gensys - CRE TECHNOLOGY

Transcription

GENSYS
April 2009
Generator management module
Technical Documentation
CRE Technology believes that all information provided herein is correct and reliable and reserves the right to
update at any time. CRE Technology does not assume any responsibility for its use unless otherwise expressly
undertaken.
CRE Technology
130 Allée Charles-Victor Naudin
Zone des Templiers - Sophia Antipolis
06410 BIOT - FRANCE
Phone: + 33 (0)4.92.38.86.82 - Fax: + 33 (0)4.92.38.86.83
www.cretechnology.com - [email protected]
SARL au Capital de 300.000 Euros - RCS Antibes: 7488 625 000 15 N°TVA FR54 488 625 583
GENSYS – Documentation technique
A40 Z0 9 0020 K-EN Technical documentation
page 1/1
Date
Version
28-10-2008
J
Comments
Integration of application notes and general reorganization
Par
LB
K
Révision générale et mise à jour
JAM
31-03-2009
You can download this documentation and the different documentation relating to GENSYS on our
web site: http://www.cretechnology.com/ .
Documentation list on web site:
• GENSYS technical documentation (this manual)
• Complete variable list with label, units and limits
• GENSYS menu help file (HELP windows file)
• Web JAVA machine
• CPA technical documentation
• GCR technical documentation
• C2S/SCR technical documentation
NOTE :
Bureau VERITAS marine approval :
The control and monitoring functions must not be undertaken on the same module. The
engine securities (min oil pressure, over speed and oil absent) must not be handled by
the same module.
NOTE :
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury
and/or property damage.
Contact your CRE dealer for course training.
page 2/2
Table of contents
1
2
Overview .............................................................................................................. 9
1.1
European Union Directive Compliance CE ............................................................ 9
1.2
Environment .............................................................................................................. 9
1.3
Characteristics .......................................................................................................... 9
Description......................................................................................................... 10
2.1
Front panel .............................................................................................................. 10
2.1.1
2.1.2
2.1.3
2.1.4
2.2
Rear panel ............................................................................................................... 13
2.2.1
2.2.2
3
Overview .......................................................................................................................... 13
Inputs/Outputs ................................................................................................................. 13
User interface .................................................................................................... 17
3.1
Internal browser description ................................................................................. 17
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.3
Navigation Mode .............................................................................................................. 17
Input Mode ....................................................................................................................... 18
Save parameters configuration........................................................................................ 18
Password protection ........................................................................................................ 18
PC browser .............................................................................................................. 19
3.2.1
3.2.2
3.2.3
4
Display panel ................................................................................................................... 10
Service panel ................................................................................................................... 11
Control Panel ................................................................................................................... 11
Upper Panel ..................................................................................................................... 12
Setting up Windows XP ................................................................................................... 20
View Web Pages from the GENSYS Web Server ........................................................... 31
First level screens ............................................................................................................ 31
Screensaver ............................................................................................................ 32
Operating modes ............................................................................................... 34
4.1
Manu mode .............................................................................................................. 34
4.2
Auto mode ............................................................................................................... 34
4.3
Test mode ................................................................................................................ 35
4.4
Semi Auto Mode ..................................................................................................... 35
5
Typical start sequence for fuel engines .......................................................... 36
6
Predefined configurations ................................................................................ 37
6.1
Single generator in change-over mode (without paralleling) ............................. 37
6.2
Generators paralleling with inter GENSYS CANbus ........................................... 39
6.3
Generators paralleling with GENSYS and parallel line modules ....................... 40
6.4
Multiple generators with static paralleling ........................................................... 41
6.4.1
6.4.2
6.5
Single generator paralleled with mains (option 2)............................................... 42
6.5.1
6.6
7
Mains paralleling modes: ................................................................................................. 43
Power plant paralleled with mains ........................................................................ 44
6.6.1
6.7
Configuration ................................................................................................................... 41
Sequence:........................................................................................................................ 41
Interfacing GENSYS with GCR ....................................................................................... 45
Power plant paralleled with several mains .......................................................... 46
Installing and commissioning a GENSYS application ................................... 48
page 3/3
7.1
Wiring diagram ........................................................................................................ 48
7.2
Installation instructions: ........................................................................................ 48
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
8
Panel cut-out: ................................................................................................................... 49
Mounting: ......................................................................................................................... 49
Earth grounding: .............................................................................................................. 50
Wiring guidelines:............................................................................................................. 50
Vibrations: ........................................................................................................................ 51
Real time clock battery:.................................................................................................... 51
7.3
Before commissioning (before going on site) ..................................................... 51
7.4
During commissioning ........................................................................................... 52
Predefined functions ........................................................................................ 58
8.1
Water preheat / Pre-lubrication / Pre-glow functions .......................................... 58
Auto mode ...................................................................................................................................... 58
Manual mode .................................................................................................................................. 58
8.2
Crank / Fuel / Starter 2 / Starter 3 functions ......................................................... 58
8.3
Air fans..................................................................................................................... 59
Auto mode ...................................................................................................................................... 59
Manu mode..................................................................................................................................... 59
8.4
Fuel filling / Coolant filling / Oil filling................................................................... 59
Auto mode ...................................................................................................................................... 60
Manu mode..................................................................................................................................... 60
8.5
Configurable I/Os functions ................................................................................... 60
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
8.6
Digital output functions.......................................................................................... 63
8.6.1
8.6.2
8.7
Output functions ............................................................................................................... 63
Polarity ............................................................................................................................. 67
Use spare analog input for digital input ............................................................... 67
8.7.1
8.7.2
8.7.3
9
Digital input functions ....................................................................................................... 60
Configurable input label ................................................................................................... 60
Validity.............................................................................................................................. 60
Input functions .................................................................................................................. 60
Direction ........................................................................................................................... 63
Dedicated inputs .............................................................................................................. 63
Purpose: ........................................................................................................................... 67
Configuration: ................................................................................................................... 67
Parameters: ..................................................................................................................... 67
Special functions .............................................................................................. 69
9.1
Fuel crank relay function ....................................................................................... 69
9.1.1
9.1.2
9.2
Load sharing using a central frequency (de-drooping) ...................................... 70
9.2.1
9.2.2
9.2.3
9.2.4
9.3
Introduction ...................................................................................................................... 69
Configuration .................................................................................................................... 69
Introduction ...................................................................................................................... 70
Procedure......................................................................................................................... 70
GCR synchronization & mains paralleling ....................................................................... 71
INTEGRAL INHIBITION ................................................................................................... 71
Pulse control calibration procedure ..................................................................... 72
9.3.1
Parameters....................................................................................................................... 74
9.4
Operator controlled return of mains ..................................................................... 74
9.5
Mains & Generator electrical fault options ........................................................... 74
9.6
GENSYS with external automatic start module ................................................... 77
9.6.1
Overview .......................................................................................................................... 77
page 4/4
9.7
Remote start upon external pulse ......................................................................... 79
9.7.1
9.8
Setting external input ....................................................................................................... 79
Safety Inhibitions .................................................................................................... 80
9.8.1
9.8.2
9.9
Objective .......................................................................................................................... 80
Configuration ................................................................................................................... 80
GENSYS with 500Hz PWM (Cat/Perkins) .............................................................. 82
9.9.1
9.9.2
9.10
9.10.1
9.10.2
9.10.3
9.11
9.11.1
9.11.2
Schematic ........................................................................................................................ 82
Configuration ................................................................................................................... 83
GENSYS with BSM II ........................................................................................... 84
Configuration ................................................................................................................... 84
Standard procedure ......................................................................................................... 84
Custom procedure ........................................................................................................... 85
GENSYS with Carantec ....................................................................................... 86
Wiring parallel lines:......................................................................................................... 86
Configuration of GENSYS ............................................................................................... 86
9.12
GENSYS with TEM compact ............................................................................... 86
9.13
Under voltage trip coil ........................................................................................ 88
9.14
Level -1 (G59 & counters) ................................................................................... 89
9.15
Scada .................................................................................................................... 89
9.16
How to set a GPID ............................................................................................... 89
9.16.1
9.16.2
9.17
10
Principle ........................................................................................................................... 89
Empirical method settings ............................................................................................... 90
Automatic load / unload ...................................................................................... 90
GENSYS PLC .................................................................................................. 91
10.1
Introduction ......................................................................................................... 91
10.2
File description .................................................................................................... 91
10.3
Parameter definition block ................................................................................. 91
10.4
Label definition block ......................................................................................... 92
10.5
Unit definition block ............................................................................................ 92
10.6
Initialization definition block .............................................................................. 93
10.7
Equation definition block ................................................................................... 93
10.8
End of file ............................................................................................................. 93
10.9
PLC programming language .............................................................................. 94
11
Communication .............................................................................................. 96
11.1
CANBUS GOOD PRACTICES ............................................................................. 96
11.2
COM1: RS232 to PC ............................................................................................ 97
11.3
COM2: CAN bus inter GENSYS .......................................................................... 97
11.3.1
11.3.2
11.4
11.4.1
11.4.2
11.5
11.5.1
11.6
Wiring ............................................................................................................................... 97
CAN bus fault................................................................................................................... 98
Broadcasting Data between GENSYS units ...................................................... 99
Introduction: ..................................................................................................................... 99
Procedure / Example ....................................................................................................... 99
Can Bus Inhibition ............................................................................................. 103
How to set theses functions:.......................................................................................... 103
COM3: CANopen remote I/O ............................................................................. 104
page 5/5
11.6.1
11.6.2
11.7
11.7.1
11.8
11.8.1
11.8.2
11.8.3
11.8.4
11.8.5
11.8.6
11.8.7
11.8.8
11.8.9
11.9
System configuration ..................................................................................................... 106
Read / write I/O .............................................................................................................. 106
COM3: MDEC (MTU) .......................................................................................... 107
Procedure....................................................................................................................... 107
COM3: J1939 ...................................................................................................... 111
Configuration .................................................................................................................. 111
J1939 fault...................................................................................................................... 111
Engine Speed ................................................................................................................ 111
Coolant temperature ...................................................................................................... 111
Oil pressure .................................................................................................................... 111
Engine diagnostic........................................................................................................... 112
J1939 Messages ............................................................................................................ 112
Advanced functions........................................................................................................ 115
Engine notes .................................................................................................................. 115
COM4: MODBUS RTU on serial port RS485 .................................................... 116
12
Troubleshooting........................................................................................... 119
13
Variables ....................................................................................................... 121
14
Precautions .................................................................................................. 122
15
References ................................................................................................... 124
15.1
Options ............................................................................................................... 124
15.2
Accessories ....................................................................................................... 124
16
Company Information .................................................................................. 126
page 6/6
List of illustrations
Figure 1 - Rear panel ............................................................................................................................ 13
Figure 2- Browser link description ......................................................................................................... 18
Figure 3 - Contextual keys for Input Mode ............................................................................................ 18
Figure 4 - Password input mode display ............................................................................................... 18
Figure 5 - Typical menu page................................................................................................................ 19
Figure 6 - Typical configuration page .................................................................................................... 20
Figure 7 - GENSYS Ù PC ................................................................................................................... 20
Figure 8 - Tree menu description .......................................................................................................... 32
Figure 9 - State machine ...................................................................................................................... 35
Figure 10 - Typical start sequence for fuel engines .............................................................................. 36
Figure 11 - Power plant in change over mode without paralleling ........................................................ 37
Figure 12 - Power plant with several generators................................................................................... 39
Figure 13 - Static paralleling with 4 generators coupled together in emergency situation.................... 41
Figure 14 - Example with 4 generators coupled together in emergency situation. ............................... 42
Figure 15- Paralleling with mains .......................................................................................................... 42
Figure 16 - Typical sequence in No Break CO mode............................................................................ 43
Figure 17 - Typical sequence in permanent mode ................................................................................ 44
Figure 18 - Power plant paralleling with mains ..................................................................................... 44
Figure 19 - GCR Ù GENSYS wiring diagram....................................................................................... 45
Figure 20 - Power plant paralleling with several mains ......................................................................... 46
Figure 21 - Power plant paralleling with several mains configuration ................................................... 47
Figure 22 - Panel cut-out ....................................................................................................................... 49
Figure 23 - Mounting kit......................................................................................................................... 49
Figure 24 - Mounting brackets on GENSYS ......................................................................................... 49
Figure 25 - Earth grounding .................................................................................................................. 50
Figure 26 - Interconnection of all battery negatives .............................................................................. 51
Figure 27 - Connecting CAN bus with isolators .................................................................................... 51
Figure 28 - Speed output....................................................................................................................... 53
Figure 29 - Voltage output ..................................................................................................................... 55
Figure 30 - Connections for water preheat, pre lubrication and pre glow ............................................. 58
Figure 31 - Connection for air fans ........................................................................................................ 59
Figure 32 - Connections for filling.......................................................................................................... 59
Figure 33 - Fuel filling diagram .............................................................................................................. 60
Figure 34 - Speed and voltage control with Contact / Pulses (1) .......................................................... 73
Figure 35 - Speed and voltage control with Contact / Pulses (2) .......................................................... 73
Figure 38 - Schematic ........................................................................................................................... 84
Figure 39 - Wiring GENSYS Ù TEM ................................................................................................... 87
Figure 40 - Typical GPID controller ....................................................................................................... 89
Figure 41 - CAN Bus wiring ................................................................................................................... 97
Figure 42 - GENSYS Ù GENSYS ........................................................................................................ 97
Figure 43 - GENSYS Ù GENSYS Ù GENSYS Ù … .......................................................................... 98
Figure 44 - Mobile generator sets ......................................................................................................... 98
Figure 45 - CAN bus inhibition schematic (example) .......................................................................... 103
Figure 46 - Modular remote I/O extension module.............................................................................. 105
Figure 47 - CANopen coupler wiring ................................................................................................... 105
Figure 48 - Wiring diagram for Volvo EMS2........................................................................................ 116
Figure 49 - GENSYS Ù GENSYS ÙGENSYS Ù … (MODBUS) ..................................................... 117
Figure 50 - Several generators warning .............................................................................................. 122
Figure 51 - One generator with mains warning ................................................................................... 122
Figure 52 - Standard cables ................................................................................................................ 125
Figure 53 - Access to CRE Technology in Sophia Antipolis ............................................................... 126
page 7/7
List of tables
Table 1 - GENSYS Front Panel ............................................................................................................. 10
Table 2 - LCD screen characteristics .................................................................................................... 10
Table 3 - Display Panel keys ................................................................................................................. 11
Table 4 - Service Panel keys ................................................................................................................. 11
Table 5 - Control Panel keys ................................................................................................................. 12
Table 6 - Control Panel LEDs ................................................................................................................ 12
Table 7 - Inputs/Outputs description...................................................................................................... 16
Table 8 - User interface ......................................................................................................................... 17
Table 9 - Screensaver description ......................................................................................................... 33
Table 10- Typical change over mode configuration .............................................................................. 37
Table 11 - Typical sequence in change over mode............................................................................... 38
Table 12 - Typical basic multi Generator configuration ......................................................................... 39
Table 13 - Generator paralleling with parallel lines ............................................................................... 40
Table 14 - Typical basic configuration for GENSYS with parallel lines modules .................................. 40
Table 15 - Typical basic mains paralleling configuration ....................................................................... 43
Table 16 - Paralleling with mains configuration ..................................................................................... 45
Table 17 - GENSYS /GCR configuration ............................................................................................... 46
Table 18 - Input functions ...................................................................................................................... 63
Table 19 - Wiring GENSYS Ù Auto Start Module ................................................................................ 78
Table 20 - Wiring GENSYS Ù TEM ...................................................................................................... 87
Table 21 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus ................................... 99
Table 22 - Variables received by BROADCAST DATA via Inter GENSYS CANbus .......................... 100
Table 23 - CAN bus inhibition parameters........................................................................................... 104
Table 24 - CANopen configuration example ....................................................................................... 107
Table 25 - MDEC connection .............................................................................................................. 108
Table 26 - Important parameters ......................................................................................................... 108
page 8/8
1 Overview
1.1
European Union Directive Compliance CE
The EMC Directive (89/336/EEC) deals with electromagnetic emissions and immunity. This product is
tested by applying the standards, in whole or in part, which are documented in the following technical
construction file:
CEM 2004/108/EC, which replaces directive CEM (89/336/EEC) relative to electromagnetic emissions
as from July 20th 2009.
This product is developed to respect harmonized norms:
EN 55099:2009
EN 55099:2010
EN 55088:2008
2006/95/EC (replaced directive 73/23/EEC since January 16th 2007).
SAE J1939/71, /73, /31
Other norms:
EN 61326-1: 2006 (Industrial location)
EN 55011
EN 61000-3-2
EN 61000-3-3
1.2
Environment
Operating temperature
A40Z0
0 to 55°C
A40Z1
-20 to 70°C
A40Z2(GNSS)
0 to 55°C (UL certified)
A40B0,B1, B2, B3, B4, B5
5 to 55 °C (Bureau Veritas Marine agreement)
Storage temperature
-30 to +70°C
Humidity
5 to 95%
Tropic-proof circuits for normal operation in humid conditions.
Front panel:
IP54 protection.
Back panel:
IP20 protection.
Altitude:
2000m
1.3
Characteristics
Size
248x197x57mm (9.76x7.76x2.24in)
Weight 1.9kg (4.2oz)
page 9/9
2 Description
2.1
Front panel
Display
Panel
Service
Panel
Control
Panel
Table 1 - GENSYS Front Panel
The display panel allows setting up and monitoring of the GENSYS configuration and the power plant
it controls. It provides a large LCD display and a keypad. See "User interface" chapter, for more details
about the functions of LEDs & Keys.
LCD characteristics
Value
Unit
Viewing area 240x128
dot
114x64 (4.49x2.52)
30x16
mm (in)
Characters
Character size (small font) 2.7x3.6 (0.1x0.14)
mm (in)
(standard font) 3.6x3.6 (0.14x0.14)
mm (in)
9.45x9.45 (0.37x0.37)
mm (in)
(large font)
Back light 60
cd/m²
LCD mode STN
Table 2 - LCD screen characteristics
2.1.1 Display panel
Key
Navigation bar
Enter
Navigation mode
Input mode
(during parameter modification)
scroll / select menus and
parameters
change parameter value
enter a menu / switch to ‘Input
mode’
Validate parameter and return to
‘Navigation mode’
page 10/10
Used with other keys only (F1, F2, Not used.
I). Shift + I saves all parameters.
Shift
F1
Shortcut to special function
Increase speed in manual mode.
Increase voltage when associated
with Shift key in manual mode.
F2
Shortcut to special function
Decrease speed in manual mode.
Decrease voltage when
associated with Shift key in
manual mode.
Return to parent menu
Esc
Discard parameter changes and
return to ‘Navigation mode’
Table 3 - Display Panel keys
2.1.2 Service panel
The five dedicated keys of the service panel allow you to switch to special menus or functions directly.
See "User interface" chapter for more details about the functions of LEDs & Keys.
Key
Function
This key will stop the buzzer and turn the associated LED off.
The associated red LED indicates the status of the buzzer output.
Buzzer
Fault
!
!
Alarm
Direct access to the Fault menu.
An associated red LED indicates the Fault status of the generator.
Pressing this key will switch to the associated menu, showing active faults.
Pressing a second time on the same key will switch back to the menu displayed
beforehand.
Direct access to the Alarm menu.
An associated orange LED indicates the Alarm status of the generator.
Pressing this key will switch to the associated menu, showing active alarms.
beforehand.
Info
1. Direct access to global monitoring page (user configurable).
2. Save parameters in flash storage when pressed with SHIFT: this action is called
“SHIFT-I”
Pressing this key will switch to the associated menu, which is custom made and
contains parameters the user wants to monitor easily.
beforehand.
Bulb
LED test: pressing this key will turn on all GENSYS LEDs. It is a simple test to
check the LEDs and the keypad.
Table 4 - Service Panel keys
2.1.3 Control Panel
The control panel allows the user to pilot and control the generator. See "User interface" chapter, page
17, for more details about the functions of LEDs & Keys.
Function
Key
LED
upper
right
This LED is not associated with any key. It is illuminated when a key is
pressed and switched off when all keys are released. This LED also stays on
during a save parameters command (see SHIFT-I above).
page 11/11
Auto
Switches the system to automatic mode. The associated LED is ON when
AUTO mode is activated.
Test
Switches the system to test mode. The associated LED is ON when TEST
mode is activated.
Manu
Switches the system to manual mode. The associated LED is ON when
MANU mode is activated.
Start
Starts the generator (only available in manual mode).
Stop
Stops the generator (only in manual mode).
O/I
Closes/opens the generator breaker (only in manual mode).
O/I
Closes/opens the mains breaker if available (only in manual mode).
Table 5 - Control Panel keys
Led
Function
Shows green when engine is running
Engine
Shows green when generator voltage is present
Alternator
Genset
breaker
Mains
breaker
Shows green when generator breaker is closed
Shows green when mains breaker is closed
Shows green when voltage is present at Mains/bus input
Mains /
Bus
voltage
Table 6 - Control Panel LEDs
2.1.4 Upper Panel
The upper panel displays the status of the power supply. See "User interface" chapter for more details
about the functions of LEDs & Keys.
page 12/12
2.2
Rear panel
2.2.1 Overview
Figure 1 - Rear panel
2.2.2 Inputs/Outputs
Description
Terminal
capacity
(mm² /
AWG)
Crank relay out
2.5 / 12
Supplied via emergency stop input at battery positive
voltage; 16 Amps.
Fuel relay out
2.5 / 12
Supplied via emergency stop input at battery positive
voltage; 16 Amps.
Emergency stop
2.5 / 12
To battery positive, normally closed; direct supply to
crank and fuel relay outputs.
Generator N
2.5 / 12
Not necessarily connected: if not connected, GENSYS
will calculate a virtual neutral voltage.
B2
Generator L1
2.5 / 12
B3
Generator L2
2.5 / 12
Generator L3
2.5 / 12
100 to 480 VAC line to line. Frequency: 50 or 60 Hz.
100 mAmps / 600 VAC fuses.
For UL homologation:
- 100 to 230VAC line to line
- Fuses must be UL 248-14 listed.
- Surge protection must be UL1449 listed.
Mains L1
2.5 / 12
Pin nb
A1
A2
A3
B1
B4
B5
Comment
100 to 480 VAC line to line. Frequency: 50 or 60 Hz.
page 13/13
Mains L3
2.5 / 12
100 mAmps / 600 VAC fuses.
- 100 to 230VAC line to line
- Fuses must be UL 248-14 listed.
- Surge protection must be UL1449 listed.
Output 1 to 5
2.5 / 12
350 mAmp. Over current protected. Reactive load.
Each output can be configured with a specific function
(see option list in the Z090014.chm file) or
programmed with an equation.
D1
Generator I1-
2.5 / 12
D2
Generator I1+
2.5 / 12
D3
Generator I2-
2.5 / 12
D4
Generator I2+
2.5 / 12
0 to 5 Amps. Maximum rating: 15 Amps during 10s.
1 VA consumption.
Each phase is isolated from the others and from the
supply voltage.
External current transformer must be UL506 listed.
D5
Generator I3-
2.5 / 12
D6
Generator I3+
2.5 / 12
D7
Mains I1-
2.5 / 12
Mains I1+
2.5 / 12
E1
Mains breaker NC
2.5 / 12
E2
Mains breaker NO
2.5 / 12
E3
Mains common
2.5 / 12
E4
Gen breaker NC
2.5 / 12
E5
Gen breaker NO
2.5 / 12
E6
Gen common
2.5 / 12
F1
Engine meas. 1-
2.5 / 12
F2
Engine meas. 1+
2.5 / 12
F3
Engine meas. 2-
2.5 / 12
F4
Engine meas. 2+
2.5 / 12
F5
Shield
2.5 / 12
F6
Water temp meas. -
2.5 / 12
F7
Water temp meas. +
2.5 / 12
F8
Oil pressure meas. -
2.5 / 12
F9
Oil pressure meas. +
2.5 / 12
G1
0-20 mA +
2.5 / 12
G2
Shield
2.5 / 12
0-20 mA -
2.5 / 12
G4
Parallel. -
2.5 / 12
G5
Shield
2.5 / 12
B6
C1 to
C5
D8
G3
0 to 5 Amps. Maximum rating: 15 Amps during 10s.
1 VA consumption.
Each phase is isolated from the others and from the
supply voltage.
External current transformer must be UL506 listed.
230 VAC, 5 Amps.
Isolated relay contact.
230 VAC, 5 Amps.
Isolated relay contact.
0 to 10 kOhms resistive sensors with programmable
gain.
0 to 10 kOhms resistive sensors with programmable
gain.
0 to 400 Ohms resistive sensors.
0 to 400 Ohms resistive sensors.
+/- 10 V (20 kOhms input) or +/- 20 mAmps (50 Ohms
input).
Used as Mains power input with single generator.
Used as synchronization input from GCR (terminal 42)
when several generators parallel with mains
5V (10KOhms)
Load sharing and power set level (kW only).
page 14/14
Parallel. +
2.5 / 12
Compatibility with GCR (CRE product) and with
analogue load sharing line.
Compatibility with Wheatstone bridge.
Only used with GCR or old ILS
Isolated.
Pickup -
2.5 / 12
Pickup +
2.5 / 12
50 Hz to 10 kHz. Maximum voltage: 40VAC
Used for speed regulation, crank drop out and overspeed (see precautions in chapter 4.2.8).
If not wired, the speed measurement can be made by
the alternator voltage. But pickup is recommended.
G9
Speed out +
2.5 / 12
G10
Shield
2.5 / 12
Speed ref
2.5 / 12
H1
Not connected
2.5 / 12
H2
AVR out +
2.5 / 12
H3
Shield
2.5 / 12
AVR out -
2.5 / 12
Mains breaker in
2.5 / 12
Digital input with 10 kOhms pull-up.
Dedicated input for mains breaker feedback.
Accepts NO or NC contacts to 0V.
Not isolated.
Gen breaker in
2.5 / 12
Dedicated input for generator breaker feed back.
Not isolated.
Remote start/stop
2.5 / 12
Dedicated input for remote start/stop request in Auto
mode.
Not isolated.
Oil pressure
2.5 / 12
Dedicated input for oil pressure fault.
This sensor is needed to start the engine whatever the
mode.
Accept s NO or NC contacts to 0V.
Not isolated.
Water temp
2.5 / 12
Dedicated input for water temperature fault.
Not isolated.
Input 1 to 10
2.5 / 12
Digital inputs with 10 kOhms pull-up.
10 inputs can be configured with a specific function
(see option list in the Z090014.chm file) or
programmed with PLC equations.
Not isolated.
Reserved
2.5 / 12
Used for 12V power supply backup during crank time.
See A40U200000 documentation for more information.
Power supply +
2.5 / 12
9 to 40 V, 10 Watt consumption (without actuator).
G6
G7
G8
G11
H4
J1
J2
J3
J4
J5
J6 to
J15
K1
K2
G9: +/- 10 V analogue outputs.
G11: +/-10V input from speed governor (ESG)
Compatibility with most of speed regulators.
Independent gain and offset software adjustment (see
Z0900014.chm file).
Analogue output.
Automatic voltage regulator (AVR) set level (see
Z0900014.chm file for further explanations).
Stanford, AVK and Leroy Somer automatic voltage
regulators already tested. For others, ask your dealer.
Isolated.
page 15/15
Power supply -
2.5 / 12
Polarity inversion protection.
Note:
The "Power supply -" must be wired from the speed
governor using 4 mm² wires. See "state of the art"
rules wiring diagram.
5 Amps / 40 VDC fuse recommended.
Fuse must be UL 248-14 listed.
Actuator +
2.5 / 12
Actuator -
2.5 / 12
200 Hz PWM output (6 Amps continuous).
Power supply of actuator.
Compatibility with most standard electromagnetic
actuators. (Barber Colman, GAC, SynchroStart)
Needed to activate an OPTION
(To be ordered with the product).
RS232 to PC or
modem
Female
DB9
K3
K4
K5
COM1
CAN1 to other
GENSYS
Male DB9 125 kbaud.
Standard CAN© / proprietary protocol.
Used to communicate with other GENSYS units (kW,
kVAR, dead bus management) and for broadcast data
function.
Not isolated.
CAN2 to options
Male DB9 125 kbaud.
Standard CAN© / CANOPEN© protocol.
Used to communicate with remote I/O (WAGO) (see
remote I/O chapter) or with engine management units
(option 4).
Not isolated.
COM2
COM3
Straight cable is needed.
19200 bps, 8b, no parity, 1 stop bit.
Communication with a local computer.
Used for configuration, parameters, file downloading
and uploading.
Uses a TCP/IP protocol to communicate.
Not isolated.
Not to be connected while engine running.
RS485 / MODBUS RTU Male DB9 4800, 9600 or 19200 bps.
Used to communicate with SCADA.
MODBUS RTU slave. Read (04 and 03) and write (06)
COM4
functions.
2 wires mode.
Table 7 - Inputs/Outputs description
page 16/16
3 User interface
Table 8 - User interface
The user interface can be controlled through two different ways:
• Directly on local browser using front panel LCD screen and keyboard
• Remotely through an internet browser running on a PC
3.1
Internal browser description
GENSYS can be configured and monitored remotely with a Web browser such as Internet Explorer or
Netscape Navigator.
For local usage, GENSYS has an embedded browser which is able to display the same information
pages as the remote Web browser.
The user can navigate through the different menus with the navigation bar and the
/
keys.
3.1.1 Navigation Mode
The navigation bar provides 5 contextual keys. Depending on the menu displayed, different icons may
appear above these keys, allowing the user to scroll up/down the pages or to select a link to a new
menu or parameter.
When the user selects a parameter and presses the ‘
mode’.
’ key, the browser switches to the ‘Input
The 5 icons above contextual keys will change appearance depending on the type of parameter to
change (list of choice, label, numerical value, password...).
When in ‘Input mode’, the
mode’. The
key will discard the parameter changes and return to the ‘Navigation
key will confirm the parameter changes and return to the ‘Navigation mode’.
The browser displays a white pointer in front of each link or parameter of a menu. A black pointer will
indicate the active link or parameter. Figure 2- Browser link description shows these two pointers:
page 17/17
Figure 2- Browser link description
3.1.2 Input Mode
To change a parameter, first select it with contextual keys and press
to switch to ‘Input mode’.
New icons will appear above the contextual keys, depending on the kind of parameter selected.
Label modification:
Digital value modification:
List of options modification :
Figure 3 - Contextual keys for Input Mode
When the new parameter value is input, the user must press
value.
key to store and confirm the new
3.1.3 Save parameters configuration
All GENSYS parameters used in configuration are stored in a FLASH memory. When a parameter is
changed by the user, the new value is stored in a RAM memory. This new value will be effective as
soon as it is entered, but it will be lost if the GENSYS power supply is cut or too low. To save the new
+
keys together.
parameters in FLASH, you must use “SHIFT-I”. The user must press both
This will start the backup sequence and store all parameters in the FLASH memory. Now, the new
parameters will be effective even after a power supply failure.
NOTE:
Due to the great number of parameters. The back-up procedure may take a few
seconds. It is thus essential to save parameters when the motor is stopped. To save all
+
keys on the
parameters, the user must press at the same time on both
GENSYS front panel. Otherwise, the new parameters will be lost when shutting down the
GENSYS.
3.1.4 Password protection
The GENSYS has different password levels, allowing access to more or less critical parameters or
menus. When the password page is shown on the LCD display, the user must first press on the
key (like for other parameters) to switch to the ‘Password Input mode’.
Figure 4 - Password input mode display
Three lines of characters (upper case and lower case letters and ‘0’ to ‘9’ characters) will appear along
with 5 icons above the contextual keys.
page 18/18
The first four contextual keys allow the user to move the cursor up, down left or right onto the desired
character. The last key (OK icon) will validate the selected character and write it in the password line
(a * will appear).
key will validate the password. If it is
When all characters are entered, another press on the
correct, the main menu will appear on the LCD display. Otherwise, the password page will be
displayed again.
Default settings for the password are:
• Level 0: no password entered, just press "Enter" key.
• Level 1: 1.
• Level 2: Only for distributors.
The password of your level and those lower can be changed in the system menu.
Note: the menus might differ according to the security level of the password entered.
3.2
PC browser
GENSYS provides an efficient way of configuring your application thanks to its embedded Web server.
It is thus possible to access the different menus with a simple Web browser such as Netscape
Navigator or Internet Explorer. However, it is not recommended to be connected with the PC while the
engine is running.
Before connecting with the GENSYS you have to configure your computer as described in the next
chapter ". The next figure show a typical GENSYS menu accessed from a PC Web browser.
Figure 5 - Typical menu page
In this page, the user can choose from among 6 submenus (Generator electrical meters for example).
It is also possible to scroll up/down the other pages of the menu with the page up << and page down
>> links. The ESC link acts in the same way as the GENSYS ESC key: it will display the parent menu.
The last 3 links are identical to the Fault / Alarm / Information key on the GENSYS front panel.
The next figure shows a typical configuration page. The user can change 5 different parameters (in
this case, two numerical values and three option lists) and send them to the GENSYS using the [Save]
button. Clicking on the [Save] button changes the parameter immediately.
page 19/19
Figure 6 - Typical configuration page
NOTE :
+
keys at the same time on the GENSYS front
The user must press on both
panel to save the parameters permanently. Otherwise, the new parameters will be lost
when shutting down the GENSYS.
3.2.1 Setting up Windows XP
Connecting a GENSYS with a PC is similar to connecting to Internet with a modem.
GENSYS works as a modem and the integrated software works as an Internet provider.
GENSYS also provides 1 web server. This web server sends HTML pages to your PC, and your PC
browser is used to display it. Live data is refreshed with the JAVA applet.
A40W0
Figure 7 - GENSYS Ù PC
Data transfer takes place through a straight serial cable (with 9 wire DB9 connectors), as shown on
the figure above.
A few steps are required to configure a PC before controlling a GENSYS:
• Install the modem.
• Create a Dial-Up Networking Connection.
• Check the network properties.
• Set-up the internet security properties.
Communication between the GENSYS and the PC is carried out via a Dial-Up Network.
page 20/20
The PC must be configured to communicate with a 19.2K bps modem with TCP/IP networking
enabled.
3.2.1.1 Check the network properties
Click Start, Settings, and Network Connection.
Dial-Up Adapter and TCP/IP -> Dial-Up Adapter protocols must be present in the list. If they are not
there, create a new connection using the new connection wizard.
In the New Connection Wizard, select “connect to the network at my work place”. Then, click “Next”.
page 21/21
Select “Dial-up connection”. Click on “Next”
In the next page, select a 19 200 bps modem. Then, click “Next”.
In the connection name dialog box, in the “Company name” field write “GENSYS”. Click on “Next”
In the “Phone number to dial” dialog box, in the “Phone number” field, write: “123”. Then click “Next”.
page 22/22
The new connection is now installed. Select “Add a shortcut to this connection to my desktop”. Then
click on “Finish”.
3.2.1.2 Install the Modem
Click Start, Settings, and Control Panel.
In the Control Panel, double-click the Modems icon.
In the Modems Properties dialog box, click Add.
Double click on “Add hardware” icon.
page 23/23
Click on “Next”.
Choose the “Modem” icon.
Then, choose “Add a new hardware device”, and click “Next”.
Select “Yes, I have already installed the hardware”, and click “Next”.
page 24/24
Select install the hardware that I manually select from a list (Advanced)”. Then, click “Next”.
The following dialog box will appear: select option “don’t detect my modem; I will select it from a list”.
Then, click “Next”.
In the next dialog box, under Manufacturers, Standard Model Types should be selected. Under
Models, select Standard 19200 bps Modem, then click Next.
In the next dialog box, select the Communications Port where GENSYS is connected as the port, and
then click Next.
page 25/25
After Windows installs the modem, click Finish.
3.2.1.3 Set the Modem Properties
Back in the Modem Properties dialog box, select the new modem (Standard 19200 bps Modem) and
then click Properties.
In the “General” tab, check that the port speed is: 19 200 and the flow control is “hardware”.
In the Advanced parameters, in the “advanced options” tab, ensure that the modem is configured for 8
data bits, no parity, and one stop bit. Then click “OK”.
Click OK until you exit this dialog box.
Create a Dial-Up Networking Connection.
In the Control Panel, select Network Connection.
Double click on the “GENSYS” icon.
page 26/26
In the “Connection to GENSYS dialog box”, click on “Properties”.
In the “General” tab, ensure that the selected modem is the modem installed in the previous step.
In the “Option” tab, in the dialling option, select “Display progress while connecting”.
page 27/27
In the “Security” tab, select “Typical (recommended settings)”.
In the “Networking” tab, select “PPP Windows 95/98/NT4/2000, Internet”. Select “Internet Protocol”.
Click on “Install”.
In the “General” tab, select “Use the following IP address” and write: 192.168.11.2. Then select
“Advanced”.
page 28/28
In the “General” tab, disable every tick box.
In the “DNS” tab, select “Append primary and connection specific DNS suffixes” and “Append parent
suffixes of the primary DNS suffix”.
In the “WINS” tab, select “enable LMHOSTS lookup” and in the NetBIOS setting, select “enable
NetBIOS over TCP/IP. Then, click OK.
page 29/29
Back in the “GENSYS properties dialog box”, click on “Advanced tab. In this tab, ensure that every
option is disabled. Then, click OK.
3.2.1.4 Setting the internet security properties
•
•
•
•
•
•
•
•
•
•
•
In the Control panel, double-click the Add/Remove program icon.
If present, uninstall the Java sun program. Click OK.
Run the msjavwu_.exe program provided in the CD Rom.
Click Start, Settings, and Control Panel.
In the Control Panel, double-click the Internet Options icon.
Under the Security tab, select Trusted Sites and click on Add Sites…. Check that Require server
verification (https :) for all sites in the zone is disabled. In the Zone field write "http://GENSYS"
and click on Add. Click OK.
Under the Security tab, select trusted sites, click on Customize…. In Java (or Java VM for 95, or
Microsoft VM for ME) and Java permissions, select Custom. Click on the Java Custom Settings
button. Under the Edit permissions tab, enable the Access to all Network Addresses in the Run
Unsigned Content part. Click OK. Click OK. If a dialog box appears, click YES.
In the Connection tab, click on Never establish connection. Select GENSYS modem in the
modem list Click on Settings, Use a proxy server must be disabled. Click OK.
Under the Advanced tab, in the Java VM field (Microsoft VM for ME); check that Java JIT
enabled is selected. Click OK.
Close Control panel.
Copy the file named hosts from the GENSYS CD Rom “C:\WINDOWS\system32\drivers\etc”
page 30/30
3.2.1.5 Connect the GENSYS
Connect one end of a DB-9 serial cable to the COM1 port of the PC. Connect the other end of the
cable to the connector labelled "RS232 to PC or modem" on the GENSYS.
Double-click on the Shortcut to GENSYS icon. In the Connect to dialog box, click CONNECT. Click
close.
If the connection is OK, an icon (2 small computers) in the bottom right of the screen appears.
3.2.2 View Web Pages from the GENSYS Web Server
After the TCP/IP connection has been established with GENSYS, you can view GENSYS menus with
any standard Web browser such as Firefox or Internet Explorer.
Start the web browser (Internet explorer, Firefox …).
In the “Location” or “Address” field of the web browser, enter the URL of the GENSYS: http://gensys
(CAUTION: host file must be present in “C:\WINDOWS\system32\drivers\etc” and must contain a line
such as:
« 192.168.11.1 GENSYS »
The GENSYS password page should appear in the browser window. Enter your password.
You can now browse through the different GENSYS menus.
To close the connection, double-click on the connection icon in the status bar of Windows. In the
Connected to GENSYS dialog box, click Disconnect. Close your web browser.
3.2.3 First level screens
Upon power up, GENSYS displays the genset status (if EMERGENCY STOP not connected) or
WELCOME SCREEN.
The first level menu contains three entries:
• Display
• Configuration
• System
You can access it with next KEY sequence:
=>
=>
=>
You then have access to the top level menu:
=>
=>
page 31/31
Figure 8 - Tree menu description
See the Help file for the complete description of the tree menus.
3.3
Screensaver
GENSYS has automatic screensavers. They only appear on the GENSYS LCD screen when you
press "Esc" in the password page or after an adjustable delay (GENSYS variable 1266). There are
four screensavers and the display depends on the mode and state of GENSYS:
Screensaver
Description
4 customized lines
Customer Logo
Date and time
KW (in large font)
Voltage (in large font)
Generator
Frequency (in big font)
overview
Running hours (in large
font)
Crank Relay Output
Fuel Relay Output
Water Temp Digital
Input
Oil Pressure Digital
Input
Engine
Emergency Stop
overview
Remote start
Nb of start attempts
Battery voltage (bar
graph)
Engine speed (bar
graph)
Frequency difference
(bar graph)
Synchronization Voltage difference (bar
graph)
column
Phase difference
(column)
Customized
screen
Display in Auto mode
Display in Manu
mode
In Wait state (engine stopped).
In other cases.
When the generator breaker is
closed.
When the generator
breaker is closed.
In Start state and fault state.
When you press Start
or when in fault state.
In Synchronization state.
When the generator is
ready and the
generator breaker is
opened.
page 32/32
Frequency match (OK /
NOK)
Voltage match (OK /
NOK)
Phase match (OK /
NOK)
Table 9 - Screensaver description
page 33/33
4 Operating modes
With the GENSYS unit, three main operating modes and one special mode are available to allow you
to control your generator.
Modes are:
•
•
•
4.1
Manual
Automatic
Test Mode
Manu mode
In manual mode, it is possible to control the generator with the front panel of the GENSYS. All steps
from engine start to paralleling are controlled by pushing keys.
To start the engine push the [Start] key and hold down until the oil pressure fault disappears. On the
front panel, the 2 LEDs above the generator should light up. The left hand LED indicates that a speed
greater than zero is measured, whereas the right hand LED indicates that a voltage other than zero is
measured.
If a speed regulator is connected to GENSYS, it is possible to increase the speed with the F1 key, and
decrease it with the F2 key.
If a voltage regulator is connected to GENSYS, it is possible to increase and decrease the voltage with
the SHIFT+F1 keys and SHIFT+F2 keys.
When the generator is synchronized, it is possible to close the breakers with the 0/I keys.
Important: The internal synch check relay is always active, i.e. it is impossible to close the breaker if
the conditions for closing are not met.
When the breaker is closed the corresponding LED on the front panel should light up.
As soon as the generator breaker is closed, the GENSYS is switched to droop mode for speed and
voltage, i.e. the speed and the voltage will decrease when the load increases.
To stop the engine, push the Stop key.
4.2
Auto mode
Speed and voltage droop are inhibited in this mode, the system is running isochronously, i.e. the
speed and the voltage remain unchanged whatever the load.
This mode has 4 main ways of operating:
One generator with Change Over:
The generator starts with a remote start or in the case of mains failure. When the generator is ready
(voltage, frequency), the mains breaker is opened and the generator breaker is closed. Should the
mains return to normal conditions or remote start is off, after a programmed delay the generator
breaker is opened, the mains breaker is closed and the generator set is stopped.
One generator paralleling with the mains (option 2):
The generator starts with a remote start or if there is a mains failure. Paralleling depends on
configuration: NO CHANGE OVER, CHANGE OVER, NO BREAK CHANGE OVER, or PERMANENT
Load sharing can be on a "base load" or "peak shaving" basis. Depending on the configuration, the
generator will stop either when there is a remote stop or when mains power returns to a stable level.
Power plant with several generators without automatic load/unload:
The generator starts with a remote start signal, and parallels with the bus. If there is a dead bus,
GENSYS will check with the other GENSYS units before closing the bus breaker (this depends on the
page 34/34
validation of the dead bus management). The load sharing is accomplished via the inter GENSYS
CAN© or via the parallel lines. The generators stop with a remote stop signal.
Power plant with several generators with automatic load/unload:
The communication between GENSYS units is via the inter GENSYS CANbus and determines which
generators start or stop. The number of generators used depends on load requirements (all generators
receive the remote start signal but only start if necessary).
4.3
Test mode
This mode tests the Auto mode. When you press the [Test] key, the engine starts as if there was a
remote start, and GENSYS will carry out the standard Auto mode sequence. To exit “TEST MODE”,
push the [AUTO] key.
4.4
Semi Auto Mode
Similar to Auto Mode, except that to pass from one state to another you press a button. The following
illustration shows the various states.
Figure 9 - State machine
page 35/35
5 Typical start sequence for fuel engines
During the start sequence protections are inhibited. This concerns all engine protections. When the
engine reaches the required state (E2057 = 6, see next figure) the protections are activated. A timer
can be added to inhibit protections during the "safety on" delay (E1514). The timer will start when
E2057=6.
Nominal speed (1080 or 1081)
Speed
Idle speed (1079)
Crank drop out
(1325 or 1326 or 1327)
Stop
request
Start
request
Prelub
1145
Running timers
Engine state (2057)
0
1
Preglow
1157
12
Crank
1135
Crank rest
1136
Preglow
1157
Crank
1135
Warm up
1139
RPM stab
1140
2
11
12
2
3
4
Volt stab
1141
Safety on
1514
5
6
Engine
ready
Crank relay out (2018)
(Terminal A1)
Cooling
1142
6
8
Rest
1144
9
10
0
Gen. ready
Fuel relay out (2019)
(Terminal A2)
Warm up (2214)
(Terminal J6 to J15)
Validation protection (2192)
Figure 10 - Typical start sequence for fuel engines
page 36/36
6 Predefined configurations
GENSET
Power
Single generator in change-over mode (without paralleling)
t
MAINS
Power
OU
t
LOAD
Conso
LOAD
Conso
t
t
MAINS
Power
GENSET
Power
6.1
t
t
GENSYS
Functions:
- Manual mode
- Auto mode
- Test mode
- Nb of running hours
Analog / logical inputs :
- Oil Pressure
- Water temp
- remote start
- Emergency stop
- Genset breaker aux
- Mains breaker aux
- Pickup frequency
- Spares ...
Logical outputs:
- Crank
- Fuel solenoid
- Mains breaker
- Genset breaker
- Spares
Analog output:
- analog signal to speed regulator
- RMS reasurements
(three or single phase)
- Electrical protections
(>V,<V,>f,<f,>Q,
>P,>I, ...)
Start/stop
LV
or
HV
(100480Vac)
Alarms ...
Mains
LV
or
HV
(100480Vac)
Breakers
management
Utility
Figure 11 - Power plant in change over mode without paralleling
Variable number
Variable label
Variable value
1179
Gen. number
1
1147
Nb of gen.
1
1148
Mains parallel
ChangeOver
1153
Mains regul
X
1158
ILS compatible
No
1177
Synchro mode
Dynamic
1515
Deadbus manag.
X
1258
Load/Unl. mode
Inhibited
1846
Break Ma Fault
Mains
1841
Fault start
Yes
Table 10- Typical change over mode configuration
page 37/37
In Change over mode, as shown in Table 10- Typical change over mode configuration, the generator
starts and takes the load when a mains electrical fault occurs. When mains power returns, the
generator breaker is opened and the mains breaker is closed after a pre-set delay.
For the generator to start when mains failure occurs, either a protection (mains or other) or a digital
input has to be configured as a "Mains electrical fault".
If remote start is on when mains are present the generator starts, GENSYS opens the mains breaker,
then closes the generator breaker and takes the load.
E0022
Mains voltage
400 V
E2201
triggered by a protection or
digital input set as "Mains
electrical fault"
Mains electrical fault
Fastest mains
electrical fault
E2002
Remote start on
terminal J3
E0003
Genset voltage
E1085
Mains back
timer
Genset ready
400 V
E2001
E2000
E1142
Cool
down
Switchover
delay
E1459
Generator CB
E1459
Swithover
delay
E1459
Swithover delay
Mains CB
Second black
START FOR EMERGENCY
will only start if a mains protection or a digital input is programmed as
"Mains electrical Fault".
First black
Second black
First black
There are 2 blacks
E1142
Cool
down
E1459
Switchover
delay
There are 2 blacks
START FOR TEST
or switch load from mains to genset
Table 11 - Typical sequence in change over mode
Note:
in "No change over" mode (1148) GENSYS only starts upon a remote start demand and
doesn't manage the mains breaker.
page 38/38
6.2
Generators paralleling with inter GENSYS CANbus
KW, KVAR, COS (f), ...
GENSYS 1
CAN Bus
GENSYS 2
GENSYS n
Utility
Figure 12 - Power plant with several generators
Variable number
Variable label
Variable
value
1179
Gen. number
1 to n
1147
Nb of gen.
N (>=2)
1148
Mains parallel
No ch.over
1153
Mains regul
X
1158
ILS compatible
No
1177
Synchro mode
Dynamic
1515
Deadbus manag.
Yes
1258
Load/Unl. mode
X
1020
MA kW <-> 20mA
0
1021
MA 0kW setting
0
Table 12 - Typical basic multi Generator configuration
page 39/39
6.3
Generators paralleling with GENSYS and parallel line modules
Analog load sharing lines
KW, KVAR, COS (f), ...
ILS
PowRcon
GENSYS 1
CAN Bus
GENSYS 2
GENSYS n
Utility
Table 13 - Generator paralleling with parallel lines
Variable number
Variable label
Variable value
1179
Gen. number
1 to n
1147
Nb of gen.
n (>=2)
1148
Mains parallel
No ch.over
1153
Mains regul
X
1158
ILS compatible
Yes
1177
Synchro mode
Dynamic
1515
Deadbus
manag.
No
1258
Load/Unl. mode
Inhibited
Table 14 - Typical basic configuration for GENSYS with parallel lines modules
When GENSYS is in ILS compatible mode, the active power sharing is handled via the parallel lines.
You have to disconnect the AVR output (H2-H4) and have an external device control the reactive
power (CT droop...).
page 40/40
6.4
Multiple generators with static paralleling
This mode is useful as it allows:
• Gradual magnetization of the step-up transformers (no transient short-circuit).
• Full plant availability in less than 10 seconds.
6.4.1 Configuration
•
•
•
•
•
•
•
•
One GENSYS per genset.
CAN bus must be connected between GENSYS units.
An "Excitation" output (e.g. exit C1) must be configured on each GENSYS unit.
GE breaker must be powered by 24VDC (so as to close without AC).
In the Setup menu / plant overview / sync mode. E1177 must be set as "A stop".
The value of the maximum excitation rpm is set with E1896 (default: 97%).
The alternators must be identical.
Each GENSYS must be equipped with a speed sensor (magnetic sensor / Pick-up).
Figure 13 - Static paralleling with 4 generators coupled together in emergency situation
6.4.2 Sequence:
•
•
•
•
•
•
•
•
•
•
Loss of voltage -> Dead Busbar
Each GENSYS is ordered to start (Terminal J3).
CB1, CB2, CB3 & CB4 close as ordered by the GENSYS units.
DG1, DG2, DG 3, and DG4 start.
All generators reach the speed defined by the E1896 setting (CANBUS synchronization).
All C1outputs close simultaneously to activate excitation (after dialogue between GENSYS
units).
Alternator voltages increase gradually at the same time.
The plant is available to take up required load.
Breakers are closed when engine is stopped.
There is a residual voltage of 80V.
page 41/41
Speed
1500tr/min
Voltage
400V
80V
Time
9
Figure 14 - Example with 4 generators coupled together in emergency situation.
6.5
Single generator paralleled with mains (option 2)
GENSYS
Mains
CPA2
Utility
Figure 15- Paralleling with mains
In permanent mode (1148) and peak shaving mode (1153), a mains power measurement is required.
Internal via D7-D8 inputs (Mains I1) or external via G1-G3 inputs (0-20 mA).
Variable number
Variable label
Variable value
1179
Gen. number
1
1147
Nb of gen.
1
1148
Mains parallel
NoBreak CO / Permanent
1153
Mains regul
Base load / Peak shav.
page 42/42
1158
ILS compatible
No
1177
Synchro mode
Dynamic
1515
Deadbus
manag.
X
1258
Load/Unl. mode
Inhibited
Table 15 - Typical basic mains paralleling configuration
In all mains paralleling modes, if a "mains electrical fault" is set (via protections or digital inputs), the
generator starts and takes the entire load upon mains loss even if the remote start is off. In all cases,
you have to set a mains protection in order to determine the behaviour of your generator when mains
power disappears.
6.5.1 Mains paralleling modes:
Choice of mains paralleling mode is configured through parameter E1178.
No Break CO (No break change over):
When remote start is on, the generator starts, synchronizes and parallels with the mains, then takes
the load (ramps up). Once the mains are unloaded, GENSYS opens the mains breaker. When remote
start is off, the mains takes the load in the same way as the generator did previously. If the generator
started for a mains failure, when mains power returns the GENSYS synchronizes the load transfer
(ramps down), opens the breaker and then stops the generator.
E0022
Mains voltage
400 V
E2201
E2002
Remote start on
terminal J3
E0003
Triggered by
fastest "Mains
electrical fault"
Genset voltage
400 V
GE ready
E1142
Cool
down
There is only 1 black
START FOR EMERGENCY
E1152
Unload
ramp
Synchro back
Short transfert from
mains to GE
Synchro
E1151
Load ramp
Short transfert from GE
to mains
E1152
Unload
ramp
Short transfert from GE
to Mains
E1085
Mains back
timer
Synchro back
E1459
Swithover
delay
Mains CB
First Black
E2000
Generator CB
GE ready
E2001
E1142
Cool
down
No black
START FOR TEST
or to transfert load from mains to GE.
Figure 16 - Typical sequence in No Break CO mode
Permanent:
When the remote start is on, GENSYS starts the generator, synchronizes and parallels with the mains,
then ramps up load until it reaches its set point. In base load mode (E1153), the generator has a
constant load and the mains take the utility load variations. If the utility load is less than the generator
page 43/43
set point, mains are in reverse power. In the peak shaving mode (E1153), the mains have a constant
load and the generator takes the utility load variations.
E0022
Mains voltage
400 V
E2201
E2002
Remote start on
terminal J3
E0003
Triggered by
fastest "Mains
electrical fault"
Cool
down
Genset voltage
400 V
GE ready
E1152
Unload
ramp
There is only one black
Unload ramp
Base load or peak
shaving (CHP for
example)
E1151
Load ramp
Load ramp
Synchro back
E1152
Unload
ramp
Synchro
E1085
Mains back
timer
Transfert load from GE
to Mains
E1459
Swithover
delay
Mains CB
First Black
E2000
E1142
Cool
down
GE ready
Generator CB
E2001
No black. Mains CB is always closed
START FOR PRODUCTION /
base load or peak shaving
START FOR EMERGENCY
Figure 17 - Typical sequence in permanent mode
6.6
Power plant paralleled with mains
Synchronization bus
KW, KVAR, COS (phi), ...
GENSYS 1
GENSYS 2
CAN bus
GCR
GENSYS n
Réseau
PLC
Mains kW
CPA2
Utility
Figure 18 - Power plant paralleling with mains
In this configuration, base load or peak shaving regulation can be selected, depending on GCR
configuration. In base load mode, GCR doesn't need CPA.
page 44/44
Variable number
Variable label
Variable value
1179
Gen. number
1 to n
1147
Nb of gen.
n (>=2)
1148
Mains parallel
No ch.over
1153
Mains regul
X
1158
ILS compatible
Yes
1177
Synchro mode
Dynamic
1515
Deadbus manag.
Yes
1258
Load/Unl. mode
X
1020
MA kW <-> 20mA
18000
1021
MA 0kW setting
0
1461
Ext kW measure
+/- 10V
Table 16 - Paralleling with mains configuration
To allow Power Factor regulation, the "Mains breaker in" (J1) information to GENSYS must be wired.
Power Factor regulation is not an option.
6.6.1 Interfacing GENSYS with GCR
Figure 19 - GCR Ù GENSYS wiring diagram
•
GCR (39-40) – GENSYS (G4-G6): parallel lines (0-3V) to control active power.
page 45/45
•
•
GCR (42-43) – GENSYS (G1-G3): mains synchronization bus (+/- 3V).
GENSYS (K3): -VBat from speed governor.
Variable number
Variable label
Variable value
1464
Mains kW Meas.
External
1461
Ext kW measure
+/- 10V
1020
MA kW <-> 20mA
20000
1021
MA 0kW setting
0
Table 17 - GENSYS /GCR configuration
6.7
Power plant paralleled with several mains
Synchronization bus
KW
KVAR
COS (f)
...
GENSYS 1
CAN bus
GENSYS 2
GENSYS n
PLC
GCR 1
Mains 1
kW
CPA
GCR 2
Mains 2
CPA
Utility 1
CPA
GCR n
CPA
Mains n
Utility 2
CPA
CPA
Utility n
Figure 20 - Power plant paralleling with several mains
page 46/46
For further information concerning managing several mains using GCR, refer to the GCR technical
documentation.
Variable number
Variable label
Variable value
1179
Gen. number
1 to n
1147
Nb of gen.
n (>=2)
1148
Mains parallel
No ch.over
1153
Mains regul
X
1158
ILS compatible
Yes
1177
Synchro mode
Dynamic
1515
Deadbus
manag.
Yes
1258
Load/Unl. mode
X
Figure 21 - Power plant paralleling with several mains configuration
page 47/47
7 Installing and commissioning a GENSYS application
7.1
Wiring diagram
7.2
Installation instructions:
The GENSYS module has been designed for front panel mounting.
Indoor or outdoor installation is possible as long as the following requirements are met:
•
The chosen cabinet must meet the standard safety rules of the workplace.
page 48/48
•
The chosen cabinet must be closed during normal use to prevent the user from coming into
contact with power cables.
Only the front panel must be accessible during normal use.
In accordance with the Bureau VERITAS marine agreement, the module must not be installed in
areas which are exposed to the weather.
•
•
7.2.1 Panel cut-out:
177 mm /
6.97 in
228 mm /
8.98 in
Figure 22 - Panel cut-out
Note:
Cut-out must be cleaned of any metal dust before mounting.
7.2.2 Mounting:
To secure the GENSYS onto the panel, use the special kit provided with the module. The kit contains
4 screws, 2 brackets and 1 mounting tool.
Figure 23 - Mounting kit
1. Remove the connectors.
2. Pass the module through the panel cut-out. Ensure that the gasket is properly positioned on
the panel and that it is flat.
3. On the rear side of the module, insert the first bracket into the two holes on the upper edge of
the module and push it to the left.
Figure 24 - Mounting brackets on GENSYS
4. Use the tool which is provided to screw the bracket gently onto the panel (just to hold the
module in place)
5. Insert the second bracket into the two holes on the lower edge of the module and push it to
the right.
6. Use the tool to screw the bracket gently onto the panel.
7. Tighten brackets gradually until the module is firmly secured.
8. Plug in the connectors.
page 49/49
7.2.3 Earth grounding:
Earth grounding of the GENSYS must be made with two M5 screws & fan washers. Use a short 4mm²
cable to connect the unit to earth (see below).
Figure 25 - Earth grounding
For UL homologation, the screw must be hexagonal with green head.
7.2.4 Wiring guidelines:
The power cable must be kept separate from the communication cable. The communication cable can
be installed in the same conduit as the low level DC I/O lines (under 10 volts).
If power and communication cables have to cross, they should do so at right angles.
Correct grounding is essential to minimise noise from electromagnetic interference (EMI) and is a
safety measure in electrical installations. To avoid EMI, shield communication and ground cables
appropriately.
If several GENSYS are used, all the power supply 0V (pin K3) must connected together with mini
10mm².
WARNING :
Please read the following recommendations to avoid any hardware damage to the
GENSYS CANBUS Driver (not isolated).
Power supply to circuit breaker
Terminal K3 (0V) should never be disconnected. The battery circuit should only be opened using a
breaker placed between the battery's positive terminal and the K2 terminal (Power supply +).
Note:
If the K3 (0V) terminal is disconnected and the bus bar voltage is applied to the GENSYS,
there is the risk of getting AC voltage on the CANBUS terminals.
page 50/50
Interconnection of all battery negatives
Figure 26 - Interconnection of all battery negatives
Rental fleet & HV generating sets
CANBUS isolators are recommended for generating sets used for rental fleet, Marine, or High Voltage
switchboards.
Figure 27 - Connecting CAN bus with isolators
Note:
These isolators are fitted to prevent any damage due to a disconnection of any K3
terminal from the inter-negative connection.
These isolators can be supplied by CRE Technology with the reference A40M0.
7.2.5 Vibrations:
In case of excessive vibration, the module must be mounted on suitable anti-vibration mountings.
7.2.6 Real time clock battery:
If the battery is disconnected, remove the rear panel and connect a 3V battery to the ST1 jumper
(+battery: ST1 up; -battery: ST1 down).
Battery maintenance must be provided separately from the GENSYS unit.
7.3
Before commissioning (before going on site)
Schematics check
How?
• Be sure you have the latest power plant schematics.
Why?
• To be sure the wires will be present on site (Can bus connector, shielded wires...).
What?
• 0 Volt wiring
• Shields
• Speed governor / GENSYS Interface
• Automatic Voltage Regulator / GENSYS Interface (droop current transformer must be removed)
• CAN Bus
• GCR
page 51/51
Check the list of input/output
How?
• Check if the required function is present in the list of preset functions.
• If any doubt check with distributor.
Why?
•
•
•
To evaluate if an input/output needs an extra equation.
To evaluate / quote development time.
To evaluate necessary password clearance: Level 1 (consumer), Level 2 (Distributor), or Level 3
(CRE Technology only).
7.4
During commissioning
Start with safe condition
How?
• Disconnect the GENSYS connector labelled as “E” (breaker control).
• Disconnect the wires between GENSYS and the speed governor (G9 / G11).
• Disconnect the wires between GENSYS and the AVR (H2 / H4).
• Check important GENSYS parameters (See chapter 4.2).
• Ask the technician who wired the power plant to lock the generator breaker open.
Why?
•
So as to be sure not to cause a false paralleling during commissioning.
Download the text file from the GENSYS.
How?
• With a PC and Internet explorer.
Why?
•
To store all parameters before starting the commissioning.
Check speed detection.
How?
• Press on manual key.
• Lock the fuel closed.
• Access the information menu.
• Press and hold the start button during 5 sec.
• While the starter turns over, check that GENSYS RPM is close to 200RPM.
Why?
•
•
To be sure that the GENSYS will release the starter motor at the correct speed (around
400RPM).
To have over speed protection.
Start the generator, check speed detection.
How?
•
•
•
•
•
Set the speed governor potentiometer to its minimal value.
In [Manu] mode, press and hold [Start] button for 10s.
Adjust the speed to 1500 RPM (using speed governor potentiometer).
In the information menu check that Frequency= 50.00 when RPM=1500RPM. You may have to
adjust the number of teeth on the gear where the measure is taken (for example).
Press [Stop] to stop the generator.
page 52/52
Check the 5 minimum protections before carrying out any other
tests:
• Over speed
• Over voltage
• Emergency stop
• Oil Pressure
• Temp
How?
•
•
Short-circuit the sensors.
For over speed and over voltage, set the thresholds to 101%.
GENSYS / Speed governor Interface
How?
•
•
•
•
•
•
•
•
Connect only the reference wire.
Set the recommended gain and offset (if not in the list, contact CRE technology).
Start the generator at 1500RPM to obtain exactly 50.00 Hz (60.00 Hz if applicable).
Measure the voltage between Ref and remote voltage input on the speed regulator side.
Adjust GENSYS output voltage (G11 G9) using the offset.
Connect the control wire.
Check the maximum speed range in manual mode with F1 and F2.
This range must be near +/- 3Hz.
Deviation
ESG amplitude
(1076)
+
ESG offset (1077)
G9
Speed out
+
G11
Speed
ref
Figure 28 - Speed output
•
•
•
The ESG offset adjustment (E1077) can be set between -10V and +10V, and is added to the
external speed reference (G11). The values in % are % of 10V. E.g. 51%=5.1 volts.
The Speed ref (G11) doesn't need to be connected if there is no voltage reference available.
0V must be wired with 4 mm² as follows: battery Ö speed regulator Ö GENSYS
Manufacturer
Model
ESG
Amplitude
(1076)
ESG
offset
(1077)
Terminal
G9 (out)
E6
10%
0%
B3
KG6 / System
E6
-25.00%
46.50%
E3
Terminal
G11 (ref)
Remark
NC
HEINZMANN
PANDAROS
DC6
24%
26%
B3
A3
Voltage converter
to isolate the
signal on the line.
(DC/DC) (advise)
page 53/53
ECM pour
QSK23 / QSK40
/ QSK45 /
QSX15 / QSK
60
1.00%
EFC
2%
0%
8
9
ECM (QST30)
1.00%
-3.00%
18
15(7,75v)
All models with
analog input
5%
-1.65%
ILS input
4v
10%
-1.05%
ILS signal
2,5V
1.6%
-27%
ILS signal
Digital
supply
(+5V)
1.6%
25%
ILS signal
BAT-
25.00%
25.00%
10
11
90.00%
0%
25
26
Shunt 26 (com) to
0V
2301D
25.00%
00.00%
15
16
G11 connected to
0v
2301A Speed
only
99.00%
-1.00%
15
16
16 connected to
0V
Pro-act / Pro-act
II
25.00%
00.00%
Aux +
Aux -
Aux- connected to
0V
8290-189 /
8290-184
25.00%
30.00%
11
NC
11-12 open
MDEC
25.00%
20.00%
8
31 (5v)
Programmable
EDC 4
15.00%
25.50%
24 / conn.
F
25 / conn.
F
EDC III
20.00%
25,00%
Pot signal
NC
ECM
25.00%
25.00%
30
3 (5v)
EMR
8.00% to
13.50%
26.20%
24
25
+/- 1.5 Hz not to
reach EMR
overspeed
TEM compact
--
--
--
--
See application
note A40Z090200
GAC
All ESD
-20%
-63.8%
N
P
Ghana Control
PWC 2000
75.5%
-25%
J
G
SCANIA
16 ltr full
electronic
engine
20%
-36%
54
28
CATERPILLAR
EMCPII
interface
5%
13.10%
CUMMINS
BARBER
COLMAN
DPG 2201
- 2301A/D
ILS+speed
- (w/o U & I)
WOODWARD
MTU
VOLVO
PERKINS
Deutz
10 (Barber
Colman
00.00%
Frequency
bias input)
2
06 (5
Volts)
1
Shunt 14-16
-2Hz and +0,8Hz
(although the
GENSYS output
still increase)
page 54/54
38%
JOHN DEERE
LEVEL III
23.80%
ECU
34%
G2(speed
input line)
915
-15%
G2
D2(sensor
return)914
5V(ref
speed) 999
Two different
wirings for the
same governor.
GENSYS / Auto Voltage Regulator Interface
To set AVR control correctly:
Start engine (MANU Mode), then set gain E1103:= 0 and Offset E1104:=0 on GENSYS.
Set the AVR system to 400 VAC using its potentiometer.
Gain and Offset adjustment: Enter maximum correction (E2038 = + 7000) with Shift and “F1” buttons.
From the following table, choose the best values for Gain and offset to obtain 430VAC ±5V:
GAIN
0
255
255
0
OFFSET
0
0
255
255
If necessary, modify Gain and then Offset to obtain 430VAC ±5.
Enter minimum correction (E2038 = - 7000) with Shift and “F2” buttons, then check that you have
370VAC ±5
Set to no correction (E2038 = 0) and check that you have 400VAC.
Gain and Offset adjustment if you cannot obtain 400V on the AVR: Adjust the maximum voltage with
the AVR potentiometer, which is normally below 400VAC. Choose the best values for Gain and offset
to obtain the maximum deviation.
Deviation
AVR gain (1103)
H2
AVR out +
H4
AVR out -
47R
AVR offset
(1104)
Figure 29 - Voltage output
•
AVR gain and AVR offset settings:
000 -> 0 kOhms
255 -> 10 kOhms
•
•
AVR gain is set to 255 for an output between -5V and +5V.
See table below for predefined settings. For specific setting contact your dealer.
AVR
AVR
Terminal Terminal
Manufacturer
Model
gain
offset
H2
H4
(1103)
(1104)
STAMFORD
MX321
255
0
A2 (+)
A1 (-)
Remark
Trim pot of AVR
fully CW
page 55/55
BASLER
MARATHON
ELECTRIC
AVK
SX440
155
0
A2 (+)
A1 (-)
Trim pot of AVR
fully CW
AEC63-7
AVC63-4
AVC63-4A
APR63-5
APR125-5
SSR63-12
240
240
6
7
Remove the shunt
DECS32-15xxx
DECS63-15xxx
DECS12515-xxx
DECS300
-
-
-
-
Use VAR control
included in the
DECS.
VR63-4
240
240
VAR+
VAR-
Remove the shunt
DVR2010
100
0
Aux input
A
Aux input
B
DVR2000
-
-
-
-
Cosimat N+
255
0
Pot +
Pot -
MA329
155
0
A2(+)
A1(-)
M8B
240
240
P
Q
Remove the shunt
PQ
6
470nF capacitor
between 8 and M.
Don’t connect
shield.
M8B400
0
0
8
MarelliMotori
Replace with SE350
or DVR2000E
M405A640
0
0
6
8
470nF capacitor
between 6 and M.
Don’t connect
shield.
KATO
K65-12B
K125-10B
255
0
2
Or 4
3
Or 7
Jumpers have to be
removed.
Available soon
MECC ALTE SPA
UVR6
250
200
Pot +
Pot -
50kOhms in serial
with H2
R449
253
255
Pot input
+
Pot input -
Remove the shunt
R448
253
255
Pot input
+
Pot input -
Remove the shunt
R221
100
241
Pot input
+(6)
Pot input – Remove the shunt.
(7)
Pot ineffective
R230
253
255
Pot input
+
Pot input -
DVR
KVAR/PF
130
210
7
45
VR6
130
245
CDVR
255
100
LEROY SOMER
CATERPILLAR
Remove the shunt
1.5kOhms in serial
with H2
P12.6
P12.3
page 56/56
Check the control of the breaker on dead bus
How?
•
•
•
•
•
•
•
Be sure there is no critical load connected to bus bar
Connect the “E” connector
Start the engine in manual mode
Press the generator breaker 0/I key.
The breaker must close (control OK) and the GENSYS front face led must light up (feedback
position OK).
Press the generator breaker 0/I Key.
The breaker must open and the led must go out.
Check mains / bus ref L1 and L3
How?
•
•
•
Start the generator
Close the breaker
Enter the Synchronization menu to check that phase difference is 0°.
Check synchronization
How?
Unplug “E” connector
•
•
•
•
•
•
•
•
•
•
•
Check voltage on bus bar
Set the “Fail to synchronize” parameter at 500s.
Start the generator in auto mode.
Check that you are now in synchronization mode using the information screen key [i].
Adjust the phase and frequency PID.
When the difference between phases is stable and near to 0°, measure the voltages (L1 L2 and
L3) directly on the circuit breaker between generator and bus bar.
When you are sure there is no wiring problem, stop the generator
Set the “Fail to synchronize” parameter according to the customer's request.
Connect the “E” connector
Start in automatic mode.
The generator must be paralleled in less than 10s.
Load sharing / kW regulation
•
For this application, check the stability of KW and kVAR regulation.
page 57/57
8 Predefined functions
Inputs/outputs are associated with functions. Some of these I/Os are dedicated, others are
programmable via parameters.
8.1
Water preheat / Pre-lubrication / Pre-glow functions
GENSYS
J6: Input 1: Preheating (2273)
J7: Input 2: Manual water preheat request (2224)
J8: Input 3: Manual oil prelub. request (2225)
Output 1: C1
J9: Input 4: Manual preglow request (2226)
Output 2: C2
J10: Input 5: Manual start request (2227)
Output 3: C3
F6 / F7
Pre heat
relay
Pre lubrication
relay
Pre glow
relay
F8 / F9
Water
temperature
sensor
Oil pressure
sensor
Output 1 function (1260) = Water preheats (2083)
Output 2 function (1261) = Pre lubrication (2084)
Output 3 function (1262) = Pre glow (2085)
Figure 30 - Connections for water preheat, pre lubrication and pre glow
Auto mode
Pre-heat is activated if J6 is closed and if temperature is under the pre-set threshold (E0030 < E1154).
Note: The water temperature sensor is required in this instance.
Pre-lubrication will be activated when engine is in pre-start (E2057 = 1) if pressure is under the
threshold (E0029 < E1155). If the threshold (E1155) is 0, then pre-lubrication is active while the engine
is in pre-start (E2057 = 1). In the last case the oil pressure sensor isn’t required.
Pre glow is active when engine state is pre glow or start (E2057 = 12 or 2).
Manual mode
Preheat will be activated when J7 is closed. The water temperature sensor isn’t required.
Pre lubrication will be activated when J8 is closed. The oil pressure sensor isn’t required.
Pre glow will be activated when J9 is closed, when you push GENSYS start button, or when J10 is
closed.
8.2
Crank / Fuel / Starter 2 / Starter 3 functions
If there is an external crank relay, you can use the crank function (E2018) on digital output. The
behaviour will be exactly the same as the crank relay output (terminal A1).
If there is an external fuel relay, you can use the fuel function (E2019) on a digital output. The
behaviour will be exactly the same as the fuel relay output (terminal A2).
For multiple starters (E1138 = 2 or 3), the outputs can be configured with the Starter 2 (E2267) and
Starter 3 (E2268) functions. The number of attempts (E1134) is the global number and not the number
of attempts per starter. For example:
•
•
•
•
•
the number of attempts (E1134) is 4
the default starter (E1602) is 2
the number of starters (E1138) is 3
output 1 (terminal C1) is configured as Starter 2 (E1260 = 2267)
output 2 (terminal C2) is configured as Starter 3 (E1261 = 2268)
page 58/58
Note:
8.3
Should the engine refuse to start, the sequence will be:
C1 activated, crank rest, C2 activated, crank rest, A1 activated, crank rest, C1 activated,
start failure.
Air fans
GENSYS
J5: water temp input
Output 1: C1
Air fan relay
F6 / F7
Water temperature
sensor
Output 1 function (1260) = Air fan (2215)
Figure 31 - Connection for air fans
In all cases, the air fans will be activated when J5 is activated or when the “max water temp” protection
(F6/F7 analogue input) is configured and triggers.
Auto mode
This output is activated if temperature is over the pre-set threshold (E1178) and de-activated when
water temperature is lower than 80% of the threshold. AIR FAN is not activated if engine is stopped
(E2057=0).
Manu mode
This output activated when the speed is other than 0.
8.4
Fuel filling / Coolant filling / Oil filling
GENSYS
J6: Input 1: Fuel low level (2230)
J7: Input 2: Fuel high level (2231)
J8: Input 3: Manu fuel fill (2252)
J9: Input 4: Coolant low level (2243)
J10: Input 5: Coolant high level (2244)
J11: Input 6: Man cool fill (2253)
J12: Input 7: oil low level (2246)
J13: Input 8: oil high level (2247)
J14: Input 9: Manu oil fill (2254)
F1/F2
F3/F4
Level sensor
Level sensor
Fuel fill relay
Output 1: C1
Output 2: C2
Output 3: C3
Coolant fill relay
Oil fill relay
Output 1 function (1260) = Fuel filling (2229)
Output 2 function (1261) = Coolant filling (2242)
Output 3 function (1262) = Oil filling (2245)
Figure 32 - Connections for filling
The 3 filling features all have exactly the same behaviour. Fuel filling will be described below. For the
other functions, fuel is to be replaced by coolant or oil and the variable number by the values shown in
the figure above.
page 59/59
Auto mode
Fuel filling
(2229)
Fuel high level
(2231)
Fuel low level
(2230)
Figure 33 - Fuel filling diagram
Note:
If the tank is fitted with a fuel level sender that can be connected to an analogue input
(F1/F2 or F3/F4), it is possible to calculate the fuel low/high limits using equations (see
application note Z090203). In this case, J6 and J7 connections are not needed.
Manu mode
Output is only activated when J8 is closed.
8.5
Configurable I/Os functions
8.5.1 Digital input functions
The digital input functions are distinguished between dedicated and configurable inputs.
For Digital inputs 1 to 10 [E2006,E2007,E2008,E2009,E2010,E2011,E2012,E2013,E2014,E2015] :
• Label
• Validity
• Direction
• Function
have to be defined. For dedicated inputs, only polarity is to be defined.
Input variables numbers: [E2000, E2001, E2002, E2003, E2004]
8.5.2 Configurable input label
This is the name you give to the input. The name will be displayed in the info, alarm, and fault screens
if so programmed.
8.5.3 Validity
Input validity variable numbers [E1287 to 1296] can be set as:
• Never: [E2329]: never active: should be selected if you do not use the input.
• Always: [E2330]: always active: input will be monitored as long as GENSYS has power.
• Post-Starting: [E2331] input will be monitored at the end of the "safety on" timer.
• Stabilized: input will be monitored when genset frequency and voltage have become stable.
• Spare scenario: [E2332]: input will be monitored as programmed in equations.
8.5.4 Input functions
Input function variable numbers: [E1267 to 1286] can be set as indicated in next table.
Unused [0] Should be selected if you do not use the input.
Used by equations [1] if the effect of input activation is not listed below, choose
"used by equations"
Manual water preheat request [E2224] Can be chosen if a coolant pre heating system is installed;
can be used in conjunction with digital transistor output. Will
only work in manual mode.
page 60/60
Manual oil prelub. request [E2225] Can be chosen if a pre lubrication pump is installed on the
engine; can be used in conjunction with digital transistor
output. Will only work in manual mode.
Manual preglow request [E2226] Can be chosen if pre heating plugs are installed on the
engine; can be used in conjunction with digital transistor
output. Will only work in manual mode.
Fault reset request [E2205] If an external reset is wired to the input, choose fault reset
request. This will have the same effect as pressing the reset
key on the GENSYS front panel on Faults and Alarms
displays.
Manual start request [E2227] To be selected if a remote start command in manual mode is
to be installed.
Manual stop request [E2228] To be selected if a remote stop command in manual mode is
to be installed - different from emergency stop.
Manual +f request [E2233] To be selected if a remote frequency increasing command is
to be installed.
Manual -f request [E2234] To be selected if a remote frequency decreasing command is
to be installed.
Manual +U request [E2235] To be selected if a remote voltage increasing command is to
be installed.
Manual -U request [E2236] To be selected if a remote voltage decreasing command is to
be installed.
Fuel high level [E2231] To be selected for a max level sensor or a calculation; can
be used in conjunction with digital transistor output.
Fuel low level [E2230] To be selected for a min level sensor or a calculation; can be
used in conjunction with digital transistor output.
Coolant high level [2244] To be selected for a max level sensor or a calculation; can
Coolant low level [E2243] To be selected for a min level sensor or a calculation; can be
Oil high level [E2247] To be selected for a max level sensor or a calculation; can
Oil low level [E2246] To be selected for a min level sensor or a calculation; can be
Securities inhibition [E2197] Will inhibit all protections. These alarms and faults remain
listed in the faults and alarm logging.
No cranking [E2198] To be selected to prevent engine from starting.
Ext. secu.(Hard shut down) [E2210] If external protections are installed, for immediate stop of the
engine. See recommendation in Directions paragraph.
Ext. fault(Soft shut down) [E2209] If external protections are installed, for immediate opening of
Genset breaker and stop of the engine after cooling down
timer has expired. See recommendation in Directions
paragraph.
External alarm [E2208] If external protections are installed, to report an alarm. See
recommendation in Directions paragraph.
Generator electrical fault [E2217] If external protections are installed, protection will open
genset breaker and try to synchronize again. See
page 61/61
Mains electrical fault [E2218] If external protections are installed, protection will open
mains breaker and try to synchronize again. See
Non essential trip alarm [E2681] Remote non essential load.
HELP + FAULT ( Soft shut down) To be selected to stop the engine after cool down. The
[E2736] GENSYS will ask another engine to start before stopping
itself
HELP + Gen Electrical Fault [E2737] To be selected to activate the "gen electrical fault" action.
The GENSYS will ask another engine to start before
stopping itself
Remote stop horn [E2655] To be selected to stop the external Horn. Useful if one output
is set as "Horn". To be used in conjunction with digital
outputs
Gen. breaker Close manual [E2336] To be selected if manual remote close button for genset
breaker is programmed.
Gen. breaker Open manual [E2337] To be selected if manual remote open button for genset
breaker is programmed
Mains breaker Close manual [E2338] To be selected if manual remote close button for mains
Mains breaker Open manual [E2339] To be selected if manual remote open button for mains
Generator breaker Aux [E2001] To be selected if a different input for the generator breaker
position is required.
Mains breaker Aux [E2000] To be selected if a different input for the mains breaker is
required.
Remote start [E2002] To be selected if a different input for remote start is required.
Oil pressure fault [E2003] To be selected if a different input for oil pressure fault is
required.
Water temperature fault [2004] To be selected if a different input for water temperature fault
is required.
Priority generator [E2241] To be selected if load/unload features depend on a priority
genset; see Configuration -> load / unload menu
Synchronization forced [E2257] Will force GENSYS to synchronize the output with the
governing system. AVR will act so as to synchronize the
genset. The “Power mode” (E2088) is forced to
Synchronization (1).
Fixed kW forced [E2258] Will force GENSYS to give constant power delivery. The
output governing system will maintain a fixed power output
from the genset. The “Power mode” (E2088) is forced to
Fixed kW (4).
kVAR sharing forced [E2259] The output to AVR will share reactive load with other
gensets, using the inter GENSYS CANbus. (E.g. to be used
in manual mode). The “AVR cont. mode” (E2090) is forced to
kVAR sharing (5).
Voltage Droop forced [E2656] Will force the GENSYS to apply Droop to the AVR command.
Set with [E1105]. The “AVR cont. mode” (E2090) is forced to
Voltage droop (1).
page 62/62
No manu mode [E2260] Will inhibit the "Manu" key on the GENSYS front panel.
GENSYS will never be in Manu mode even if you press the
GENSYS Manu key.
External manu mode request [E2261] Will put GENSYS into Manual mode. Will have the same
effect as the GENSYS "Manu" key.
Running with breaker open [E2661] Allow the engine to run in Auto mode without paralleling or
closing its breaker.
Select speed 2 [E2279] Will select the second speed set point.
Select volt 2 [E2280] Will select the second voltage set point.
Select KW 2 [E2281] Will select the second power output set point.
Select PNom 2 [E2513] Will select the second nominal power (active and reactive).
Preheating [E2273] Can be chosen if a coolant pre heating system is installed;
can be used in conjunction with a digital transistor output.
Will work in auto mode.
Manu fuel fill [E2252] To be selected for a manual fuel refill; to be used in
conjunction with digital outputs.
Man cool fill [E2253] To be selected for a manual coolant refill; to be used in
Manu oil fill [E2254] To be selected for a manual lubricant refill; to be used in
Heavy consumer request [E2766] To be selected to activate the "Heavy consumer control"
special sequence.
Table 18 - Input functions
8.5.5 Direction
Input direction variable numbers: [E1297 to 1306]
For each of the ten inputs, two options are possible:
• NO: [0] normally open; should be selected unless the input is used for protection.
• NC: [1] normally closed; should be selected if the input is normally connected to 0V and opens
when active.
8.5.6 Dedicated inputs
In the menu list, each input is named after its pin number on the wiring of GENSYS. Polarity can be
normally open or normally closed. Program this according to the wiring you will have on site.
As a reminder:
• J1 is the Mains breaker position
• J2 is the Genset breaker position
• J3 is the remote start input
• J4 is the oil pressure switch
• J5 is the coolant temperature switch.
[E2000, E2001, E2002, E2003, E2004]
8.6
Digital output functions
Outputs 1 to 5: [E1260,E1261,E1262,E1262,E1264], function and polarity have to be defined.
The "Crank" and "Fuel" relay outputs can be set up for other functions. The initial settings are for
"Crank" and "Fuel". Polarity cannot be changed for these relay outputs. "Crank" output function can be
set with [E1989]; Fuel output function is set with [E1916].
8.6.1 Output functions
Unused [0] To be selected if output is not wired.
Used by equations [1] To be selected if output is used by equations.
Water preheat [E2083] Can be used for coolant pre heat system.
page 63/63
Pre lubrication [E2084] Can be used for pre lubrication pump.
Pre glow [E2085] Can be used for cylinder pre heating plugs
Crank [E2018] Can be used for external crank relay
Fuel [E2019] Can be used for external fuel relay
Excitation [E2211] Can be used to activate an external AVR in a static
synchronizing configuration [see Configuration -> power
plant overview]
Will activate an external excitation relay when engine state
[E2057] is: engine ready [5]; generator ready [6]; wait after
stop request [7]; cool down [8]. In the case of dynamic
paralleling [E1177 = 0], the output will also be activated in
the start [2], warm up [3], and nominal speed [4] states.
Fuel (energize to stop) [E2212] Can be used for an external relay if fuel solenoid has to be
energized to stop the engine. Will activate an external fuel
relay [Energize to stop] when engine is running [E0033 > 0]
and if there is an engine fault [E2046] or a stop request. In
Manual mode the stop request will be the “Stop key” [E2047]
or the “Manual stop request” [E2228] or no fuel [E2019 off].
Generator breaker order [E2016] Can be used to open or close genset breaker.
Mains breaker order [E2017] The outputs configured with this function will have exactly the
same behaviour as the outputs for the Generator breaker [E4
to E6].
Alarms summary [E2202] Faults summary: will activate an output when there is at least
Faults summary [E2203] one “alarm” / “security” / “fault” / “gen. elec. fault” / “mains
Securities summary [E2204] elec. fault” triggered by GENSYS.
Gen. electrical faults summary [E2200]
Mains elec. faults summary [E2201]
Output will be activated whenever a protection triggers a
mains electrical fault.
Trip out 1 [E2724] Output activated by the protection in "Non essential
consumer trip" sequence. This is the first trip; Non Essential
consumer trip
consumer trip" sequence. This is the 2nd trip activated
[E1894] sec after the previous one. Non Essential consumer
trip
consumer trip" sequence. This is the 3rd trip activated
trip
consumer trip" sequence. This is the 4th trip activated
trip
consumer trip" sequence. This is the 5th trip activated
trip
Trip out direct [E2774] Output activated by the protection in "Non essential
consumer trip" sequence. This one is activated directly. Non
Essential consumer trip
page 64/64
Smoke limiter [E2213] Output to be used if external speed controller has smoke
limit input. Will activate an output upon start. In Manu mode,
when GENSYS start button is pressed or with a manual start
request. In Auto mode, when engine state [E2057] is “Start”
[2], “Warm up” [3] and “Nominal speed” [4].
Warm up [E2214] This output will activate when engine is warming up. Will
activate an output upon start. In Manu mode, when GENSYS
start button is pressed or with a manual start request and
while the warm up timer [E2061] is different from 0. In Auto
mode, when engine state [E2057] is “Start” [2] and “Warm
up” [3].
Horn [E2206] Can be used for external horn or flashing light relay; output
will activate whenever a protection triggers. The output will
have the same behaviour as the GENSYS front face LED. It
will be activated when a generator electrical fault [E2200],
mains electrical fault [E2201], alarm [E2202], fault [E2203] or
security [E2204] triggers, and while the GENSYS horn button
is pressed.
Air fans [E2215] To be wired to fan relay.
Generator breaker Close [E2219]
Generator breaker Open [E2221]
Mains breaker Close [E2220]
Mains breaker Open [E2222]
Can be used to close genset breaker [100 ms pulse]
Can be used to open genset breaker
Can be used to close mains breaker.
Can be used to open mains breaker.
Generates a 100ms pulse on the output, when
Generator/Mains breaker [E2016/E2017] wants to
close/open
Fuel filling [E2229] Can be used for an external fuel pump in conjunction with
"Fuel low level" and "Fuel high level" or "Manu fuel fill"
functions of spare digital inputs.
Coolant filling [E2242] Can be used for a compressor in conjunction with "Coolant
high level" and "Coolant low level" or "Manu air fill" functions
of spare digital inputs.
Oil filling [2245] Can be used for oil level filling in conjunction with "Oil high
level" and "Oil low level" or "Manu oil fill" functions attributed
to spare digital inputs.
+f [E2341]
-f [E2342]
+U [E2343]
-U [E2344]
The behaviour will change according to the mode. In Manual
mode, if you program the +f function, the output will be
activated when you press the GENSYS [+] key or if there is a
“Manual +f request” [E2233]. Likewise for the other functions;
-f activates with [-] key or “Manual –f request [E2234]; -f
activates with [+]+SHIFT keys or “Manual +U request
[E2235]; -f activates with [-]+SHIFT keys or “Manual –U
request [E2236]. In Auto mode, these functions will control a
speed / voltage regulator requiring +/- contacts. You can
configure the no action range for the speed [E1598] and for
the voltage [E1599], the impulsion delay for the speed
[E1600] and for the voltage [E1601].
Damper [E2223] Will activate in stop sequence to stop the engine when
damping flap is fitted. Will be activated when there is an
engine fault [2046].
Light test [E2232] This will activate the output whenever the light test key is
pressed on the front panel of GENSYS, or an input
programmed for light test is active
page 65/65
Generator ready [E2331] Output will be active when start sequence is completed and
voltage is present on the generator. In Auto mode, the output
will be activated when the engine state [E2057] is “Gen
ready” [6]. In Manu mode the output will be activated when
the speed [E0033] is positive.
Generator stopped [E2240] Output will be active when genset is at rest. In Auto mode,
the output will be activated when the engine state [E2057] is
“Waiting” [0]. In Manu mode the output will be activated when
there is no speed [E0033].
F1 key [E2262] These keys are useful in Manu mode to control the speed
Shift + F1 keys [E2263] and the voltage.
F2 key [E2264]
Shift + F2 keys [E2265]
Manu mode [E2056] Output will be active when GENSYS is in manual mode.
Starter 2 [E2267] Will be active when a second engine starting system is
present and programmed in Configuration -> Start sequence
menu.
Starter 3 [E2268] Will be active when a third engine starting system is present
and programmed in Configuration -> Start sequence menu.
Ana1 threshold [E2269] Output will be active when the measurement of analogue
input 1 [oil pressure] is under the set value; it will not deactivate until measurement is over [set value + hysteresis
value]. To be programmed and used with the following
parameters: “Oil threshold” [E1175], “Oil hysteresis” [E1176].
input 2 [water temperature] is over the set value; it will not
de-activate until measurement is under [set value minus
hysteresis value]. To be programmed and used with the
following parameters, “Wat temp thresh” [E1426], “Wat temp
hyst.” [E1427]
input 3 [1st spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 1 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 1 thresh.” [E1428], “Meas 1 hyst.” [E1429].
input 4 [2nd spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 2 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 2 thresh.” [E1430] and “Meas 2 hyst.” [E1431].
Available in Auto [E2525] Will activate when the genset has completed its start
sequence in auto mode - can be used for external logic. The
output will be activated when GENSYS is in Auto mode and
the power state [E2071] is not in fault [40, 100 or 255].
Heavy consumer authorization [E2767] Output activated when the heavy consumer starting is
allowed in the "Heavy consumer control" sequence.
8.6.2
page 66/66
Polarity
For each of the five outputs, two options are possible:
•
•
8.7
NE: normally energized; the output will de-energize when required, according to its function.
ND: normally de-energized; the output will energize when required.
Use spare analog input for digital input
8.7.1 Purpose:
Use spare analog inputs (spare 1 & 2, connections F1-F2 and F3-F4) as digital inputs.
In this case, GENSYS will have 12 digital inputs.
8.7.2 Configuration:
Spare analogue input calibration table should be set as shown below to mimic digital input.
For « Normally closed » or « normally opened » inputs, wiring will be similar, only the software
requires modification.
GENSYS
F1
F2
-BAT
8.7.3 Parameters:
Calibration table for a normally closed input:
V1210 0
N
Spare1 calib1
-32768
+32767
V1211 1
N
Spare1 calib2
-32768
+32767
V1212 1
N
Spare1 calib3
-32768
+32767
V1213 1
N
Spare1 calib4
-32768
+32767
V1214 1
N
Spare1 calib5
-32768
+32767
V1215 1
N
Spare1 calib6
-32768
+32767
V1216 1
N
Spare1 calib7
-32768
+32767
V1217 1
N
Spare1 calib8
-32768
+32767
V1218 1
N
Spare1 calib9
-32768
+32767
V1219 1
N
Spare1 calib10
-32768
+32767
V1220 1
N
Spare1 calib11
-32768
+32767
V1221 0
N
Spare1 res1
+00000
+10000
page 67/67
V1222 1000
N
Spare1 res2
+00000
+65535
V1223 2000
N
Spare1 res3
+00000
+65535
V1224 3000
N
Spare1 res4
+00000
+65535
V1225 4000
N
Spare1 res5
+00000
+65535
V1226 5000
N
Spare1 res6
+00000
+65535
V1227 6000
N
Spare1 res7
+00000
+65535
V1228 7000
N
Spare1 res8
+00000
+65535
V1229 8000
N
Spare1 res9
+00000
+65535
V1230 9000
N
Spare1 res10
+00000
+65535
V1231 10000
N
Spare1 res11
+00000
+10000
Then write these equations, to switch to virtual input :
@*********************************;
@analog input to DI/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1 ;
@*********************************;
E2283:= E0031 ;
For normaly opened input, calibration table is similar, you must only
change equation by :
@*********************************;
@entree analogique en TOR/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1;
@*********************************;
E2283:= !E0031 ;
NB: See files:
•
•
test_ana_NF.txt
test_ana_NO.txt
page 68/68
9 Special functions
9.1
Fuel crank relay function
9.1.1 Introduction
With software version 2.09d and later (3.03a for the Crank) it is possible to change this function and
create specific equations for the Fuel and Crank Relays.
This section describes the Custom behaviour of the Fuel and Crank Relays.
9.1.2 Configuration
For Fuel:
If E1916:= 0: The standard function applies, with E2019 to the A2 (fuel) output.
If E1916 := 2xxx: One can create a new equation and switch to the A2 (fuel) output. For this function,
write equations for the variable E2xxx.
For Crank:
If E1989:= 0: The standard function applies, with E2018 to the A1 (crank) output.
If E1989 := 2xxx: One can create a new equation and switch to the A1 (crank) output. For this function,
write equations for the variable E2xxx.
Example 1:
Use the Crank Output to indicate an engine fault.
E1989:= E2217
Example 2:
Create a pulse to the A2 output (fuel)
E1710 is the time of the pulse (100 = 10 seconds)
E1916:= 2440;
BLOC
@example to create a pulse to the output A2 (fuel) pulse ;
TEST E2450 EQ 0 THEN
TEST E2019 EQ 1 THEN E2450 := 1 TEND
ELIF E2450 EQ 1 THEN
TEST E2451 GT E1710 THEN
E2450 := 2
ELSE INC E2451
TEND
BLOC
E2451 :=0;
TEST E2019 EQ 0 THEN E2450 :=0 TEND
BEND
TEND;
E2440 := E2450 EQ 1
BEND
page 69/69
9.2
Load sharing using a central frequency (de-drooping)
9.2.1 Introduction
This section describes the GENSYS’ new load sharing function.
This modification appears in versions 2.09 and later.
It allows perfect load sharing at the right frequency even if the generators are not the same.
When several generators are on the bus bar, one takes a central role with a fixed frequency of 50Hz.
The other generators determine load sharing using an integral so that each one has a perfect share.
The set point of the central frequency is the parameter E1080 (or E1081 if selected).
When the GENSYS starts, one genset is elected to be the master (the first one on the bus). The
master determines the central frequency and load sharing is without an integral. The other gensets
determine the load sharing with an integral, but without using the central frequency.
When you are in state E2071=29 (several generators paralleled with mains), the central frequency is
disabled.
9.2.2 Procedure
1. Download firmware 2.09 or later.
2. In manual mode, using F1 and F2, adjust the speed control output (G9-G11) to obtain the desired
frequency +/-2Hz from each genset.
3. Test that load sharing is working properly (default values inhibit the integral).
4. Activation of frequency centre with genset 1:
In Configuration/modification by variable number adjust E1476 to 2.
In Configuration/Active power regulation menu:
kW sharing GPI
G = 50 %(E1102)
P = 5 %( E1900)
I = 2 %(E1901)
Central Hz gain
G = 25% (E1902)
5. Adjust genset speed to 49Hz on speed governor (GENSYS in manual mode without load).
6. Switch to TEST mode. When the breaker is closed speed should go back to 50.00Hz within 5
seconds. Adjust the Hz central gain (E1902) to adjust the time if needed.
7. Repeat step 6 for all gensets.
8. Test the load sharing by changing the nominal frequency of one generator to 49Hz.
-> bus frequency should remain at 50 Hz and kW load sharing within 2% of that desired. The stability
of load sharing is adjusted with kW sharing GPI / I (E1901)
Remarks:
E1902 = stability of de-drooping (only activated in the master GENSYS, e.g. the one which closes its
breaker first). Adjust to recover 1Hz within 5 sec.
E1476 = 0 Ù Inhibition of central frequency; factory setting.
E1476 = with a high value, response time will be slower (recommended default value =2)
E1901 = Load sharing integral, is only active on the slave GENSYS units.
E1102 = Global gain of load sharing is obtained by multiplying the PI and the central Hz gain.
E2739 = 1 Ù I am the master (I control the frequency).
E2739 = 0 Ù I am a slave (I share load using the integral)
page 70/70
9.2.3 GCR synchronization & mains paralleling
The following equations should be added in level 1 or 2 if the synchronization bus is used (terminal 42
of GCR, terminals G1 & G3 of GENSYS):
@ ******************************************************;
@ digital input 1 is closed during mains synchronization;
@ mains breaker feedback is connected to terminal J1
;
@ Don’t forget to allow parameter E1476 and E1020 to be ;
@ modifiable by modbus and equations
;
@*******************************************************;
TEST (E2006 EQ 1) AND (E2000 EQ 0) EQ 1 THEN
BLOC
E1476:=0;
E1020:=20000
BEND
ELSE
BLOC
E1476:=2;
E1020:=0
BEND
TEND;
9.2.4 INTEGRAL INHIBITION
To disable this type of load sharing and return to the factory setting, apply the “Disable value” from the
table below.
The variables involved in this new load sharing are:
Variable
number
Label
Description
Dedroop
value
Disable
value
V1900
Load sharing P
Parameter to set the Proportional gain.
5
1
V1901
Load sharing I
Parameter to set the Integral gain.
2
0
V1902
Hz centre gain
Parameter to control the central frequency, acting
as a frequency standard
25
0
V1476
XXXXXX
2
0
V2739
Master gen. Nb
not
used
not
used
If 1 this GENSYS is the master.
Warning:
When the CAN bus is not used, you have to disable load sharing (see table above).
In the case of a CAN bus failure where E1259 is not set at 6 (load sharing in droop
disabled), you also have to disable load sharing.
page 71/71
9.3
Pulse control calibration procedure
Procedure for calibrating the +Hz and –Hz outputs on the GENSYS in order to have good frequency
droop compensation and load sharing.
1.
Enter the following parameter in the information screen: E2058.
2.
Set the external speed potentiometer to its centre position.
3.
Set the following parameters:
•
•
•
•
•
•
E1598 on “50” which is about 1 percent load sharing difference (dead band on E2058)
E1600 on “2” which is 200 msec. pulse time
E1874 on 2,0 sec which is the pulse pause time for frequency/voltage compensation
E1873 on 0,1 sec which is the pulse length for frequency/voltage compensation.
E1309 on 0 which is the phase Integral gain.
E1113 on 0 which is Frequency Integral gain.
NB: For best results in sync it's important to set the GPID synch values high (80 to 200).
4.
Start the engine with GENSYS in manual mode.
5.
Engine should run near the nominal speed with deviation due to mechanical droop.
6.
Put engine in Automatic mode. In this case the GENSYS should control the output until it
is running at the nominal speed, if a difference is present.
7.
Set the frequency compensation for a recovery time of 10 sec for 0,5 Hz compensation
(E1874).
8.
If the generator is changing the speed but over- or undershoots the nominal speed the
length of the E1873 pulse is too long. Make it a little bit shorter.
9.
If it takes too long to reach the nominal speed the E1874 period is too long. Make this a
little bit shorter.
10.
If you are not able to get the right compensation than the following needs to be checked:
- Does the potentiometer still turn if the GENSYS is sending an output signal.
- If not, the potentiometer is not able to control a sufficient speed range.
11.
If each pulse causes overshooting it can be caused by the potentiometer motor running
on, even when the pulse is off. A shunt resistor over the motor input could solve this
problem.
12.
Load the generator in island operation and the GENSYS in automatic mode, if possible
with full load.
13.
Check if it still compensates the frequency according to the above specification (0,5 Hz in
10 sec).
14.
If this is OK the Frequency compensation is set. (Repeat for all available engines)
15.
Switch on one engine in auto mode and load it at 100 percent.
16.
Disconnect the output to close the generator breaker of the next engine.
17.
Start this engine in auto mode and wait until it shows in the information screen that it is
synchronizing. Simulate on the Generator aux input that the breaker is closed.
18.
In the information screen you should see that the unit is in Load sharing mode.
19.
Check the value of E2058: this should read as follows:
a. For the engine which is supplying the load, the value should be about – 6000.
b. For the engine which is not supplying the load, the value should be about + 6000.
20.
If this value is lower than + 6000 or higher than – 6000 you have to increase the Load
sharing Gain.
21.
If this value is higher than + 6000 or lower than – 6000 you have to decrease the Load
sharing Gain.
22.
If you are still not able to reach this value you can do the following:
page 72/72
•
•
Reduce the value of the load sharing 3 times.
Set parameter E1473 to “1” instead of “3”, which makes the value of the Load sharing Gain 3
times stronger.
Repeat from step 19.
The same procedure has to be used for the calibration of the voltage control.
•
•
•
•
E1599 No action window +U/-U (in %), default value = 50
E1601 Impulsion delay +U/-U, default value = 2 (200ms)
E1874 on 2 sec which is the pulse pause time for frequency/voltage compensation, this
parameter was adjusted for the speed control, do not modify.
E1873 on 0,1 sec which is the pulse length for frequency/voltage compensation, this
parameter was adjusted for the speed control, do not modify.
E2058
Load sharing / Synchro pulses only
GENSYS wants the genset to go faster
Maxi(+Hz) = +7000
E1598 = DEADBAND
Maxi( –Hz) = -7000
GENSYS wants the genset to go slower
E1600
E2342
= pulse -Hz
T=700/E2058 seconds
E2341
= pulse +Hz
Frequency center pulses only
Frequency Hz=E0020
GENSYS wants the genset to go slower
DEADBAND=0.1Hz
GENSYS wants the
genset to go faster
E1873
E2342
= pulse -Hz
E1874
E2341
= pulse +Hz
E1873
E1874
Somation of both signals
E2342
= pulse -Hz
E1873
E1874
E2341
= pulse +Hz
E1873
Figure 34 - Speed and voltage control with Contact / Pulses (1)
GENSYS
K1
K4
C4
K4
Lower Volt
K3
K3
Raise Volt
K2
C3
Raise Hz
K1
C2
Lower Hz
C1
K2
Figure 35 - Speed and voltage control with Contact / Pulses (2)
page 73/73
9.3.1 Parameters
Parameter
Value
Description
Menu
E1260
+f [E2341]
Output C1
Configuration/Transistor digital outputs
E1261
-f [E2342]
Output C2
E1262
+U [2343]
Output C3
E1263
-U [2344]
Output C4
9.4
Operator controlled return of mains
Explanation:
Normal operation: In the case of mains failure, the engine starts and takes the load. When the mains
voltage returns, the engine resynchronizes with the mains and automatically gives back the load.
The “Operator controlled return to mains” special function (set with the parameter E1620 = 1) allows
the operator to control the moment the engine will return the load to the mains.
The GENSYS waits for E2584 = 1 (Virtual input 40) before re-synchronizing the engine to the mains.
How to set this function:
The E1620 variable must be set to 1.
The Virtual Input 40 must be set as “used by equations” (E1699=1)
This virtual input can be associated to:
•
•
•
a digital input: Ex: E2584= E2006;
a Wago deported digital input : Ex: E2584:= E0158;
an equation result:
E2584 := ( E2440 GT 1000) AND ( E2006 EQ 1)
Summary:
•
•
•
E1620 = 1.
E2854 = Virtual Input 40 to allow the genset to return the load to the mains.
E1699 = 1 : (E2584 ( VI 40) is “used by the equations)
Variables used
E1620
Inhibition of Variable 13= Operator return Mains ( + E2584)
E2584
Virtual input Spare 40
E1699
Virtual Input 40 associated function.
9.5
Mains & Generator electrical fault options
Mains electrical fault management
Parameters (default value in bold):
E1846: Open breaker: selects the breaker that will be opened upon a "Mains electrical fault". Choose
between the "Mains" breaker or the "Generator" breaker or "both".
E1841: Fault start: allows the engine to start upon a "Mains electrical fault". You can select "Yes" to
start the engine or "No".
E1840: Start delay (0.0): is the delay between the "Mains electrical fault" and the engine start. It will
delay a digital or virtual input. In the case of an internal detection, this delay bypasses the delay of the
protection.
E1842: No load delay (60.0): is the time for which the engine runs without load when the generator
breaker is opened. If the delay is 0, the generator will never stop.
page 74/74
Default configuration
Start on fault and open generator on fault
This parameter is useful in permanent mains paralleling mode with "open generator breaker on mains
failure". It can be used if the generator nominal power is not high enough to take the load in island
mode.
In this case, the generator will provide power, but if there is a mains failure the generator will not take
the load alone, and opens its breaker.
In case the setup of the unit does not generate an engine start upon mains failure, it will run with no
load and stop after a preset time (E1842).
Generator electrical fault
Parameters (default value in bold):
E1843: TM re-synch. (30.0): the delay before the generator tries to re-synchronize with the Mains after
a "Generator electrical fault".
E1844: Nb re-synch. (3): number of attempts to re-synchronize.
In the case of a generator electrical fault, the generator breaker is opened and the GENSYS is in state
40. In this state, the alternator is de-excited (if wired) during a timer (E1265). After this timer, if the fault
is still present, there is a hard shutdown. Otherwise GENSYS will try to re-synchronize.
Configuration : Change over with one digital input programmed
in "Mains electrical fault"
When Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Voltage bus
presence E2054
Start sequence
Timer before start on
Mains back timer
Production
request E2072
page 75/75
Configuration : permanent mains paralleling with one digital
input programmed in "Mains electrical fault"
Breaker openned on Mains electrical fault is Mains
Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back Synchronization
timer
Production
request E2072
Breaker openned on Mains electrical fault is Generator
Start on Mains electrical fault is No
Remote start is always On
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back
timer
Synchronization
No load
running timer
Mains back timer
Production
request E2072
page 76/76
Breaker openned on Mains electrical fault is Generator
Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back
timer
Synchronization
No load
running timer
Mains back timer
Production
request E2072
Permanent Mains paralleling and
generator electrical fault
Power state
E2071 ParalleledFaultSync Paralleled
Fault Sync ParalleledFault Sync ParalleledFault Sync ParalleledFault Stop
Generator CB
E2001
Generator electrical
fault E2200
Number of resynchronization
attempt = 3
Delay before resynchronization
Delay before reset of the
number of re-synchronization
attempt
0
1
0
1
2
3
4
0
NOTE :
Never use “No start on fault” in conjunction with "open mains on fault" in permanent
mode or no break change over mode.
Always use “No start on fault” when "generator breaker" or "both breakers" to open is
selected.
9.6
GENSYS with external automatic start module
9.6.1 Overview
This chapter describes how to interface the GENSYS with an engine which has got its own automatic
start module. The start sequence is redundant in the system. The following diagram shows the main
functions of each device:
page 77/77
Remote start
Auto Start
Module
GENSYS
Start request
Start sequence
Engine
protections
Crank
Generator ready
Engine alarm
Engine fault
Synchronisation
Electrical protections
GE breaker control
PF control
kW control
Monitoring
Mains/Bus voltage
Oil pressure
Water temp
Pickup
Governor
3*U
AVR
3*I
Engine
M
Figure 36 - Wiring GENSYS with Auto Start Module
Signal description
Direction
Auto Start Module (ASM)
GENSYS
Start request
GENSYS->ASM
Remote start input
C5
Genset ready
ASM->GENSYS
Digital output
J15
Engine Alarm
ASM->GENSYS
Digital output
J7
Engine Fault
ASM->GENSYS
Digital output
J6
Table 19 - Wiring GENSYS Ù Auto Start Module
GENSYS does not need oil pressure and water temp digital inputs. This table is shown as an example
only and can be customized as needed.
Specific parameters & equations to enter into the GENSYS:
1. To inhibit the auto start sequence of the GENSYS you need to set 1608 = 1. You will also find this
parameter in the example of text file:
V1608 1
Inhibit var 1
+00000
+65535
2. To accept the “Generator OK” input you need to add the following equation in level 1.
E2515 := E2015;
If your Auto Start Module only has an “Engine start” output (activated when crank disconnect set point
is reached), add an external delay timer or enter the following equation:
E2515 := E2015 AND ((E0033 GT (E1080*95/100)) OR E2515);
E0033 is the speed and E1080 is the “Speed setpoint 1”.
3. To set output C5 as a “Start request” you need to add the following equation in level 1:
E2024 := (!E2005) AND (!E2046) AND ((E2056 AND (E2045 OR E2227 OR
E2024) AND (!E2047) AND (!E2228)) OR (E2055 AND E2059));
4. To display the Engine Fault set the GENSYS' digital input 2 as an alarm.
5. To open the breaker upon an engine fault, set GENSYS digital input 1 as a hard shut down.
page 78/78
The following text file is the text file of an application tested on site:
Power plant example:
One single genset (1800 RPM) in parallel with mains in base load mode.
Emergency start.
Manual breaker on the mains side.
Motorized breaker on generator side.
Auto Start Module has a generator ready output.
Copy the following text and paste it in a new text file only.
You can download it to a GENSYS (level 1) as a starting point before commissioning.
CAUTION: this file is only a guide and is not enough to start a new application.
{PARAMETERS}
V1080 1800
Speed 1
+00000
+65535
V1081 1800
Speed 2
+00000
+65535
V1608 1
Inhibit var 1
+00000
+65535
{INIT L1}
@ WARNING : if section empty or missing, existing equations will be lost.
{EQUATIONS L1(every 100ms)}
@ WARNING : if section empty or missing, existing equations will be lost.
PROG 1
BLOC
E2515 := E2015;
E2024 := (!E2005) AND (!E2046) AND ((E2056 AND (E2045 OR E2227
OR E2024) AND (!E2047) AND (!E2228)) OR (E2055 AND E2059))
BEND
.
{END OF FILE}
9.7
Remote start upon external pulse
To set the GENSYS to start upon an external pulse input, 2 solutions can be used:
-Use a relay
-Set an external input
9.7.1 Setting external input
This variable E2514 (Virtual Start) must be maintained at « 1 » after the first rising edge and
go to 0 after the second rising edge.
Example is for the J10 input:
@ WARNING : if section empty or missing, existing equations will be lost;
PROG 1
BLOC
page 79/79
@@@@ PULSE ON REMOTE START FROM EXTERNAL
@@@@;
@ E2585 = Value of the E2015 with one cycle less to detect a pulse;
@ ( E2015 EQ 1) AND (E2585 EQ 0) Detection of a top pulse;
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@;
E2585:=E2015;
E2514:=((E2514 OR ((E2015 EQ 1) AND (E2585 EQ 0))) AND ((E2514 AND
((E2015 EQ 1) AND (E2585 EQ 0))) EQ 0))
BEND
.
Don’t forget to set the input
V1276 1
N
DI10 function
+00000
+02999
Here the variable E2585 detects a rising edge on E2815.
The cycle or the variable E2815 goes from 0 to 1. The variable E2585 stays at 0 a cycle longer in
order to see E2815 =1 and detect the rising edge.
You can also detect the falling edge by changing the equation:
(E2815 EQ 1) AND (E2585 EQ 0) to (E2815 EQ 0) AND (E2585 EQ 1).
9.8
Safety Inhibitions
9.8.1 Objective
Safety inhibitions are mandatory on certain types of application, particularly in safety generators used
in public spaces (norm NF E 37-312).
The aim is to inhibit the oil pressure and water temperature safeties on the GENSYS. Thus, in the
case of a fault, the generator remains in operation. Other protections (over speed, overload, etc...) are
still active if set.
9.8.2 Configuration
Note: If E2197 is active, there will never be a Generator electrical fault (E2046).
Hardware:
Contacts for oil pressure and water temperature are no longer connected to J4 and J5 but to spare
configurable inputs.
In this example, the oil pressure and water temperature contacts are on J13 and J14.
Software:
The following equations must be downloaded to level 1 or 2
BLOC
@***************************************************************;
@Inhibition de la pression d'huile et de la temp eau
;
@***************************************************************;
@E2011 Entree logique 6 GENSYS inhibition securite
@E2012 entree spare 8 J13 pression d huile
;
;
page 80/80
@E2013 entree spare 9 J14 temperature eau
;
@E1274 fct entree spare 8
;
@E1275 fct entree spare 9
;
@E0033 vitesse
;
@E1712 param utilisateur: seuil de vitesse demarrage
;
@E1714 param utilisateur: seuil de vitesse arret
;
@E1456 Sens pression dhuile
;
@E1457 Sens temperature eau
;
@E2283 entree virtuelle 1 alarme inhibition
;
@***************************************************************;
BLOC
E1457:=0;
E2283:=1;
E1275:=2208;
TEST E0033 GT E1712 THEN E1456:=0
ELIF E0033 LE E1714 THEN E1456:=1
TEND;
E1274:=2208
BEND
ELSE
BLOC
E1456:=E2012;
E1457:=!E2013;
E2283:=0;
E1274:=1;
E1275:=1
BEND
TEND
BEND
page 81/81
9.9
GENSYS with 500Hz PWM (Cat/Perkins)
9.9.1 Schematic
Actuator +
K4
Actuator -
K5
AVR out +
AVR out Shield 1
H2 H4 H3
Gen L1
B2 B3 B4 B1
A3
Emergency
stop
A1
Crank
relais out
A2
Fuel
relay out
OR
K2
Power supply +
See note 4
Shield
G10
power supply -
Pickup input
F
Battery
K3
-
G8 G7
Chassis
isolated from
power supply
-Alim
See note 1
Pickup -
Pickup +
F
G
AVR
See note 5
+Alim
Surge
diverter
FUEL
Speed
regulator
+
CRANK
L1
L3
D2
Gen I1-
L2
D3
Gen I1+
D1
1-5A
Output 2
P1
P2
- Alim
Utility
J9
Input 5
J10
Input 6
J11
Input 7
J12
Input 8
J13
Input 9
J14
Input 10
J15
See note 3
J8
Input 4
L1
J7
Input 3
- Alim
J6
Input 2
Mains
Input 1
L3
F
Water temp
J5
1 - NC
2 - Tx
3 - Rx
4 - DTR
5 - 0V
6 - DSR
7 - RTS
8 - CTS
9 - RI
DB9 female
RS 232
RS232 to PC or
modem
Oil pressure
J4
1 - NC
2 - CANL
3 - 0V
4 - NC
5 - 0V
6 - 0V
7 - CANH
8 - NC
9 - NC
DB9 male
CAN 2
CAN 2 to
options
J3
1 - NC
2 - CANL
3 - 0V
4 - NC
5 - 0V
6 - 0V
7 - CANH
8 - NC
9 - NC
DB9 male
CAN 1
See note 6
CAN1 to
other GENSYS
J2
1 - NC
2 - NC
3 - 0V
4 - 0V
5 - B (-)
6 - A (+)
7 - NC
8 - NC
9 - 0V
DB9 male
RS 485
MODBUS
Gen Breaker IN
Remote start/stop
P2
F
Surge
diverter
Mains breaker IN
J1
See note 6
Parallel lines to
GCR or BC analog
load sharing
Parallel +
Connected to the
bus bar when
several generators
Mains L1
100 - 480 V
B6 B5
Mains L3
- Alim P1
Mains I1 -
D7
G4
Parallel -
D8
G5 G6
Shield
+/- 20mA or +/- 10V
Mains I1 +
See note 2
G1
0-20mA +
0-20mA -
GENSYS
G2 G3
See note 2
Shield
Mains Breaker NC
S2
F4
Engine meas. 2 +
Mains common
Mains Breaker NO
S1
F3
Engine meas. 2 -
S2
F2
Engine meas. +
E1
F1
Engine meas. 1 -
E2
F7
Water temp meas +
Gen Breaker NC
E3
F6
Water temp meas. -
E4
F9
Oil pressure meas. +
Gen common
Gen Breaker NO
E5
F8
Oil pressure meas. -
E6
F5
Shield
+Alim
C5
Output 5
P2 S1
S2
C4
Output 4
P1
Output 3
P2 S1
S2
C3
Always present
Not required
See note 7
Synchronisation input
from GCR for several
generators
Mains power for single
generator
P1
D4
Gen I2-
N S1
D5
Gen I2+
F
D6
C2
Gen 3-
F
C1
Gen N
Gen I3+
F
Gen L3
100 - 480 V
Gen L2
Output 1
Note 1: If a speed governor is used, connect the battery negative to the speed governor and connect
“Power supply –“(K3) to the speed governor. Otherwise, connect directly to the battery. Always use
4mm² wires.
page 82/82
Note 2: For a peak shaving application, a mains power measurement is required. This can be done
internally via the Mains current input (D7/D8), or externally, if you use an external power measurement
such as a CPA connected to the “0-20 mA input” (G1/G3). You have to choose one of the two
measurements and you can disconnect the other.
Note 3: “Mains breaker in” (J1) is useless in the following cases:
- Several generators with no voltage regulator.
- Generator alone on the utility.
- In “No change over” mode.
Note 4: If the speed measurement is taken from a magnetic pick up, then “Pickup-“ (G7), “Pickup+”
(G8) and “Shield” (G2, G5 or G10) are required. You can also measure the speed from the alternator
frequency, but magnetic pick-up is recommended.
Note 5: Only if an AVR is used for kVAR sharing and cosφ regulation, but not necessary.
Note 6: For load sharing communication lines are necessary. If you use only GENSYS, the COM2 is
required. If there is another module using analogue load sharing, parallel lines (G4/G6) are required.
Note 7: In several generators mode, an external synchronization module (such as GCR) is necessary
for synchronization with mains.
9.9.2 Configuration
The GENSYS has to be ordered with the modification number A40M090.
Variable number
Label
Value
Description
E1639
500 Hz ACT
1
Activates the speed control with 500Hz PWM. In this mode
the analogue speed output (G9 / G11) is unavailable.
E1077
ESG offset
70%
Is the PWM for nominal frequency. If 50.00% is set, the PWM
will be 50%.
E1076
ESG
amplitude
30%
Is the range of PWM. For example, if you have set 20.0%, the
PWM will vary +/- 10%.
Offset = 70%
Amplitude = 30%
PWM (%)
100
85
70
55
Min correction
0
Max correction
Deviation
(E2058)
Figure 37 – PWM dynamic diagram
page 83/83
GENSYS with BSM II
Schematic
BSM II
5 CANH ; 7 CAN L
+ R 120Ohms
GENSYS
CAN2(COM3)
A40W2
Figure 38 - Schematic
Note 1:
An A40W2 cable (a CRE product) is recommended to connect GENSYS to BSM II.
Connect “CAN H” (terminal 5) of BSM II to the Blue/white striped wire and connect “CAN
L“(terminal 7) of BSM II to White/Blue striped wire.
Note 2:
If BSM II is at the end of the CAN bus, add one 120Ω resistor in parallel with terminals 5
and 7.
9.9.3 Configuration
The communication between GENSYS and BSM II uses CANopen protocol. BSM II is a slave unit and
GENSYS is a master unit.
GENSYS can be connected to several devices by its COM3 port: BSM II (Max 2), Wago© coupler
(Max 32).
Only one of the two BSM II must be set to archive data from GENSYS (limited by the number of
message sent from GENSYS).
9.9.4 Standard procedure
This example allows you to log the most significant variables of your application when an alarm
occurs.
See also the application note “A43Z090100A” to configure the BSM II logging.
• Download the text file (level 1 equation) “Z090211a_1.txt” to the GENSYS.
• Download the text file (level 1 equation) “A43Z090100a_1.txt” to the BSM II.
Archiving of data begins immediately.
Variables are stored in the BSM II when an alarm occurs:
• 1 sample per second
• 5 samples before the alarm
• 1 sample when alarm occurs
• 5 samples after the alarm
See the application note “A43Z090100A” to retrieve archives from the BSM II.
Note 1:
in this configuration, the BSM II node ID is equal to 1. Be careful that any other device on
the CAN bus has the same node ID.
Note 2: Variable transmitted
AO
1
2
Var.
Alarm
E0516
kW
mains
AO
5
6
E0036
3
Hz
mains
7
E0023
4
U13
Var.
kW GE
E0018
Hz GE
E0020
cosϕ
GE
AO
9
10
11
E0021
8
Sum
12
Var.
V1
E0000
V2
E0001
V3
E0002
I1
AO
13
14
15
16
Var.
I2
E0007
I3
E0008
kW1
E0009
kW2
AO
17
18
Var.
kW3
E0011
PwrMngt
Status
AO
Var.
21
Free
22
Free
23
Free
24
Free
E2071
19
Engine
Status
E2057
20
free
page 84/84
mains
Digital
E0006
E0010
E0022
Sum Digital = each digital variable is equal to one bit.
•
•
•
•
Bit0 = breaker in mains (E2000)
Bit1 = breaker in GE (E2001)
Bit2 Æ Bit14 : free
Bit15: forbidden
9.9.5 Custom procedure
This procedure shows you how to customize equations to send your own variables to the BSM II.
See also the application note “A43Z090101A” to customize the BSM II archiving.
Download the text file (level 1 equation) “Z090211a_1.txt” to the GENSYS.
Download the text file (level 1 equation) “A43Z090100a_1.txt” to the BSM II.
Customisation: see notes below.
Note1:
Change the Node ID of BSM II
See BSM II user's manual to choose the node ID in the BSM II.
Then change this Node ID in the settings of the GENSYS (default ID equal 1):
-Go to CANopen menu: configuration / << / CANopen
-In each input/output message used, change "Mod. ID" to the correct value.
Note2:
Delete message
If you do not need to send all variables set in default equations, you can delete output
messages.
Go to CANopen menu: configuration / << / CANopen / Output message
Change “Typ. Out mess” to UNUSED to remove the message
Change “Mod. ID” to 0
Note3:
Add message
Each message sends a maximum of 4 Analogue values to BSM II.
Go to CANopen menu: configuration / << / CANopen / Output message
Set "Mod. ID" to the correct Node ID of the BSM II.
Set “Typ. Out mess” to ANALOG
Set “Nb of Outputs” (Max 4)
Add equations as described below:
All variables are transferred as analogue outputs from GENSYS to BSM II.
Analogue output
GENSYS Variable
AO1 Æ AO8
E2432 Æ E2439
AO9 Æ AO16
E2682 Æ E2689
AO17 Æ AO32
E2708 Æ E2723
All variables are transferred as analogue inputs from BSM II to GENSYS.
Analogue input
GENSYS Variable
AI1 Æ AI44
E0285 Æ E0328
page 85/85
To transfer a variable from GENSYS to BSM II, write the equation below in level 1:
Example:
@ Allocate AO1 (E2432) to the measure of kW (E0018)
E2432:=E0018;
Transfer several digital variables (max 15) in one analogue output.
Each bit of the AO is equal to a digital variable.
Example:
@ allocate AO8 to digital outputs
@Breaker mains(b6) + 6 Digital Outputs(DO6=b5 -> DO1=b0);
E2439:= 0;
E2439:= X2439 + (64*E2000) + (32*E2445) + (16*E2444) + (8*E2443) +
(4*E2442) + (2*E2441) + E2440;
Note:
In the PLC equation, variables are considered as signed integers. This means that bit 31
is the sign and cannot be used.
9.10 GENSYS with Carantec
9.10.1 Wiring parallel lines:
Carantec
Gensys
Parrallel lines +
G6
13
Parrallel lines +
Parrallel lines -
G4
44
Parrallel lines -
9.10.2 Configuration of GENSYS
Change the next parameter in the PLANT/CONFIGURATION menu:
Compatible ILS 1158= YES (0)
Gest Dead bus 1515= NON (1)
9.11 GENSYS with TEM compact
This chapter describes how to interface the GENSYS with the TEM compact from Deutz Engines.
The association of the TEM and the GENSYS is an excellent solution to parallel a generator set with a
Deutz Engine prime mover.
Some functions are redundant: the kW regulation and the start sequence. The following diagram
shows the main function of each device:
page 86/86
Remote start
TEM
Start sequence
Engine
protections
KW control
Gaz protections
Actual
kW
kW
demand
Remote
I/O
GENSYS
Synchronisation
Electrical protections
kW measurement
GE breaker control
PF control
Can
Open
2* 0-20mA
outputs
Mains voltage
Start request
+ Hz
-Hz
Generator ready
Engine alarmt
Engine fault
3*U
AVR
3*I
Deutz gaz
engine
M
Figure 39 - Wiring GENSYS Ù TEM
Signal
description
Remark
Direction
Start request
used only if the kW set
point is in the TEM
GENSYS->TEM
kW demand
0-20mA
Used to start/stop and to
fix the kW set point.
GENSYS/Wago
->TEM
Genset ready
TEM Compact GENSYS / Wago
X141-4 X142-4
C5
Wago output 2
TEM->GENSYS
X31-5
X31-6
J15
TEM Alarm
Relay
TEM->GENSYS
X31-1
X31-2
J7
TEM Fault
Relay
TEM->GENSYS
X31-3
X31-4
J6
+ Hz
Digital signal
GENSYS->TEM
X141-6
X142-6
C1
- Hz
Digital signal
GENSYS->TEM
X141-7
X142-7
C2
G7 – G8
Pickup
Analog AVR
signal
Actual kW
0-20mA
AVR=MX321
GENSYS->AVR
H2 – H4
GENSYS -> TEM
Wago output 1
Table 20 - Wiring GENSYS Ù TEM
The following text file is the text file of an application tested on site:
Power plant:
•
•
•
•
One single genset in parallel with mains in base load mode.
No emergency start.
Manual breaker on the mains side.
Motorized breaker on generator side.
page 87/87
Generator set:
Engine:
• DEUTZ TBG 616V12K,
• 450/525kW 1800RPM.
• TEM COMPACT engine management system
Generator:
• Newage/Stanford 1800RPM,
• 480/277V, 910kVA
• AVR MX321
Power management:
•
•
GENSYS (CRE), Soft V1.25
Remote analog I/O 0-20mA (Wago)
Copy the downloadable text file from the website and paste it in a new text only file. You can download
it to a GENSYS as a starting point before commissioning. This file is only a guide and is not enough to
start a new application.
9.12 Under voltage trip coil
Equation for under voltage trip coil:
Example (two different ways):
@***************************************************************;
@Bobine à manque
;
@***************************************************************;
@E2020 Digital output
@E2016 Command Output
;
breaker GE
@E2001 Gen breaker in
;
;
@***************************************************************;
BLOC
TEST (E2001) AND (E2016) EQ 1 THEN E2470:=1 TEND
BEND
BLOC
TEST E2016 EQ 0 THEN E2470:=2 TEND
BEND
BLOC
TEST E2001 EQ 0 THEN E2470:=0 TEND
BEND
TEND;
E2020:=!(E2470 EQ 2);
Or:
E2020:=!((!E2016) AND E2001);
page 88/88
9.13 Level -1 (G59 & counters)
The end user can access limited parameters without using the level 1 password.
To activate the level 1 password menu, you have to connect in level 2, enter the “System” menu, and
then go to “level-1 password menu”.
Then set 1610 to the menu you want (None, G59 or Meter Pres).
Press [ENTER]
Don’t forget to save the settings on the GENSYS by pressing [SHIFT] + [ i ]
In this menu, you can also change the custom password. The default password is “CustMenu”.
Now, you can only access the specific menu and its parameters by inserting the custom password in
the password menu.
Specific applications
Meters preset
With this option you can set all the counters, and not only reset them.
Don’t forget to save the settings on the GENSYS [SHIFT] + [ i ].
G59 option
G59 is a protection norm widely used in the UK.
You can set and lock the following protections:
Mains Under / Over frequency
Mains Under / Over voltage
Vector surge
ROCOF (df/dt)
When the protections are locked, thresholds, timers and controls are also locked.
You can also change the custom password to an official application.
Don’t forget to save the settings on the GENSYS [SHIFT] + [ i ]
9.14 Scada
GENSYS communication uses industrial standards. This product is versatile, and can be used with
Modbus, for example to be controlled by a SCADA system.
CRE Technology offers different solutions for such applications (remote display, remote control, event
and alarm management …). Contact us for more information.
9.15 How to set a GPID
9.15.1 Principle
A GPID allows the control of any system in a simple way. Figure 38 shows a typical GPID.
P
Set
point
+
G
Deviation
I
Measure
D
G: global gain
P: proportional gain
I: integral gain
D: derivative gain
Figure 40 - Typical GPID controller
page 89/89
The G parameter acts as sensitivity adjustment for the other parameters.
The P parameter adjusts the rise time (time needed for the system to reach its set point for the first
time). By increasing P, the rise time will decrease. However, overshoot will increase and may also
render the system unstable (fast hunting). Using only the P factor will always leave a difference
between the set point and the actual value (this difference is also called droop).
The I parameter reduces the difference between the set point and the actual value. By increasing I,
the rise time will decrease. However, overshoot will increase and may also render the system unstable
(slow hunting).
The D parameter increases the stability and minimizes the overshoot phenomena. By increasing D,
overshoot will decrease but the system may still be unstable, particularly if the measured signal is
disturbed (sensor signal not filtered).
9.15.2 Empirical method settings
First set G to 50%.
Set the parameters P, I and D to zero.
Increase the value of P until the system becomes unstable. From this position, decrease the value of P
to 60% of the previous value.
Set I in the same way.
Increase D if the system is unstable upon fast load variation.
If stability cannot be achieved, restart the settings and reduce (system unstable) or increase (system
too slow) G.
9.16 Automatic load / unload
This function automatically controls the start and stopping of several generators of a power plant
depending on the load request, whether paralleling with the mains or not. Coordination with the other
GENSYS units is via the CAN bus (COM2).
Required configuration to allow automatic load / unload:
-All the remote start inputs must be on, on each GENSYS (connected to 0V).
-At least 2 generators must have GENSYS units.
-The "Load/Unl. Mode" (E1258) variable should be set to "Hours run" or "Digital in", which sets the
priority generator.
-If remote start is off, the generator never starts.
A generator can run in "Forced running" mode using a digital input. Select a digital input with the
function "Priority generator". Activate this input. The generator starts, synchronizes, closes its breaker
and stays on the bus bar until "Remote start/stop" is de-activated.
If there are no generators in "Forced running" mode, the priority generator with "remote start" always
starts and closes its breaker on the bus bar, even if there is no load.
When all generators are stopped and have "remote start" activated, upon start-up the "Forced
running"" generators stay on the bus bar while the others coordinate stopping one by one.
How to determine the priority generator (which starts/stops) by using the variable "Load/Unl. mode"
(E1258):
-"Hours run" selected: the generator which has the least running hours has the priority to start, the
generator which has the most running hours has the priority to stop.
-"Digital in" selected: the generators start following a logical sequence ("Gen. number": E1179),
starting from the generator which is in "Forced running" mode (as shown below).
Note:
To force the start of a generator in load / unload mode, during commissioning for example, remote
start and digital input (in "Priority generator" mode) must be activated.
In "Hour run" mode, if a generator starts and goes past the hours run by a generator which is stopped,
the first one does not immediately stop and the second one immediately start. Coordination between
generators is activated only during a load or unload request, i.e. in the next start/stop on load request.
During a load request, only the stopped and available generators coordinate (auto mode selected; no
hard fault).
During an unload request, only the started generators coordinate.
GENSYS units in manual mode do not take part in start or load sequence.
page 90/90
10 GENSYS PLC
10.1 Introduction
The core system of the GENSYS is based on a list of predefined variables.
The file named “40 Z0 9 0030.xls” gives an explanation of each of them.
The variable number always uses the same format.
The first digit is the type of variable:
• 0 Measurement or real time value (Ex: Voltage phase 1, CAN Bus Fault …)
• 1 Parameter to be stored in non-volatile memory (Ex: Genset number, Nominal power …)
• 2 General purpose variable (Ex: Alarms, PLC variables …)
•
The next 3 digits are the number of the variable.
All the parameters (Variable from 1000 to 1999) of the GENSYS are stored in a non-volatile FLASH
memory in the module. It is possible to download or upload these parameters with a computer allowing
the user to save, modify and reuse these parameters later.
All these values are stored in a text file. The following chapter describes the layout of that file.
10.2 File description
The text file is composed of 5 parts:
•
•
•
•
•
Parameter definitions
Label definitions
Unit definitions
Initialization definitions
Equation definitions
10.3 Parameter definition block
The starting point of this block is designated by a "{PARAMETERS}" statement.
Each parameter (1xxx or 4xxx variable) can be found as an input in this block. The structure of the
input is as follows:
The variable parameter number preceded by the letter V
The value
R/W attribute (for MODBUS and PLC equations)
The label (only for clarification)
The minimal value (only for clarification)
The maximal value (only for clarification)
(Ex: V1006)
(Ex: 320)
(Ex: Y)
(Ex: Gen Nominal KW)
(Ex: +00000)
(Ex: +65535)
Ex:
{PARAMETERS}
V1006 320
Gen nominal kW
+00000
+65535
V1007 1.00
Gen PT ratio
+00000
+65535
It is possible to modify the values directly in the text file before uploading it into the GENSYS. The user
must be sure that the modified value is within the minimum / maximum range. Failure to do so will lead
to an error message during uploading (Compilation result: VARIABLE).
It is also possible to write an incomplete parameter block (not all parameters are displayed in the list).
When uploaded, such a file will only modify the parameters which have been entered, the others
remain unchanged. This procedure can be used to upload an old text file into a newer GENSYS or to
activate special features independently.
page 91/91
10.4 Label definition block
The starting point of this bloc is designated by a "{LABELS}" statement.
Only the 2 spare analogue inputs, the 10 digital inputs, the 40 virtual digital inputs, the 10 maintenance
cycles and the 4 lines in the Logo Page can have an input in this bloc (see file Z090030.xls for variable
number).
The structure of the input is as follows:
The variable number preceded by the letter L
(Ex: L1130)
The text (14 characters maximum)
(Ex: Sample Label)
Ex:
{LABELS}
L1130 Sample label
Note:
The label is language sensitive, i.e. a text file uploaded with PC language set to French will
modify only the French labels. The English or Italian labels will remain unchanged. For the
same reason, a text file uploaded with PC language set to French will display only French
labels.
10.5 Unit definition block
The starting point of this bloc is designated by a "{UNITS}" statement.
Only the 4 analogue inputs have an input in this bloc (see file Z090030.xls for variable number).
The structure of the input is as follows:
The variable number preceded by the letter U
(Ex: U1130)
The digital code of the unit
(Ex: 14)
List of valid units:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
00 : No unit
01 : V
02 : kV
03 : mA
04 : A
05 : kA
06 : Hz
07 : kW
08 : kWh
09 : kVAR
10 : kVARh
11 : rpm
12 : %
13 : Bar
14 : mBar
15 : kPa
16 : PSI
17 : °
18 : °C
19 : °F
20 : L
21 : Gal
22 : s
23 : h
24 : days
25 : Hz/s
26 : m3/h
27 : Gal/h
28 : L/h
page 92/92
Ex:
{UNITS}
U00029
14
Note: Only the 4 analogue inputs can be present in this bloc, but the associated parameters, like
thresholds for example, are modified automatically.
10.6 Initialization definition block
The beginning of these blocks is shown by the statements "{INIT1}" or "{INIT2}" depending on the level
of access (1st or 2nd level password).
A user connected in level 0 (no password) cannot read equations from, or transfer equations to, the
GENSYS.
A user connected in level 2 will get access to INIT1 and INIT2 blocks.
A user connected in level 1 will only get access to the INIT1 block.
INIT equations are only run by the PLC when the power supply of the module is turned ON. They
won’t be run again until power supply is turned OFF and then ON again. The purpose of these blocks
is to provide custom equations to the user. They are run during the power up stage.
INIT blocks are typically used to set the initialization values of outputs, timers or counters associated
to custom equations or custom parameters.
For further details on the programming language see the "PLC" chapter.
10.7 Equation definition block
The beginning of this these blocks is shown by the statements "{EQUATIONS L1}", "{EQUATIONS
L2}", depending on the level of access (1st level password or 2nd level password).
A user connected in level 0 (no password) cannot read equations from or transfer equations to the
GENSYS.
A user connected in level 2 will get access to EQUATIONS L1 and EQUATIONS L2 blocks.
A user connected in level 1 will only get access to EQUATIONS L1 block.
The purpose of these blocks is to provide custom equations to the user which are run cyclically. These
equations are run every 100ms (PLC cycle time).
Non standard equations can be entered here to handle user defined features like thresholds,
Input/Output expansions, PID controls …
For further details on the programming language see the "PLC" chapter.
10.8 End of file
Every text file must end with the "{END OF FILE}" statement.
GENSYS will not try to read data following that statement, so you can place your own comments here.
Note:
It is strongly recommended not to add too many comments after the" End of File"
statement because the size of the file must not exceed 62Kbytes.
NOTE:
This file is a text ONLY file. Do not use word processors (like Microsoft© Word) to edit
this file: it would include layout information and corrupt the file. Use text editors only
(Notepad for example).
The file should not exceed 62Kbytes. If you try to transmit a bigger file to a GENSYS, it
will be rejected.
CAUTION :
When you download or upload a file, you must disconnect all connectors, except power
supply.
page 93/93
10.9 PLC programming language
It is strongly advised that you follow training before using custom PLC equations on a power plant.
Contact your local dealer for details on training sessions.
The PLC equations use a simple language with a small number of commands. The code is intrinsically
linear, each equation being executed one after the other (without any loop). Level 1 equations are
executed first, followed by level 2 equations. This way, level 2 equation results can overwrite any
conflicting level 1 equation.
The "INIT" part is only executed upon start-up, and the "PROG" part is executed every 100 ms.
All the GENSYS variables can be used in the equations in the way defined below:
-E0xxx parameters are read only as measurements. They can’t be changed by equations.
-E1xxx parameters can be read by equations. If allowed, they can also be modified using MODBUS or
equations downloaded via the text file (see {PARAMETERS} section of the text file chapter).
E2xxx parameters are PLC outputs. They can be read and written by custom equations.
Note:
-Variables E1xxx/E4xxx are parameters stored in FLASH (non volatile memory). In level 2
and above, the user can allow the parameters to be written by PLC equations or via
MODBUS.
-Be very careful when modifying a parameter through equations, as unexpected behaviour
(due to an error in your equations for example) may damage your generator.
-It is advisable to include tests in the equations to verify that the engine is stopped prior to
changing a parameter. Otherwise, make modifications in the "INIT" block if possible.
These parameter modifications will not be saved in FLASH memory, i.e. parameters will
be reset to their previous value if power supply is turned OFF and then ON again, unless
the user saves them manually.
-Use document A53 Z0 9 0030 to get a complete list of all GENSYS variables.
-Variables E2xxx/E5xxx are outputs from the PLC; they can be read and written by PLC
equations without restrictions.
Each instruction is terminated by a semicolon (;) except before reserved words (BEND, ELIF, ELSE,
TEND). Init and program blocs are terminated by a dot (.).
Program
PROG
INIT
.
Blocs
BLOC
BEND
AND
OR
XOR
!
>
<
INC
DEC
$
+
*
/
^
|
#
:=
EQ
NE
Logical operators
Unary operators
Arithmetical operators
Bit operators
Affectation
Comparison operators
Starting
point
of
PLC
equations
Starting
point
of
INIT
equations
End of equations
Starting and ending points of
a block of equations
Logical operation used on a
whole variable (i.e. these are
not bit to bit operators)
Bit to bit complement
Sign change
Right shift
Left shift
Increment
Decrement
Hex value
Addition
Subtraction
Multiplication
Division
Rotation right
Access one bit
Bits mask
Affectation
Equal
Not Equal
page 94/94
Array
Tests
Comments
GT
LT
GE
LE
[...]
TEST
THEN
ELIF
ELSE TEND
@
Greater Than
Less Than
Greater or Equal
Less or Equal
Array element
The PLC equations only use 16 bit signed integer values. This means that all variables and data
should be between -32768 and +32767. This is an important point to keep in mind when comparing
values or doing calculations. For example, 20000*10 will produce a calculation overflow. For the same
reason, variables displayed with decimal digits are treated in the equations as if the decimal point
wasn’t there. For example, a power supply voltage of “24.5 V” will be treated as “245” in the equations.
Be careful when entering values which have digits after the decimal point. If you have one digit after
the dot, you have to multiply the number by 10. If you have two digits, multiply by 100.
For instance, the battery voltage measure (variable E0041), is from 0.0 to 6553.5, so you have one
digit after the dot. If you want to compare the battery voltage to 25.0 volts, you have to write:
TEST E0041 GT 250 THEN...
To know the number of digits after the dot, look in the “A53 Z0 9 0030-x.xls” file. In the 'Mini' / 'Maxi'
columns, the number of digits after dot appears.
Test examples:
TEST condition THEN instruction TEND;
TEST condition THEN BLOC instruction; instruction;…;instruction BEND TEND;
TEST condition THEN BLOC instruction; instruction;…;instruction BEND
ELIF condition THEN BLOC instruction; instruction;…;instruction BEND
ELIF condition THEN BLOC instruction; instruction;…;instruction BEND
ELSE BLOC instruction; instruction;…;instruction BEND
TEND;
Calculation / instruction examples:
E2680:=(E2000+E2001+E2002+E2003)/4;
E2000:=2; E2680[E2000+1]:=10;
E2680:=(E0030 GT 1450) AND ((E0030 GT 1500) OR E2680);
Condition examples:
TEST E2050 EQ 1 THEN ...
TEST E0030 GT 1500 THEN ...
TEST (!E2046) AND E2055 AND ((E2071 EQ 14) OR (E2071 EQ 15)) EQ 1 THEN …
Variable use:
There are two ways of accessing the 2xxx variables for reading. With E2xxx you access the value
locked at the start of program loop. With X2xxx you access the very last value modified by the
program executed previously.
It is strongly recommended that you use the E2xxx Eyyyy syntax. X2xxxyyyy can only be used for
special purpose and only by advanced, "High GENSYS Knowledge" users.
page 95/95
11 Communication
11.1 CANBUS GOOD PRACTICES
This chapter explains and describes good practices used to ensure a good reliable CAN
communication. This advice is true for all CAN bus connections and should be applied to both
GENSYS units for inter GENSYS bus, and for second CAN communication port.
Here is the standard pin out of a DB9 CAN connector compared with a GENSYS implementation:
SHIELD
PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
GENSYS
GROUND
NC
CAN-L
GROUND-1
NC
GROUND-2
GROUND-1
CAN-H
NC
NC
Standard
Cable Drain
CAN-L
CAN GND
free
+24V POWER
free
CAN-H
free
0V POWER
Note: GROUND-1 and GROUND-2 are each protected with a 47 ohms resistor.
CAN-BUS cable:
The CAN bus-BUS cable must be able to carry the CAN signals (CAN-L and CAN-H). These 2 signal
wires should be a 120 Ohm twisted pair (Ex: Belden's 3105A, 3082A-3087A (www.belden.com), LAPP
CABLE Unitronic bus DeviceNet or CAN (www.lappcable.com) or equivalent).
The CAN bus-BUS cable must be shielded, and must have a drain wire connected to the cable shield.
This drain connects to pin 1 of each connector. The connector housing must be connected to the
cable shield, and metallic shells should be used if possible.
For better results, a common GROUND should be used for all connected devices (this can be verified
easily with an ohmmeter, for example).
The total length of the cable must not exceed 250m for a CAN communication speed of 250kb/s. This
length may decrease with lower quality cables.
The last node on the CAN-BUS must have a 120-Ohm termination resistor plugged into its CAN
connector.
page 96/96
IMPORTANT:
Warning:
Never plug or unplug CAN-BUS bus connectors with power on. This may cause internal
damage or cause internal CAN -BUS transceivers to burn.
11.2 COM1: RS232 to PC
This communication port has been described previously in the browser chapter. This is a standard
RS232 communication port. This port can be used for:
- Manufacturing flash memory programming
- Manufacturing process calibration
- Manufacturing quality control
- On site configuration (with standard web browser)
- On site firmware update (with special utility)
11.3 COM2: CAN bus inter GENSYS
This bus will allow synchronization, load sharing (active and reactive), dead bus management and
automatic load/unload. GENSYS uses a proprietary protocol implemented on standard CAN bus
hardware.
11.3.1 Wiring
The figure below shows the connections between each GENSYS.
R
2
3
4
5
7
9
2
3
4
5
7
9
GENSYS A
2
3
4
5
7
9
GENSYS
R
GENSYS
Figure 41 - CAN Bus wiring
Terminals 2 and 7: 1 twisted pair cable.
Terminals 3 and 5: 1 twisted pair cable.
R: 120 Ohms termination resistor
The CANbus wire is a wire to wire cable, with 1 termination resistor on each extremity. The wires are
connected to a female DB9.
You can also use CRE accessories as shown below to connect several GENSYS units together.
= 2 GE
G
GENSYS1
CAN1(COM2)
G
A40W1
GENSYS2
CAN1(COM2)
7m
Figure 42 - GENSYS Ù GENSYS
page 97/97
> 2 GE
G
G
A40W4
A40W2
GENSYS1
CAN1(COM2)
G
GENSYS2
CAN1(COM2)
7m
G
A40W2
GENSYS4
CAN1(COM2)
GENSYS3
CAN1(COM2)
7m
A40W3
Figure 43 - GENSYS Ù GENSYS Ù GENSYS Ù …
The next figure shows the wiring for rental generators.
GENSYS1
CAN1(COM2)
GENSYS2
CAN1(COM2)
G
GENSYS3
CAN1(COM2)
G
G
2 GE
A40W8
A40W5
A40W5
A40W6
A40W8
+3 GE
A40W8
A40W5
A40W5
7m
A40W3
7m
Figure 44 - Mobile generator sets
11.3.2 CAN bus fault
If this fault occurs, a GENSYS is missing or there are too many GENSYS units on the CAN bus
compared to the number of generators (E1147). This fault can only be RESET if the right number of
generators is present on the CAN bus.
The kind of alarm/fault generated depends on the "bus CAN fault control" variable (E1259).
•
•
•
•
•
•
•
E1259 = 0: no action
E1259 = 1: generator electrical fault
E1259 = 2: mains electrical fault
E1259 = 3: alarm
E1259 = 4: soft shut down
E1259 = 5: hard shut down
E1259 = 6: droop mode, generates an alarm (default setting)
This fault only affects the working of a power plant with several GENSYS units (E1147 > 1).
In Auto mode, if there is a remote start and a CAN bus fault, the GENSYS starts and closes its
breaker after a delay that depends on the generator number (E1179), but only if the dead Bus
management is on (E1515 = 0) and there is no voltage on the bus bar.
Otherwise it will try to synchronize with the bus bar.
If the generator is paralleled to the Mains when a CAN bus fault occurs, and error control variable
E1259 is set to 6 (Droop mode + Alarm), speed control will be switched to droop and volt control will
be switched to power factor regulation. If the mains are not connected, both speed and voltage droop
is applied.
page 98/98
Note:
If you need to disconnect a GENSYS from the inter GENSYS CAN bus, you must change
the number of generators (parameter E1147) on all other GENSYS units of the power
plant.
When the power plant is set to load/unload mode (Parameter E1258 set to "Hours run" or "Digital in"),
all generators will start using droop mode if a CAN bus error occurs.
11.4 Broadcasting Data between GENSYS units
11.4.1 Introduction:
This section describes the Broadcast Data by Inter GENSYS CANbus.
This application is only available in versions 2.09 and later.
It is possible to exchange up to 10 digital variables and 2 analogue variables between GENSYS units
with the Inter GENSYS CAN (Com 2).
It’s necessary to use a computer to create the “Broadcast Data by Inter GENSYS CAN bus” equations.
NOTE: When you assign a variable to broadcast data (ex: E2752:=...) remove the “E” from in front of
the variable name: this is the number of the variable you assign, not the variable itself.
11.4.2 Procedure / Example
In this configuration there will be one GENSYS (GENSYS1) which sends variables and the other
GENSYS units (GENSYS 2) which receive variables.
Variables which are sent on the Broadcast Data by Inter GENSYS CANbus:
Variable
number
Description
GENSYS
E2752
VarDigCAN01
1 or 2
E2753
VarDigCAN02
1 or 2
E2754
VarDigCAN03
1 or 2
E2755
VarDigCAN04
1 or 2
E2756
VarDigCAN05
1 or 2
E2757
VarDigCAN06
1 or 2
E2758
VarDigCAN07
1 or 2
E2759
VarDigCAN08
1 or 2
E2760
VarDigCAN09
1 or 2
E2761
VarDigCAN10
1 or 2
E2762
VarAnaCAN01
1 or 2
E2763
VarAnaCAN02
1 or 2
Table 21 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus
Variable number Description
GENSYS
E0536 to E0545
Can bus extension digital input 1 to 10 – GE1
1
E0546 to E0547
Can bus extension analog input 1 to 2 – GE1
1
E0552 to E0561
2
E0562 to E0563 Can bus extension analog input 1 to 2 – GE2
2
E0568 to E0577
3
E0578 to E0579
3
E0584 to E0593
4
page 99/99
E0594 to E0595
4
E0600 to E0609
5
E0610 to E0610
5
E0616 to E0625
6
E0626 to E0627
6
E0632 to E0641
7
E0642 to E0643
7
E0648 to E0657
8
E0658 to E0659
8
E0664 to E0673
9
E0674 to E0675
9
E0680 to E0689
10
E0690 to E0691
10
E0696 to E0705
11
E0706 to E0707 Can bus extension analog input 1 to 2 – GE11
11
E0712 to E0721
12
E0722 to E0723
12
E0728 to E0737
13
E0738 to E0739
13
E0744 to E0753
14
E0754 to E0755
14
E0760 to E0769
15
E0770 to E0771
15
E0776 to E0785
16
E0786 to E0787
16
Table 22 - Variables received by BROADCAST DATA via Inter GENSYS CANbus
page 100/100
Example: Broadcast analogue and digital data
DIGITAL Values:
Input 1 (E2006)
J6
GENSYS
N° 1
E2006
E2752
E0552
CAN inter
GENSYS
Input 1 (E2006)
J6
GENSYS
N° 2
E2752
E2006
E0536
To other GENSYS
ANALOGUE Values:
Magnetic pick-up (E0033)
G7-8
GENSYS
N° 1
E0033
E2762
E0562
CAN inter
GENSYS
Magnetic pick-up (E0033)
G7-8
GENSYS
N° 2
E2762
E0033
E0546
To other GENSYS
page 101/101
To send value from GENSYS #1 to GENSYS #2, write this equation in GENSYS #1:
BLOC
@example to send digital input or analog input to each gensys oil pressure
input and speed;
E2752:=2006;
E2762:=33
BEND
In GENSYS #2, to read these two values, use these variables:
E0536 is the value of the GENSYS #1 J6 input (E2006).
E0546 is the value of the GENSYS #1 engine speed (E0033).
To send value from GENSYS #2 to GENSYS #1, write this equation in GENSYS #2:
BLOC
@example to send digital input or analogue input to each gensys oil
pressure input and speed;
E2752:=2006;
E2762:=33
BEND
In GENSYS #1, to read these two values, use these variables:
E0552 is the value of the GENSYS #2 J6 input (E2006).
E0562 is the value of the GENSYS #2 engine speed (E0033).
Example 2 (Application example):
If you don’t want to use the “remote start” inputs on each GENSYS, you can enter it on the first
GENSYS and send it to the others via the CAN.(Example with 3 GENSYS).
GENSYS #1:
@example to send digital input or analog input to each gensys;
E2752:=2002
BEND
GENSYS #2:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
GENSYS #3:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
Important: Even if CAN bus inhibition is activated between GENSYS units (see below), broadcast data
is always sent and received on the inter GENSYS CAN bus.
page 102/102
NB: When you assign a variable to broadcast data
(ex: E2752:=….) remove the “E” in front of the variable name.
11.5 Can Bus Inhibition
The CAN bus is mainly used by GENSYS modules to send power management data to each other.
CAN bus inhibition is used to prevent one GENSYS from taking into account data coming from one or
more GENSYS units. This is especially useful when tie breakers are used to change the configuration
of the power plant (for example from a 6 generator power plant to two power plants with 3 generators
each).
Variables E2691 to E2706 are used to decide with which modules the GENSYS should communicate
power management data.
CANBUS inter-GENSYS
DG1
DG2
CB1
CB2
DG3
CB3
DG4
CB4
Tie breaker
Figure 45 - CAN bus inhibition schematic (example)
The example above shows a power plant made up of 4 generators that can be split into two power
plants of two generators each. GENSYS units are connected together with a CAN bus on COM1. If it
is necessary to split a complete plant with a tie breaker, for example in a security application, it is
necessary to modify normal functioning:
In normal functioning, the tie breaker is closed, each GENSYS communicates with the others by CAN.
When the tie breaker is open, all GENSYS units need to know that they have to consider the power
plant differently, with two separate bus bars.
To allow this, we will use CAN bus inhibition.
When the tie breaker is closed, all four GENSYS units should communicate with each other for power
management, so variables E2691 to E2694 should be set to 0 (zero) on every GENSYS unit (no CAN
inhibition).
When the tie breaker is open, generators DG1 and DG2 should communicate but ignore data from
DG3 and DG4. In the same way, generators DG3 and DG4 should communicate but ignore data from
DG1 and DG2. To do so, inhibition variables should be set as follows:
E2693 and E2694 set to 1 on generators DG1 and DG2.
E2691 and E2692 set to 1 on generators DG3 and DG4.
Feedback from the tie breaker can be connected to a GENSYS digital input and then used in custom
PLC equations to set or reset these inhibition variables.
11.5.1 How to set theses functions:
Special variables can be used to inhibit CAN bus variable use.
page 103/103
Each GENSYS is able to ignore (inhibit) all the others, depending to the state of the inhibition can
variable.
Note that this does not affect “BROADCAST DATA”, but only genset related functions.
The following table describes these variables.
To take effect (inhibition active), the variable must be set at 1.
Remark:
In the GENSYS, control of inhibition is often associated with feedback from the Tie
breaker.
E2691
Inhibition variable of the GE 1 on CAN bus
E2692
E2693
E2694
E2695
E2696
E2697
E2698
E2699
E2700
E2701
E2702
E2703
E2704
E2705
E2706
Table 23 - CAN bus inhibition parameters
11.6 COM3: CANopen remote I/O
Industrial CANopen extension modules can be used to increase the number of digital/analogue inputs
and outputs of GENSYS. This is CAN bus hardware using CANopen protocol and application support
to transfer data between nodes.
page 104/104
Figure 46 - Modular remote I/O extension module
Modular remote I/O (750-337) can be added to GENSYS using a CANOPEN© protocol, on serial port
COM3 with a DB9 male connector. It allows the extension of the number of GENSYS inputs / outputs.
The refresh time of this remote I/O is 100ms.
The GENSYS DB9 wiring is the same as for the CANbus inter GENSYS with a termination resistor.
For the remote I/O see the figure below.
7 - CAN H
A40W2
Shield - Drain
GENSYS
CAN2(COM3)
120 Ohms
2 - CAN L
WAGO
5 - GND
Figure 47 - CANopen coupler wiring
•
•
•
•
•
CAN L must be connected to pin 2 of the DB9.
CAN H must be connected to pin 7 of the DB9.
CAN GND must be connected to pin 5 of the DB9.
Drain must be connected to the shield of the DB9.
A termination resistor of 120 Ω must be connected to each end of the cable between CANH and
CANL.
GENSYS can be connected with up to 3 couplers.
Each coupler can have up to 32 remote I/O terminals.
•
•
•
The remote I/O terminals available are the following:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Digital input and output
Up/down counter input
Peak time counter input
Frequency counter 0.1-10kHz input
Intruder detection input
Solid state output
Relay output
0-20mA input and output
4-20mA input and output
+/-10V input and output
0-10V input and output
PT100 input
PT1000 input
Thermocouple input
10R-1k2 input
10R-5k0 input
Ni 100 input
Ni 1000 input
page 105/105
This list in indicative and non exhaustive, consult your WAGO© dealer for further information, or go to
http://www.wago.com.
11.6.1 System configuration
The system is configured by messages. A total of 13 messages for inputs and 13 messages for
outputs are available.
Each message is determined by:
•
•
•
The identifier of the module (configurable on the coupler using switches)
The type of message: analogue or digital for input or output.
The number of channels in the message
Note: A maximum of 4 analogue inputs/outputs or 64 digital inputs/outputs can be sent by
message
The total number of input/output available is:
•
•
•
•
44 analogue inputs.
128 digital inputs.
8 analogue outputs.
64 digital outputs.
Note:
When configuring inputs or outputs, analogue I/O should be programmed first, then digital
I/O.
Note:
For a given CANopen module, always group the maximum number of data of the same type
in one message.
For example, it is better to set up one message with 50 digital inputs than 2 messages with
25 digital inputs each.
Note:
Always group messages to/from one CANopen module. For example, do not use output
messages 1 and 3 with CANopen module number 1 and message 2 with CANopen
module number 2. It is preferable to use messages 1 and 2 with module number 1 and
message 3 with module number 2.
11.6.2 Read / write I/O
With the Info screen (view by pressing the info key), you can see the remote I/O:
• Digital inputs from 0157 to 0284
• Analogue inputs from 0285 to 0328
• Digital outputs from 2368 to 2431
• Analogue outputs from 2432 to 2439
To have the right variable associated to an input output, follow this rule: the lower variable number is
associated to the lower message number and the I/O nearest to the coupler.
Configuration
First module:
2 0-20 mAmp analogue inputs
Coupler
number 1
Coupler
number 2
Second module:
2 PT100analogue inputs
Message number
0285
1:
ID = 1 ; type analog ;
nb of Input = 4
0286
0287
0288
Third module:
2 digital inputs
2:
ID = 1 ; type digital ;
nb of Input = 2
First module:
2 thermocouple analogue inputs
4:
nb of Input = 2
Variable
number
0157
0158
0291
0292
page 106/106
0159
5:
ID = 2 ; type digital ;
nb of Input = 4
Second module :
4 digital inputs
0160
0161
0162
Coupler
number 3
3:
nb of Input = 2
1 module with 2 +/- 10V analogue
inputs
0289
0290
Table 24 - CANopen configuration example
11.7 COM3: MDEC (MTU)
11.7.1 Procedure
To correctly communicate with GENSYS, MDEC internal variables have to be configured. The MDEC
should be configured as follows to activate the CAN communication:
•
•
•
200 set to 450.
201.01 set to 32.
201.05 set to 201.
For more information on MDEC configuration contact your MTU dealer.
Option 4 has to be ordered to activate the CAN connection.
Download the custom language. MDEC has labels and codes or numbers which correspond to the
MDEC variables:
• Z090210_2_vxxx.txt corresponds to the English version.
• Z090210_3_vxxx.txt corresponds to the French version.
Note: vxxx is the corresponding software version of your GENSYS.
Download the text file that will configure your GENSYS for this application:
•
Z090210i_1.txt.
GENSYS to MDEC wiring:
C1
C2
GENSYS
COM3 / 7
COM3 / 2
COM3 / 5
G9
G11
0V
25
26
h
g
43
44
N
M
MDEC
0V
49
50
51
8
36
G
F
E
AA
q
X003
connector
Label
Digital output to stop request and
emergency stop
Digital output to start request
GENSYS
terminal
C1
C2
MDEC X1
connector
h
g to ground
N
X003
connector
25
26 to ground
43
page 107/107
CAN High
CAN Low
CAN ground
Analogue speed command
Analogue speed reference
M
G
F
E
AA
q
COM 3 pin 7
COM 3 pin 2
COM 3 pin 5
G9
G11
44 to ground
49
50
51
8
36
Table 25 - MDEC connection
Variable
Label
number
V1076 ESG amplitude
V1077 ESG offset
Value
50.0
0.00
V1156
Local language
3
V1311
V1710
V1711
PC language
User param 001
User param 002
3
10
1500
V1712
User param 003
300
V1852
Branch P-oil
352
V1853
Branch T-water
400
V1854
Branch Speed
331
V1855
Opt4 protocol
MTU CANbus
Node
MTUPV110003
CT
MTUPV110010
CT
MTUPV110014
CT
MTUPV110029
CT
MTUPV110030
CT
MTUPV110047
CT
MTUPV110048
CT
MTUPV110055
CT
MTUPV110099
CT
MTUPV110129
CT
MTUPV110130
CT
MTUPV110133
CT
MTUPV110143
CT
MTUPV110168
CT
MTUPV110177
CT
1
V1856
V1857
V1858
V1859
V1860
V1861
V1862
V1863
V1864
V1865
V1866
V1867
V1868
V1869
V1870
V1871
6
0
3
5
0
0
0
0
0
0
0
0
0
0
0
0
Description
Speed output amplitude to have a trip frequency of +/-3Hz.
Offset to obtain nominal frequency.
Custom language selected for MDEC labels on the GENSYS
screen.
Custom language selected for MDEC labels on your PC.
Time to stop request on digital output C1 (1.0 sec. here)
Nominal speed for MDEC through CAN bus.
Delay (*100ms) before triggering an MTU CAN bus error. (30
seconds here).
The Analogue oil pressure that comes from the MTU CAN bus
will be used. (*)
The Analogue water temperature that comes from the MTU
CAN bus will be used. (*)
The Speed measure that comes from the MTU CAN bus will
be used. (*)
To choose the MTU MDEC CAN bus protocol on COM2.
Each device on the MTU CAN bus has a node number.
GENSYS uses have the number 6.
Protection control for over speed from MDEC (E0332). (**)
Protection control for combined alarm yellow from MDEC
(E0339). (**)
Protection control for combined alarm red from MDEC
(E0343). (**)
Protection control for low oil pressure from MDEC (E0355). (**)
Protection control for very low oil pressure from MDEC
(E0356). (**)
Protection control for low fuel pressure from MDEC (E0358).
(**)
Protection control for very low fuel pressure from MDEC
(E0359). (**)
Protection control for low coolant level from MDEC (E0363).
(**)
Protection control for low coolant level, charge air, from MDEC
(E0386). (**)
Protection control for high coolant temperature from MDEC
(E0403). (**)
Protection control for very high coolant temperature from
MDEC (E0404). (**)
Protection control for high charge air temperature from MDEC
(E0407). (**)
Protection control for high oil temperature from MDEC
(E0414). (**)
Protection control for low charge air temperature from MDEC
(E0422). (**)
Protection control for low engine speed from MDEC (E0426).
(**)
Table 26 - Important parameters
page 108/108
(*) the standard sensors required for oil pressure, water temperature and engine speed don’t need to
be connected to GENSYS. The value of these 3 analogue inputs (E0029, E0030, E0033)
will be taken from the MTU CAN bus.
(**) control can take the following values:
•
•
•
•
•
•
0: Disable.
1: Generator electrical fault.
2: Mains electrical fault.
3: Alarm.
4: Fault (soft shut down).
5: Security (hard shut down).
MDEC variables:
The following variables are used to communicate with MTU MDEC devices:
-E0330 to E0484 as input variables (MDEC to GENSYS).
-E2662 to E2677 as output variables (GENSYS to MDEC).
The variables from MDEC can be seen from E0330 to E0484.
The variables than can be written in MDEC are available from E2662 to E2677.
The table in the annexes lists all the variables with correspondences between MDEC and GENSYS.
Specific screens for MDEC:
In the “Display\Engine meters” menu you will find:
Variables
from MDEC
Additional information
page 109/109
In the standard configuration GENSYS can display all the MDEC variables available on the CAN bus
thanks to the screen seen above. These variables are displayed ‘as is’ without any further processing,
except for certain faults. If you need additional functions related to these variables you will have to
program your own PLC equations.
It is also possible to monitor and manage MDEC variables remotely through MODBUS
communication.
Alarms.
The following example will show you how to handle predefined alarms (listed is an example of the
predefined alarm seen above):
E1857 is dedicated to over speed protection from MDEC (E0332). The equation is the following:
TEST (E0332 EQ 1) AND (E1857 NE 0) EQ 1 THEN E2199[E1857]:=1 TEND;
E0332 is the over speed alarm from MDEC.
E1857 is the control.
If you set E1857 as security (E1857=5) and E0332 is set to 1, then E2204 (hard shut down) will also
be set to 1 and trigger the hard shutdown process.
If you want to use an MDEC alarm that is not handled directly by GENSYS, you can use a virtual input
as described in the following example:
For example, if you want to handle an MDEC alarm for “SS Power Reduction Active” (E0338), you can
use the virtual input 2 (E2284). In the “Enhanced / Configuration\>>\Virtual input” menu, set virtual
input 2 with the function (E1329). Choose “External alarm”, and load the following equation in a text
file:
E2284:=E0338;
You can also change the label of the virtual input to be displayed on screen when the alarm occurs.
page 110/110
Fault code numbers.
Combined yellow / red alarms are global warnings. They can be triggered by one of several faults
provided on the CAN bus (see list below). Apart from these predefined errors, additional alarm sources
are available and can be detected using MDEC fault code numbers.
The MDEC fault code is read by GENSYS and stored in MDEC (GENSYS variable E0372). If several
failures happen together, the fault code variable will be refreshed every second.
This will help you find which alarm is activated in case of a combined alarm.
11.8 COM3: J1939
This section describes J1939 configuration for the GENSYS. There are common settings and a
specific file to download in the GENSYS depending on the engine brand.
11.8.1 Configuration
The GENSYS must be configured with "option 4 CAN Engine Communication" enabled. Contact your
CRE dealer for key code & procedure. This option is installable on site. It is not possible to mix J1939
and CANopen applications because they do not use the same protocol.
•
•
•
•
Set parameter E1855 to 2, to select standard J1939 protocol.
Set parameter E1856 to 17, to set the address of the GENSYS (17 is the default value).
Press SHIFT + I to save the configuration into the FLASH memory.
Connect the engine CAN bus to COM3 of the GENSYS with an A40W2 cable or equivalent.
Note: connect: ‐CAN Hi to terminal 2 of GENSYS COM3 connector. ‐CAN Lo to terminal 7 of GENSYS COM3 connector. ‐GND to terminal 5 of GENSYS COM3 connector. • Switch the power supply OFF then ON to reset the system.
In order to display understandable texts in the display menus, all the following custom language files
must be downloaded:
• J1939_0.txt
• J1939_1.txt
• J1939_2.txt,
• J1939_3.txt,
• J1939_4.txt.
Whatever the engine make, these 5 files must be downloaded.
Note: Communication speed is 250 Kbits, non modifiable.
11.8.2 J1939 fault
Variable E2511 is used to detect a J1939 reception error. If E2511 equals 1, it means that no CAN
frames have been received from the ECU for more than 2 seconds. This error is not latched and
resets to 0 (zero) as soon as a new CAN frame is received.
11.8.3 Engine Speed
Variable E0330 contains the engine speed value read from J1939 (in RPM, from 0 to 8031).
To use this J1939 speed value instead of the GENSYS internal speed measurement, set E1854
variable to 330.
To use GENSYS internal speed measurement set E1854 to 33 (default value).
11.8.4 Coolant temperature
Variable E0333 contains coolant temperature value read from J1939 (in °C, from -40 to +210).
To use this J1939 coolant temperature value instead of the GENSYS internal measurement, set
variable E1853 to 333.
To use GENSYS internal temperature measurement set E1853 to 30 (default value).
11.8.5 Oil pressure
Variable E0331 contains oil pressure value read from J1939 (in Bars, from 0.00 to 10.00).
To use this J1939 oil pressure value instead of the GENSYS internal measurement, set variable
E1852 to 331.
To use GENSYS internal oil pressure measurement set E1852 to 29 (default value).
page 111/111
11.8.6 Engine diagnostic
The GENSYS is able to monitor diagnostic messages (DM1) from the J1939 engine ECU. Only
relevant diagnostic messages are taken into account and used in the GENSYS fault/alarm system.
GENSYS is able to understand and interpret messages for display, process, and protection.
RESET message (DM3) is sent to the engine when internal GENSYS RESET is activated (RESET
button or internal variable).
If the diagnostic message is not sent by the J1939 ECU for more than 3 seconds, the corresponding
fault/alarm is automatically reset to OFF.
11.8.7 J1939 Messages
Red "lamp"
This message is used to relay trouble code information that is of a severe enough condition that it
warrants stopping the engine. Variable E0403 contains the "Red lamp" value read from J1939. 0
means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Red lamp" message from the engine,
variable E1866 must be set (hard Shutdown is the default value).
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Disable
Alarm
Soft Shutdown
Hard Shutdown (default value)
Help + Fault (Soft shut down)
Help + Gen. Electrical fault
Amber "lamp"
This message is used to relay trouble code information that is reporting a problem with the engine
system where the engine need not be immediately stopped. Variable E0386 contains the "Amber
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Amber lamp" message from the engine,
variable E1865 must be set (disabled is the default value).
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Disable (default value)
Alarm
Soft Shutdown
Hard Shutdown
Protect "lamp"
This message is used to relay trouble code information that is reporting a problem with an engine
system that is most probably not electronic subsystem related. For instance, engine coolant
temperature is exceeding its prescribed temperature range. Variable E0363 contains the "Protect
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Protect lamp" message from the engine,
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Alarm
Soft Shutdown
Hard Shutdown
page 112/112
Malfunction "lamp"
A message used to relay only emissions-related trouble code information. This message is only
illuminated when there is an emission-related trouble code active. Variable E0359 contains the
"Malfunction lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Malfunction lamp" message from the engine,
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Alarm
Soft Shutdown
Hard Shutdown
Very high engine speed
This message is used to relay that the engine speed is above the most severe high level threshold set
for the engine. Variable E0358 contains the "Very high engine speed" value read from J1939. Value of
0 means Not Activated. Value of 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Very high engine speed" message from the
engine, variable E1862 must be set to:
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Disable
Alarm
Soft Shutdown
High engine speed
This message is used to relay that the engine speed is above the least severe high level threshold set
for the engine. Variable E0332 contains the "High engine speed" value read from J1939. 0 means Not
Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "High engine speed" message from the
engine, variable E1857 must be set (disabled is the default value).
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Alarm
Soft Shutdown
Hard Shutdown
Very high coolant temperature
This message is used to relay that the coolant temperature is above the most severe high level
threshold set for the engine. Variable E0356 contains the "very high coolant temperature" value read
from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Very high coolant temperature" message
from the engine, variable E1861 must be set (soft Shutdown is the default value).
-0:
Disable
-1:
-2:
-3:
Alarm
-4:
Soft Shutdown (default value)
-5:
Hard Shutdown
-7:
page 113/113
-8:
High coolant temperature
This message is used to relay that the coolant temperature is above the least severe high level
threshold set for the engine. Variable E0343 contains the "High coolant temperature" value read from
J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "High coolant temperature" message from
the engine, variable E1859 must be set (disabled is the default value).
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Alarm
Soft Shutdown
Hard Shutdown
Very low oil pressure
This message is used to relay that the oil pressure is below the most severe low level threshold set for
the engine. Variable E0355 contains the "Very low oil pressure" value read from J1939. 0 means Not
To set the behaviour of the GENSYS when receiving the "Very low oil pressure" message from the
engine, variable E1860 must be set (Hard Shutdown is the default value).
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Disable
Alarm
Soft Shutdown
Low oil pressure
This message is used to relay that the oil pressure is below the least severe low level threshold set for
the engine. Variable E0339 contains the "Low oil pressure" value read from J1939. 0 means Not
To set the behaviour of the GENSYS when receiving the "Low oil pressure" message from the engine,
-0:
-1:
-2:
-3:
-4:
-5:
-7:
-8:
Note:
Alarm
Soft Shutdown
Hard Shutdown
All the parameters are available in web pages in the System / Serial port / COM3 menu.
page 114/114
11.8.8 Advanced functions
Custom Rx Frames
If you need to get more values from the J1939 device than those available in the basic operations, the
system is able to read raw data from 5 different frames you can set to fit your needs.
The following variables are used to define those 5 custom Rx messages: E2675, E2676, E2677,
E2678, and E2679 define the ID of the frames to be monitored. The IDs are those defined by the
J1939/71 standards.
The raw data is available as 8 bytes in variables E0410-E0417, E0420-E0427, E0430-E0437, E0440E0447 and E0450-E0457.
Custom RX
frame
1
2
3
4
5
Frame ID
variable
E2675
E2676
E2677
E2678
E2679
Frame Raw data
variables
E0410 to E0417
E0420 to E0427
E0430 to E0437
E0440 to E0447
E0450 to E0457
Please refer to J1939/71 standards to find the frame ID that fits your needs.
Note that there are no additional web pages to configure these custom RX frames. Please use custom
PLC equations to access custom RX variables. The variables are only accessible by equations.
Custom Tx Frame
If it is needed, a custom frame can be sent every 100ms by the system.
The Variable E2662 defines the size of the frame (from 0 to 8 bytes). A value of -1 switches off custom
TX frame transmission.
The Variables E2663, E2664, E2665, E2666 define the ID of the frame to be send sent (E2663 being
the least significant byte; E2666 is the most significant byte).
The Variables E2667 to E2674 contain the raw data to be sent (E2667 contains data byte 1).
Note that there are no additional web pages to configure the custom TX frame. Please use custom
PLC equations to access custom TX variables.
There are no additional web pages to configure this system; the variables are only accessible via
equations.
11.8.9 Engine notes
PERKINS (Engine series 2800)
The following text file must be loaded into the GENSYS with level 2 access: J1939_perkins.txt
SCANIA
page 115/115
Set variable E1917 to 1 to set the J1939 refresh time to 25ms. (Only available with V2.10b and later)
The following text file must be loaded into the GENSYS with level 2 access:
J1939_SCANIA.txt
This txt file contains LEVEL 2 equation and contains START STOP and SPEED management.
VOLVO EMS2
This electronic control unit has no other means of control than J1939 CAN bus.
Note:
Do not use CIU module with GENSYS.
7
2
GENSYS
J1939 High
120
1N4007
A2
A3
J1939 Low
Batt Switched
Emergency
Stop
+V Batt
1
2
3
4
5
6
7
8
EMS2
8 poles
connector
Figure 48 - Wiring diagram for Volvo EMS2
The following text file must be loaded into the GENSYS with level 2 access:
J1939_VOLVO.txt
IVECO:
Oil pressure value from Iveco engines is never sent by J1939 CAN bus. Additional sensor should be
connected to GENSYS to get an analogue measurement used in association with an analogue input
program like VDO.
The Fuel relay is used to supply power to the control unit.
A different Crank output sequence must be used because the crank signal command must be given
after the control unit is powered up. GENSYS output supply: The C1 output1 sends the crank signal 2
seconds after the normal Crank output.
The following signals can be recovered from the control unit:
-Digital oil pressure.
-Analogue oil pressure.
-Digital water temperature.
Download the text file
J1939_cme.txt
11.9 COM4: MODBUS RTU on serial port RS485
All GENSYS internal variables (Measurements, parameters, PLC outputs…) can be monitored
remotely through an RS486 communication bus using a MODBUS RTU protocol, GENSYS being a
MODBUS slave. It is also possible to enter parameters into the GENSYS. All digital and analogue
input/output values and all other parameters which appear in the GENSYS menus can be obtained by
the serial port RS485, DB9 male COM4. If allowed, variables (2xxx) and parameters (1xxx) can be
written via MODBUS.
Warning:
Be careful when modifying a parameter while the engine is running as unexpected
behaviour while functioning may damage your generator. It is always advised to change
parameters when generator is stopped.
page 116/116
Wiring on the serial port can be achieved using 2 wires, in point to point mode (1 master and 1 slave)
or in multi-drop mode (1 master and several slaves).
The following figure shows the wiring between the GENSYS and modem.
G
G
A40W2
GENSYS1
RS485(COM4)
A40W4
GENSYS2
RS485(COM4)
7m
G
A40W4
GENSYS3
RS485(COM4)
A40W3
G
GENSYS4
RS485(COM4)
7m
A40W4
Modem A40W7
A40W3
3
5
4
5
6
6
7
8
GND TD TD/ RD RD/
Figure 49 - GENSYS Ù GENSYS ÙGENSYS Ù … (MODBUS)
MODBUS RTU is supported by GENSYS when within the following fields:
Communication speed: 4800, 9600 and 19200 (pre-setting: 4800).
Number of bits by character: 8
Number of parity bits: 0
Number of stop bits: 1
RTU address: 1 to 254 (addresses 0 and 255 are reserved). This can be modified by variable 1634,
which is only accessible in the "Modification by variable nb" menu.
Supported functions:
04 Analogue reading
03 Register reading
The RTU address of the variables is the same as their number plus 1, converted into hexadecimal. For
example, variable 2000 (Mains break in) has for RTU address 07D1h (2001). See the Z090030.xls file
to locate the variable number.
Example: Here are two MODBUS RTU frames (request from a remote device and answer from
GENSYS). In this case GENSYS slave address is 5, and the request is to read variables E0000,
E0001 and E0002. The result is a function 04 request starting at address 1 (variable E000) and ending
at address 3 (variable E0002).
Request:
Fields
Value (hex)
Slave address
05
Function
04
MSB start address
00
LSB start address
01
MSB number of registers
00
LSB number of registers
03
CRC16
--
Response:
Field
Value (hex)
Slave address
05
page 117/117
Function
04
Number of bytes
06 (3 registers * 2 bytes per register)
1st byte (MSB of 1st reg.)
xx
2nd byte (LSB of 1st reg.)
xx
3rd byte (MSB of 2nd reg.)
xx
4th byte (LSB of 2nd reg.)
xx
5th byte (MSB of 3rd reg.)
xx
6th byte (LSB of 3rd reg.)
xx
CRC16
--
page 118/118
12 Troubleshooting
GENSYS displays a « sensor lost » fault at the time of start:
Check voltage AC on terminal (B1 to B4).
Check the speed increases until 1500 RPM
If you don’t have these values and engine stops:
Increase the "sensor lost" timer (default value 4 sec.)
You can increase this timer with variable E1458 in Configuration/Speed control setting.
During starting, GENSYS display oil pressure fault or not ready:
If you are in manual mode, you must push and hold start or GENSYS will display this fault.
If you are in automatic mode, check that your J4 input activates and deactivates correctly. Change the
timing of security inhibitions at start-up.
If you use an analogue input for the oil pressure, check Variable E1155: oil pressure threshold.
GENSYS is powered and LED blinks:
Calibration lost, the GENSYS must be returned to CRE Technology to be re-calibrated.
GENSYS displays a "GENSYS CAN Bus" fault:
If the flaw appears during parameter backup, check the connection between GENSYS units.
Check the number of the set and number of sets is correct; this is in Power plant overview menu.
Check the connection between GENSYS.
The fault appears when you backup the parameters
The GENSYS displays "breaker failure":
Check that control switch is in manual mode.
Check that J2 (back breaker) is activated. If this entry did not have time to activate, you can increase
the E1149 variable delay.
This fault can occur if the opening of the circuit breaker has not been controlled by the GENSYS. See
if another module is able to control the circuit breaker.
When you power up the GENSYS, the display does not work:
Check the bootstrap button on the back of GENSYS is off. Remove the power and change the position
of the bootstrap.
If there is no change, the module is defective and needs to be returned to CRE Technology.
During the test of speed or tension:
Check the connection of 0V.
The engine starts but runs above/ below Rated speed.
Adjust ESG offset or trim speed pot
This output (G9-G11) is used to interface with the speed governor. The main objective being to bias
the speed/fuel rack for synchronizing, Load sharing, ramping Load on and off. This output only alters
the Power (KW) it can be set by parameters E 1077 ESG Offset and E1076 ESG Amplitude (span).
When connecting this output you must know the details of the input you are using. For example a
Woodward 2301A uses ± 2.5 Volts input.
Thus the span to achieve the required span (± 2.5Hz) is ± 2.5 Volts, therefore the settings are
E1076=25% and E1077=25%. If you start the engine with output connected the speed may not be at
rated, if so adjust the speed to be back at rated. N.B. On some electronic engines the input may need
configuring with the manufacturers software. In some case it may be turned off and may not respond.
Only the engine manufacturer can tell you this information.
Below describes how to set the gain and offset if you do not have previously tried settings.
page 119/119
•
The ESG offset adjustment (E1077) is settable between -10V and +10V, and it’s added to the
external speed reference (G11) (see figure 47).
• The Speed ref (G11) doesn’t need to be connected if there is no voltage reference available.
• 0V must be wired with 4 mm² as follows: battery - speed regulator - GENSYS
• Connect only the ref wire.
• Set the gain and offset .You need to know what the ref voltage is and the span
For instance the ref voltage may be 5V and have a span of 2.3 to 2.7 volts, you are trying to achieve
the centre of the voltage span (2.5V) using the setting of E1077 in percent. So 10volts =100%, thus
2.5 equals 25%. So set -25% in E1077. Next you need the span setting in E1076, again 2.3 = 23%
and 2.7 =27%. You need 2% span therefore from the nominal (25%) so set E1076 at 2%.
•
•
•
•
•
•
Start the generator, set rated speed. Stop generator.
Connect the control wire.
Start the generator. Measure the rated Frequency.
If required adjust GENSYS output voltage a small amount (E1077) thus adjusting the offset to
get back to rated.
Check the maximum range of speed in manual mode with [+] and [-].
This range must be near +/- 3Hz.
page 120/120
13 Variables
The list of all GENSYS variables is an EXCEL Workbook, with all defined parameters, labels, and in all
languages. This EXCEL Workbook is downloadable from our website. It contains around 2500
parameters, defined in 5 different languages. This folder also contains a worksheet with a history of all
different version of GENSYS firmware.
This excel file can be found in the folder at this URL:
http://www.cretechnology.com/soft/
page 121/121
14 Precautions
Change over and paralleling with mains:
For safety reasons, breakers must be equipped with an independent paralleling safety
relay to prevent failure of the automatic sequence, as shown in Figure 48 and Figure 49.
+24V
+24V
G1
G2
SYN
GENSYS
E5-E6
SYN
GENSYS
E5-E6
Gen. SYNCH
ref CHECK
volt RELAY
Bus
ref
volt
Gen. SYNCH
ref CHECK
volt RELAY
Bus
ref
volt
Figure 50 - Several generators warning
G
Mains
+24V
GENSYS
E2-E3
Generator
breaker NC
feedback
+24V
Mains
ref
volt
SYN
SYNCH
CHECK
RELAY
Gen.
ref
volt
SYN
GENSYS
E5-E6
Mains breaker
NC feedback
Figure 51 - One generator with mains warning
Warning:
When you use the virtual digital input in this way: "Generator electrical fault", "Mains
electrical Fault", "External alarm", "External fault (Soft shut down)" or "External security
(Hard shut down)", NEVER use the "Normally Open" or "Normally Close" directions but
ALWAYS "Normally Open Wired Or" or "Normally Close Wired Or".
page 122/122
Warning:
Manual breaker opening.
When an external security device opens the breaker, the order has to be latched.
GENSYS needs the feedback.
Warning:
When a power plant has several generators, even if only one generator has a GENSYS,
the number of generators (E1147) must be equal or above 2. If it is 1, you may seriously
damage your generator.
Warning:
The engine, turbine, or other type of prime mover should be equipped with an over speed
(over temperature, or overpressure, where applicable) shutdown device that operates
independently from the prime mover control device.
CAUTION:
When a power plant has several generators, each GENSYS must have a different
number ("Genset number" variable: E1179). If two have the same number, there is no
conflict but there will be some operating problems.
Note:
To close the generator breaker the following conditions have to be met:
•
Voltage must be in a window of 70% (parameter E1432) to 130% (parameter E1433) of the
nominal voltage (parameter E1107 or E1108)
• Speed must be in a window of 70% (parameter E1434) to 130% (parameter E1435) of the
nominal speed (parameter E1080 or E1081)
If the bus bar voltage is more than 10% of the nominal voltage, the generator has to be synchronizing
with the bus bar.
page 123/123
15 References
•
•
•
A40Z0
A40Z1
A40Bx
Standard environment range
Extended environment range
Bureau VERITAS marine approval
15.1 Options
Each of the following options can be selected and is password activated: contact your dealer for
procedure.
OPT1
PWM 500Hz for CATERPILLAR engine
OPT2
Mains paralleling option for single generator paralleled with the mains.
The most important paralleling functions are:
Phase shift
ROCOF
power management
OPT4
This option connects GENSYS to MTU MDEC by CANBUS.
Special characteristics include:
- MTU Friedrichshafen certified connection
- Oil pressure, engine speed, water temp, & high temp faults
- MDEC sensors are displayed by GENSYS
- GENSYS displays MTU PV number alarms
A complete application note for easy start-up of the CAN© connection option and
communication with engine is supplied. Requires technical specification from consumer and
commercial agreement to allow specific software development.
OPT5
Disable the paralleling function.
OPT6
Enable the paralleling function.
OPT7
Inhibit start sequence.
15.2 Accessories
• A40W0
• A40W1
• A40W2
• A40W3
•
•
•
•
•
•
•
A40W4
A40W5
A40W6
A40W7
A40X0
A09Tx
A24Zx
GENSYS to PC cable - DB9/DB9 - 3m.
CAN© inter GENSYS cable for 2 generators - DB9/DB9 - 120 Ohm termination resistor
included on both ends - 7m.
CAN© inter GENSYS cable for more than 2 generators or CANopen© I/O modules DB9/free wires - 120 Ohm termination resistor included on DB9 side - 7m.
DB9/Terminals connector to be used with more than 2 generators for double connection
(with screws).
Communication cable (RS485, CAN, RS232) - Price per meter.
DB9 termination resistor connector.
modem adaptor.
RS485 modem.
manual GENSYS test bench.
GCR: digital mains commander (x=0 for 100 VAC, x=1 for 230 VAC, x=2 for 400 VAC).
CPA : active power converter (x=0 for 100 VAC / 5 A, x=1 for 230 VAC / 5 A, x=2 for
400 VAC / 5 A, x=3 for 100 VAC / 1 A, x=4 for 230 VAC / 1 A, x=5 for 400 VAC / 1 A).
page 124/124
Figure 52 - Standard cables
page 125/125
16 Company Information
CRE TECHNOLOGY
130, Allée Victor Naudin
Zone des Templiers
Sophia-Antipolis
06410 Biot
FRANCE
Phone: +33 (0)4 92 38 86 82
Fax: +33 (0)4 92 38 86 83
Web: www.cretechnology.com
[email protected]
Figure 53 - Access to CRE Technology in Sophia Antipolis
page 126/126

gensys - CRE TECHNOLOGY

Transcription

Similar documents

Stringing SC28/40.indd

Help the Silly Bus kids get to school!

power source - Kemp Elektroniks

Studying the relationship of chemical and physical parameters on

the new security towers - Generac Mobile Products

YOUR SOURCE FOR - Torbram Electric Supply

Bangstick 90 Degree NFDD Delivery Pole

Container Features

Ritelite-K9-30-LED - Ritelite Portable Lighting

Croydon Community Bus flyer merton