Volt Mains Over Volt Mains Unbalanced VoltOver Current Over Current IDMTUnbalanced Current Over Load Under Speed Over Speed Crank Fail Alternator GCB Fault MCB Fault Discrete Input Fault Emergency Stop Engine Service Battery Under Volt Battery Over Volt Low Fuel Level Low Oil Pressure Low Engine Temperature HighEngineTemperatureStop Fail Over Crank Speed Sensor Fail GCB External TripMCB External TripAnalog In 1 Under Analog In 1 Over Analog In 2 Under Analog In 2 Over Analog In 3 Under Analog In 3 Over Analog In 4 Under Analog In 4 Over Comm Fail Short CircuitConfig ErrorVoltage Phase Wiring Error - GenCurrent Phase Wiring Error - GenVoltage Ph Wiring Error - MainsCAN bus Fault ECU Offline
Engine Protections
OverspeedLow Fuel Delay Low Fuel WarningLow Fuel AlarmLow Oil P DelayLow Oil P Warning Low Oil P AlarmLow Temp DelayLow Temp Warning Low Temp Alarm HiTempDelayHiTempWarningHiTempAlarmBattery Over VoltBattery Under VoltBattery DelayEngProtDelayServiceHrsRunHrs
Mains Protections
MCB Open Event MCB F/B DelayReturn DelayVolt UnblalanceVolt Unbal DelayOver Volt Alarm Over Volt Warning Under Volt WarningUnder Volt AlarmVoltage DelayOver Freq AlarmOver Freq WarningUnder Freq WarnUnder Freq Alarm Freq Delay
generator Protections
Overload Alarm Overload Warning Overload DelayOver Curr AlarmOver Curr DelayCurr Unbal Alarm Curr Unbal Delay IDMTOver Volt Alarm Over Volt WarningUnder Volt WarningUnder Volt Alarm Volt DelayVolt Unbal Alarm Volt Unbal DelayOver Freq Alarm Over Freq WarningUnder Freq WarningUnder Freq Alarm Freq DelayMin Voltage
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item.
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smartVuThe GNS2500 Series is configured using the smartVu PC configuration, control and monitoring tool. This program allows the user to set and modify security, operating set points, assign I/O, establish warning and alarm thresholds, and control overall system behavior. Once configured, the settings can be saved to a file for easy replication. While connected to a GNS, smartVu can be used to monitor generator set performance. (see Figure 1.)
Within smartVu, the layout of the display is highly customizable. The user chooses which meters are to be displayed, and the location on the screen. The screen configuration can be stored for later use.
smartVu is capable of simultaneously communicating with multiple GNS controls, and the layout of the screen is customizable.
Figure 1.
selectiOn tablesFor non-hostile environments or applications not requiring UL approval, GNS E Series controls and remote displays are lower cost alternatives.
Description Keys
12 ButtonStart, Stop, Up, Dow n, Left, Right, Enter, Lamp Test, Horn Reset, Back (Undo), GCB Open/Close, MCB Open / Close
Control CE UL °C / °F Conformal Coating Mount Display Keypad
-20 to 85 C
-4 to 185 F
-40 to 85 C
-40 to 185 F
-40 to 85 C
-40 to 185 F
-20 to 70 C
-4 to 158 F
-40 to 70 C
-40 to 158 F
-40 to 70 C
-40 to 158 F
12 Button
GNS2004BE Back --- ---
GNS2004E Front64x128
LCD
---
GNS2002E Front64x128
LCD 12 Button
GNS2004B Back ---
12 Button
GNS2004 Front64x128
LCD 12 Button
GNS2002 Front64x128
LCD
Display CE UL °C / °F Conformal Coating Mount Display Keypad
-20 to 85 C
-4 to 185 F
-40 to 85 C
-40 to 185 F
-20 to 70 C
-4 to 158 F
-40 to 70 C
-40 to 158 F
12 Button
GNS2004DE Front64x128
LCD 12 Button
GNS2002DE Front64x128
LCD
12 Button
GNS2004D Front64x128
LCD 12 Button
GNS2002D Front64x128
LCD
gnS ControllersgnS Keypad Definitions
gnS remote Displays
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item.
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BO2
LB178-2
7BINARY INPUTS
5 642 31-+ D+8-32 VDCBATTERY
-98 +P/U
MAGBO1
CANL S H
RS232/485
BINARY OUTPUTS
G 89 67 5 2ANALOG INPUTS
GG 4 3 G G 1
GENERATOR
A G
RELAYSBO3 BO4
GG CB
LB178-1
CURRENT
GENERATOR VOLTAGECN B A
LB178-3
G
NOTE:
1. U.O.S. ALL WIRES TO BE 22AWG TWISTED PAIR.
SINGLE LINE BREAKER CONTROL / FEEDBACK SHOWN.
18 AWG
RS-232 3-WIRE NULL MODEM CABLE.
2
3
4
ALTERNATOR
3
+
D+-
12/24VDC Battery
10 amp Fuse
RE
MO
TE S
TAR
T/S
TOP
ES
TOP
B+
3
MA
GN
ETI
CP
ICK
-UP
4
3
PRESTART
3 3
OIL PRESSURE
FUEL SOLENOID
B+
READY TO LOAD
ALARM
FUEL LEVEL
ENGINE TEMP
GENERATOR
STARTER
DIESEL/GAS ENGINE
G L3
N
L1L2
2
GCB
L
FUE
L LE
VE
L
EN
GIN
E T
EM
P
OIL
PR
ES
SU
RE
FUE
L S
OLE
NO
ID
STA
RTE
R
MCB
N BC AMAINS VOLTAGE
MAINS
L1
L2
L3
N
GNS2504B ONLY
REMOTE START
FAULT RESET
MAN MODE
OFF MODE
AUTO MODE
UCB F/B ( ALL GNS2500 SERIES )
GCB F/B ( ALL GNS2500 SERIES )
CN
5
BINARY INPUTS
1 2 3 4 6 7 98
MAGP/U
DETAIL C
REMOTE STOP
Wiring diagram
DETAIL A
RS485
CAN
21
ON
RS485
CANTERMINATION RESISTORS
W. JUMPERS
W. DIP SWITCHES
Jumper ON Pins 120Ω Termination Present
Jumper OFF Pins No Termination Present
Switch ON 120Ω Termination Present
Switch OFF No Termination Present
WIRING FOR D+ EXCITATION
12/24VDC Battery
3RELAYS
4
DETAIL B
D+
JUMPER TO BRIDGE INPUT 1 TO OUTPUT 1
DETAIL D
3
ON 1
24
4-20 mA INPUT ON OTHERWISE OFF
DETAIL E
DETAIL A - Switchable termination resistors for RS-485 or CAN bus networks that require termination.
DETAIL B -Connect battery positive to one side of the normally open relay and the other side, thru diode, to the D+ terminal of the alternator for D+ Excitation.
DETAIL C - Expoded view of Binary Inputs
DETAIL D - JUMPER INSTALLED - If Binary Input 1 is assigned to E-STOP and Binary Output 1 is assigned to FUEL, FUEL Output is controlled by E-STOP Input thru jumper. JUMPER NOT INSTALLED - FUEL Output is controlled by E-STOP Input thru controller software only.
DETAIL E - Dipswitches for configuring the analog inputs. The switches are ON only when connecting to a 4-20mA circuit.
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item.
6PTI 4127 C
speciFicatiOns
EnvironmentalAmbient Operating Temperature...................................GNS2504–Temp:-40 to +85°C
GNS2502–Temp:-20 to +85°C
Relative Humidity.........................................................................95% non-condensingAgency Approvals............................................................UL2200*, UL508*, CE, CUL*
input ParametersPower ......................................................................................................8VDC-32VDCRide Thru .................................................................................................0V for 50msPolarity Negative ................................................................................................GroundSpeed Sensor Signal ............................................. 0.5 – 30 Volts RMS, 30-1200 ohms9 Assignable Binary Inputs ..............................................................................0-32VDC4 Analog Inputs.....................................................Wide range of senders, includingVDO (e.g.,OilPressure,CoolantTemp)
0-5VDC+/-1.0%,4-20mA+/-5.0%0-2.4K+/-5.0%
0-32mV+/-1.0% Generator Voltage.....................................................................480VAC RMS Nominal 600VAC Max phase to phase 277VAC RMS Nominal phase to neutral
346VAC RMS Max phase to neutral Accuracy+/-1%
Generator Current (CT Secondary)..........................................................5A NominalAccuracy+/-1%
Output Parameters2 Form A Relay............................................................................................. 30VDC, 3A2 Form C Relay..............................................................................125VAC, 28VDC, 5A5 Binary Outputs...............................................................................0-32VDC,0-500mA
CommunicationsPC Configuration & Monitoring.............................................Modbus on RS-232/485ECU................................................................................................................J1939Remote Devices.........................Modbus on RS-232 or RS-485, J1939 on CAN bus
reliability
Testing.....................................................................................100%FunctionallyTested
PhysicalOverall Dimensions................................................................................ 6” x 9” x 1.75” 152mm x 229mm x 445mmPanel Opening Size.............................................................................. 4.45” x 6.89” 113mm x 175mmWeight.................................................................................................... ............ 1.3lbs 0.59kgMounting........................................................................................Front Panel MountedGNS2504B, GNS2504BE...............................................................Back Panel/Din Rail
SmartVU requirementsMicrosoft Windows 2000-Windows Vista...................Pentium II, 64M RAM, 10M Disk VGA, Serial Port* Non-E Versions Only
Options• Factory Installed Internal Modem• Remote Displays • EAM Ethernet Adapter• GNS2504B, GNS2504BE
Blackbox • Non-Display Control
• External Modem• Custom Displays (up to 65
LEDs, up to 24 Switches)• Remote Contact Relay Module • Remote Annunciator Panel
