Operation Manual For GC1200 Series Genset Controllers SEDEMAC DOC # ENG-PD-APPKIT-GC1200-002

Transcription

SEDEMAC
Operation Manual For GC1200 Series Genset Controllers
DOC #
ENG-PD-APPKIT-GC1200-002
Rev #
02
Rev Date
4 Jul 2014
Page 1 of 39
SEDEMAC
Table of Contents
1 Introduction..............................................................................................................................................3
1.1 Key Highlights Of The Product............................................................................................................................3
2 Specifications............................................................................................................................................3
2.1
2.2
2.3
2.4
2.5
Terminals............................................................................................................................................................3
Power Supply Specifications...............................................................................................................................4
Generator Voltages And Frequency Measurements............................................................................................5
Generator Current Sensing.................................................................................................................................5
Mains Voltage And Frequency Sensing...............................................................................................................5
3 Inputs........................................................................................................................................................6
3.1
3.2
3.3
3.4
3.5
Digital Inputs......................................................................................................................................................6
Analog Resistive Sensor Inputs...........................................................................................................................6
Magnetic Pick Up Input (Optional).....................................................................................................................6
Analog Voltage Input..........................................................................................................................................6
Charge Fail Input.................................................................................................................................................6
4 Outputs.....................................................................................................................................................7
4.1 Digital Outputs...................................................................................................................................................7
4.2 Actuator Outputs (Optional)...............................................................................................................................7
5 Communication Ports................................................................................................................................7
6 Dimensions...............................................................................................................................................8
7 Installation................................................................................................................................................9
7.1 Terminal Description..........................................................................................................................................9
7.2 Typical Wiring Diagram ....................................................................................................................................11
8 Module Display ......................................................................................................................................14
8.1 Monitoring Mode.............................................................................................................................................14
9 Description Of Control Keys.....................................................................................................................23
10 Configuration Mode..............................................................................................................................24
10.1 Configurable Parameters................................................................................................................................24
11 Module Operation In Manual Control Mode..........................................................................................34
11.1
11.2
11.3
11.4
11.5
Starting The Engine.........................................................................................................................................34
Stopping The Engine.......................................................................................................................................34
Acknowledging The Alarms.............................................................................................................................35
Clearing The Alarms........................................................................................................................................35
Accessing Event Log........................................................................................................................................36
12 Troubleshooting....................................................................................................................................36
Page 2 of 39
SEDEMAC
1
Introduction
SEDEMAC GC1200 is a series of modern and feature rich genset controllers with user-friendly HMI and full
graphics LCD. The GC1200 controllers come bundled with highly versatile software & extensive I/O's, and
thereby support a wide variety of industry standard features in diesel / gas / gasoline engine gensets. They also
offer unique features such as electronic governing for engines with mechanical fuel systems. With a SEDEMAC
rotary actuator as an add-on for air/fuel charge control, the GC1200 controllers can subsume the electronic
governing duty for the engine and offer tight speed governing performance within ISO 8528:G3 class limits.
This document gives operating instructions for SEDEMAC's GC1200 series genset controllers (refered to as
GC12xx further in the document). Refer to the Software Manual for Configuration Utility For GC1200 series
Genset Controllers for details of the configuration utility.
1.1
Key Highlights Of The Product
•
•
•
•
2
AMF, manual and remote start / stop modes for 1-ph & 3-ph gensets
PC connectivity via USB port (default), RS232/485 (optional), CAN (optional)
Backlit and full graphics display with power saving feature
Multiple language display (optional)
Specifications
2.1
Terminals
The GC12xx has two types of terminal blocks as shown in figure below.
2.1.1
5 mm pitch connector suitable for 2 sq mm wire.
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SEDEMAC
Connector type/
Manufacturer
Male (On genset
controller)
Female (Mating)
Male (On genset
controller)
Degson
2.1.2
Phoenix
2-Pin
2EDGVC-5.08-02P-14- 2EDGK-5.08-02P-1400AH
00AH
1755516
1754449
4-Pin
2EDGVC-5.08-04P-24- 2EDGK-5.08-04P-2400AH
00AH
NA
NA
Male (On genset
controller)
Female (Mating)
3.5 mm pitch connector suitable for 0.5 – 1.5 sq mm wire
Connector type/
Manufacturer
Male (On genset
controller)
Female (Mating)
Degson
2.2
2.3
Female (Mating)
Phoenix
4-Pin
15EDGVC-3.5-04P-14- 15EDGK-3.5-04P-1400AH
00AH
1843622
1840382
6-Pin
15EDGVC-3.5-06P-14- 15EDGK-3.5-06P-1400AH
00AH
1843648
1840405
8-Pin
15EDGVC-3.5-08P-14- 15EDGK-3.5-08P-1400AH
00AH
1843664
1840421
10-Pin
15EDGVC-3.5-10P-14- 15EDGK-3.5-10P-1400AH
00AH
1843680
1840447
Power Supply Specifications
Connector pin number
1, 2 (Ground and Battery positive respectively)
Supply voltage range
8 to 32 VDC
Maximum reverse voltage
-40VDC
Measurement accuracy
1% full scale
Resolution
0.1V
Generator Voltages And Frequency Measurements
27, 28, 29, 30 (N, B, Y, R respectively)*
Measurement type
True RMS
Phase to Neutral voltage
15VAC to 415VAC
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SEDEMAC
Phase to Phase voltage
15VAC to 750VAC
Voltage accuracy
±1% of full scale
Voltage resolution
1VAC for Phase to Neutral
2VAC for Phase to Phase
Frequency range
3Hz to 75Hz
Frequency accuracy
0.1Hz
Note: * For 1 phase genset application it is mandatory to connect the genset phase and neutral to genset controller's phase R and Neutral respectively.
2.4
2.5
Generator Current Sensing
35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for phase R)
Measurement type
True RMS
Maximum CT secondary
current rating
5A
Burden
0.25VA
Accuracy
1% of full scale (5A)
Mains Voltage And Frequency Sensing
31, 32, 33, 34 (N, B, Y, R respectively)*
Measurement type
True RMS
Phase to Neutral voltage
15VAC to 415VAC
Phase to Phase voltage
15VAC to 750VAC
Voltage accuracy
2% of full scale
Voltage resolution
1VAC for Phase to Neutral
2VAC for Phase to Phase
Frequency range
3Hz to 75Hz
Frequency accuracy
0.1Hz
Note: * For 1 phase genset application it is mandatory to connect the mains phase and neutral to genset controller's phase R and Neutral respectively.
3
3.1
3.2
Inputs
Digital Inputs
10, 11, 12, 21, 22
Number of inputs
5
Type
Negative sensing (connect to ground for activation)
Low level threshold
0.8V maximum
High level threshold
8V minimum
Open circuit voltage
Vbat – 1VDC
Analog Resistive Sensor Inputs
24, 25, 26 (Eng_temp, Fuel_Level sensor, LOP respectively)
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SEDEMAC
3.3
Number of inputs
3
Type
Ratiometric sensing
Range
10 to 1000Ω
Accuracy
2% of full scale
Magnetic Pick Up Input (Optional)
41, 42
Type
Differential ended
Frequency range
10 to 10000Hz
Input voltage range
200mV to 70V
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The
output of MPU is a sine-wave signal.
3.4
Analog Voltage Input
23
Type
Analog voltage sensing
Range
0 to 5VDC
Accuracy
0.5% of full scale
This input may used for the “Paralleling” application where the genset is governed by SEDEMAC GC12xx.
3.5
Charge Fail Input
7
Voltage range
0 to 30VDC
Excitation
PWM (Current limited to 250mA)
Accuracy
1% of full scale
The charge fail input is a combined input and output terminal. When the genset starts, the terminal provides
excitation current to the charge alternator field winding. When the charge alternator is correctly charging the battery,
the voltage of the terminal is close to the battery supply voltage. In case of failure of charging alternator, the voltage
of this terminal is pulled down to a low voltage. This drop in voltage triggers the charge failure alarm. The level at
which this operates and whether this triggers a warning or shutdown alarm is configurable.
4
4.1
4.2
Outputs
Digital Outputs
3, 4, 5, 6, 8, 9
Number of outputs
6
Type
High side driver
Maximum current
0.75A
Actuator Outputs (Optional)
17, 18, 19, 20
Type
Stepper motor drive
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SEDEMAC
Maximum current
1A each coil
The actuator outputs are used only for the SEDEMAC actuator, if installed. The SEDEMAC actuator is a 4-wire
actuator that is used for creating an electronic governing application in case of a mechanical fuel system engine. In
diesel engines, the rotary actuator's shaft output gets mechanically connected to the stop lever or the throttle lever
of an inline or rotary fuel injection pump. In case of petrol or natural gas engines, the rotary actuator's shaft output
gets connected to the throttle / charge control valve.
5
Communication Ports
USB
Used to flash the firmware
RS485 (optional)
Used for data communication
Connector pin number for
RS485
15, 16
CAN (optional)
Reserved for future use
Connector pin number for
CAN
13, 14
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SEDEMAC
6
Dimensions
Recommended mounting panel cut-out dimensions: 118 mm X 93 mm.
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SEDEMAC
7
7.1
Installation
Terminal Description
Following figure shows the rear view of module.
The following table provides the details of GC12xx terminals.
Terminal Name
Description
Sr. No.
1
BATT -
Battery ground
2
BATT +
Battery positive
3
OUT A
High side driver output – A
4
OUT B
High side driver output - B
5
OUT C
High side driver output - C
6
OUT D
High side driver output - D
7
CHARGE FAIL IN
Input for charging alternator
8
OUT E
High side driver output - E
9
OUT F
High side driver output - F
10
DIG_IN A
Input from switch - A
11
DIG_IN B
Input from switch - B
12
DIG_IN C
Input from switch - C
13
CAN H (Optional)
CAN high
14
CAN L (Optional)
CAN low
15
RS485_B (Optional)
RS485 - B
16
RS485_A (Optional)
RS485 - A
17
GOV_ACT – OUT1 (Optional)
Output for the SEDEMAC actuator
Page 9 of 39
SEDEMAC
Terminal
Sr. No.
Name
Description
18
19
20
21
DIG_IN D
Input from switch - D
22
DIG_IN E
Input from switch - E
23
ANLG_V IN
Analog 0 to 5V input - A
24
ANLG_IN ENG_TEMP
Analog input from Engine Temperature Sensor
25
ANLG_IN Fuel_Level
Analog input from Fuel Level Sensor
26
ANLG_IN LOP
Analog input from Lube Oil Pressure Sensor
27
GEN_V IN NTRL
Voltage input from Gen Neutral
28
GEN_V IN B
Voltage input from Gen B
29
GEN_V IN Y
Voltage input from Gen Y
30
GEN_V IN R
Voltage input from Gen R
31
MAINS_V IN NTRL
Voltage input from Mains Neutral
32
MAINS_V IN B
Voltage input from Mains Phase B
33
MAINS_V IN Y
Voltage input from Mains Phase Y
34
MAINS_V IN R
Voltage input from Mains Phase R
35
CT – IN B1
CT input 1 from Phase B
36
CT – IN B2
CT input 2 from Phase B
37
CT – IN Y1
CT input 1 from Phase Y
38
CT – IN Y2
CT input 2 from Phase Y
39
CT – IN R1
CT input 1 from Phase R
40
CT – IN R2
CT input 2 from Phase R
41
MPU – IN 2 (Optional)
Input 2 from engine speed sensor(Inductive)
42
MPU – IN 1 (Optional)
Input 1 from engine speed sensor(Inductive)
Page 10 of 39
SEDEMAC
7.2
Typical Wiring Diagram
7.2.1
Manual Control Application
The typical wiring diagram of GC12xx for manual control application on engine with mechanical fuel system.
7.2.2
Auo Mains Failuer Application
The typical wiring diagram of GC12xx for Auto Mains Failuer application on engine with mechanical fuel system.
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SEDEMAC
Page 12 of 39
SEDEMAC
Page 13 of 39
SEDEMAC
8
Module Display
Following sections describe the layout of screens.
8.1
Monitoring Mode
In monitoring mode the screen will scroll automatically after a predefined time which can be configured in
configuration menu or you can use the “Navigation UP/DOWN Keys” to scroll/browse the screens.
8.1.1
Home
Screen 1: Home
8.1.2
Generator L-N Voltages
Screen 2: Generator L-N Voltages
(The “L2” & “L3” will be visible only If configured for 3 phase genset)
8.1.3
Generator L-L Voltages
Screen 3: Generator L-L Voltages
(This screen will be visible only If configured for 3 phase genset)
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SEDEMAC
8.1.4
Generator Currents
Screen 4: Generator Currents
8.1.5
Mains L-N Voltages
Screen 5: Mains L-N Voltages
(The “L2” & “L3” will be visible only If configured for 3 phase mains)
8.1.6
Mains L-L Voltages
Screen 6: Mains L-L Voltages
(This screen will be visible only If configured for 3 phase mains)
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SEDEMAC
8.1.7
Generator Line kW
Screen 7: Generator Line kW
8.1.8
Generator Total kW
Screen 8: Generator Total kW
8.1.9
Generator Line kVA
Screen 9: Generator Line kVA
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SEDEMAC
8.1.10 Generator Total kVA
Screen 10: Generator Total kVA
8.1.11 Generator Line kVAr
Screen 11: Generator Line kVAr
8.1.12 Generator Total kVAr
Screen12: Generator Total kVAr
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SEDEMAC
8.1.13 Generator Line PF
Screen 13: Generator Line PF
(The “PF2” & “PF3” will be visible only If configured for 3 phase genset)
8.1.14 Generator Total PF
Screen 14: Generator Total PF
8.1.15 Generator Frequency
Screen 15: Generator Frequency
8.1.16 Mains Frequency
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SEDEMAC
Screen 16: Mains Frequency
(This screen will be visible only If “Mains monitoring” is enabled)
8.1.17 Generator Cumulative Power
Screen 17: Generator Cumulative Power
8.1.18 Engine Speed
Screen 18: Engine Speed
8.1.19 Engine Run Time
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SEDEMAC
Screen 19: Engine Run Time
8.1.20 Battery Voltage
Screen 20: Battery Voltage
8.1.21 Coolant Temperature
Screen 21: Coolant Temperature
(This screen will be visible only If “Coolant temperature” sensor is configured)
8.1.22 Lube Oil Pressure
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SEDEMAC
Screen 22: Lube Oil Pressure
(This screen will be visible only If “LOP” sensor is configured)
8.1.23 Balance Fuel
Screen 23: Balance Fuel
(This screen will be visible only If “Fuel level” sensor is configured)
8.1.24 Date And Time
Screen 24: Date And Time
8.1.25 Product ID
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SEDEMAC
Screen 25: Product ID
8.1.26 System ID
Screen 26: System ID
8.1.27 Alarms
Screen 27: Alarms
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SEDEMAC
9
Description Of Control Keys
Display
Menu
Navigation
UP Key
Alarm LED
Menu
Navigation
DOWN Key
STOP Key
START Key
AUTO/MANUAL
Mode Select Key
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SEDEMAC
10 Configuration Mode
For first-time-configuration please refer Quick start guide otherwise please follow the below mentioned instructions.
To enter into the configuration mode press and hold “STOP” and “AUTO” keys simultaneously.
Screen 28: Configuration Mode
To enter into edit mode press “START” key. If you wish to read the configuration press “STOP” key.
Screen 29: Configuration mode: Authentication Page
Please enter your 4-Digit PIN here to access the configuration menu. Once you enter into the “EDIT” mode scroll to
the parameter that you wish to edit and press “START” key to edit the parameter. At this moment the parameter will
start blinking and you can change the parameter value using ”UP” and “DOWN” keys. (Refer section 10.1 for
configuring parameters)
After selecting the required value press ”START” key to save parameter or “STOP” key to discard the value.
10.1 Configurable Parameters
10.1.1 Table 1 – List Of Configurable Parameters
Level 0
Level 1
Module
General
Display
Level 2
Possible Value
Languages
1 (English)
Start mode
0, 1 (Stop, Auto)
Lamp test enable
0, 1 (Disable, Enable)
GSM enable(Optional)
Extended event log(Optional)
Deep sleep enable
Contrast
0-100%
Power save enable
Communication Communication mode
Modbus slave ID
0, 1, 2 (None, Modbus, GSM)
0 - 247
Page 24 of 39
SEDEMAC
Level 0
Inputs
Level 1
Pressure
monitoring
Temperature
monitoring
Fuel level
monitoring
Level 2
Modbus baudrate
Refer Table 8
Low oil pressure action
0, 1, 2 (None, Warning, Shutdown)
Low oil pressure threshold
0-5 bar
Low oil pressure open circuit alarm
High engine temperature action
High engine temperature threshold
25-150 deg C
High engine temperature open circuit
alarm
0,1 (Disable, Enable)
LFL shutdown enable
LFL shutdown threshold
0-80%
LFL warning enable
LFL warning threshold
0-80%
Fuel tank capacity
0-500 Litres
Fuel theft alarm
Fuel theft threshold
0-100%
Radiator water Low level action
level monitoring
DIG IN A
DIG IN B
DIG IN C
Possible Value
Source
Refer Table 2
Polarity
0, 1 (Close to activate, Open to activate)
Action (for user configured input
source)
0, 1, 2,3 (None, Warning, Electrical trip,
Shutdown)
Activation (for user configured input
source)
Refer Table 3
Activation delay (for user configured
input source)
0-60s
Source
Refer Table 2
Polarity
0,1 (Close to activate, Open to activate)
source)
Shutdown)
source)
Refer Table 3
input source)
0-60s
Source
Refer Table 2
Polarity
source)
Shutdown)
Refer Table 3
Page 25 of 39
SEDEMAC
Level 0
Level 1
Level 2
Possible Value
source)
DIG IN D
DIG IN E
ANLG_IN LOP
input source)
0-60s
Source
Refer Table 2
Polarity
source)
Shutdown)
source)
Refer Table 3
input source)
0-60s
Source
Refer Table 2
Polarity
source)
Shutdown)
source)
Refer Table 3
input source)
0-60s
Sensor selection
0,1,2(None, DIG IN F, ANLG_IN LOP)
(Digital) Source
Refer Table 2
(Digital) Polarity
(Digital, user configured source) Action 0, 1, 2,3 (None, Warning, Electrical trip,
Shutdown)
ANLG_IN
Eng_Temp
(Digital, user configured source)
Activation
Refer Table 3
Activation delay
0-60s
Sensor selection
0,1,2(None, DIG IN G, ANLG_IN
Eng_Temp)
(Digital) Source
Refer Table 2
(Digital) Polarity
Shutdown)
ANLG_IN
Fule_Level
Activation
Refer Table 3
Activation delay
0-60s
Sensor selection
0,1,2(None, DIG IN G, ANLG_IN
Fuel_Level)
(Digital) Source
Refer Table 2
(Digital) Polarity
Page 26 of 39
SEDEMAC
Level 0
Level 1
Level 2
Possible Value
Shutdown)
Outputs
Refer Table 3
Activation delay
0-60s
LOP Sensor
Calibration
Refer Table 4
Eng_Temp
Sensor
Calibration
Refer Table 5
Fuel_Level
Sensor
Calibration
Refer Table 6
OUT A
OUT B
OUT C
OUT D
OUT E
OUT F
Timers
Activation
Cranking
Monitoring
Supervisory
Module
Source
Refer Table 7
Polarity
0, 1 (de-energise, Energise)
Source
Refer Table 7
Polarity
Source
Refer Table 7
Polarity
Source
Refer Table 7
Polarity
Source
Refer Table 7
Polarity
Source
Refer Table 7
Polarity
Crank time
0-15s
Crank rest time
0-60s
Monitoring on delay
0-60s
Mains transient delay
0-30s
Generator transient delay
0-30s
Start delay
0-30s
Return delay
0-600s
Cooling time
0-300s
Stop solenoid hold delay
0-120s
Failed to stop delay
0-120s
Transfer time
0-60s
Power save mode delay
0-1800s
Page timer
0-1800s
Deep sleep delay
0-1800s
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SEDEMAC
Level 0
Level 1
Generator
Alternator
configuration
Voltage
monitoring
Frequency
monitoring
Current
monitoring
Level 2
Possible Value
Alternator fitted
0, 1 (No, Yes)
Number of poles
0, 1, 2, 3 (2, 4, 6, 8)
Ac system
0, 1 (1Ph-2wire, 3Ph-4 Wire)
Loading voltage
90-250V
Loading frequency
40-65Hz
Under voltage shutdown enable
0, 1 (No, Yes)
Under voltage shutdown threshold
0-250V
Under voltage warning enable
0, 1 (No, Yes)
Under voltage warning threshold
0-250V
Over voltage shutdown enable
0, 1 (No, Yes)
Over voltage shutdown threshold
120-400V
Over voltage warning enable
0, 1 (No, Yes)
Over voltage warning threshold
120-400V
Under frequency shutdown enable
0, 1 (No, Yes)
Under frequency shutdown threshold
0-60Hz
Under frequency warning enable
0, 1 (No, Yes)
Under frequency warning threshold
0-60Hz
Over frequency shutdown enable
0, 1 (No, Yes)
Over frequency shutdown threshold
25-70Hz
Over frequency warning enable
0, 1 (No, Yes)
Over frequency warning threshold
25-70Hz
CT primary
0-8000
Full load rating
0-8000A
Over current threshold
50-130%
Over current delay time
0-600s
Over current action
0, 1, 2, 3 (None, Warning, Electrical
trip, Shutdown)
Unbalanced load action
0, 1, 2, 3 (None, Warning, Electrical
trip, Shutdown)
Unbalanced load threshold
0-100%
Unbalanced load delay time
0-600s
Load monitoring Generator rating
0-800 kW
Load monitoring threshold
50-130%
Overload delay time
0-600s
Overload action
Page 28 of 39
SEDEMAC
Level 0
Level 1
Mains
Mains limits
Level 2
Possible Value
Mains under voltage enable
Mains under voltage trip threshold
0-394
Mains under voltage return threshold
2-396
Mains over voltage enable
Mains over voltage trip threshold
4-398
Mains over voltage return threshold
6-400
Mains under frequency enable
Mains under frequency trip threshold
0-67
Mains under frequency return
threshold
1-68
Mains over frequency enable
Mains over frequency trip threshold
2-69
Mains over frequency return threshold 3-70
System
Engine
Mains AC system
Crank disconnect Start attempts
Speed
monitoring
Battery
monitoring
0, 1 (1Ph-2wire, 3Ph-4 Wire)
0-9
Disconnect on oil pressure
Disconnect pressure threshold
0-50 bar
Pressure monitor before start
Disconnect on oil pressure switch
Pressure switch transient time
0-30S
Crank disconnect frequency
0-30Hz
Crank disconnect engine speed
0-900RPM
Engine speed sense source
0, 1, 2 (MPU(Optional), Alternator
frequency, W-point)
Flywheel teeth
0-300
W-point frequency @ 1500RPM
0-500 Hz
Under speed shutdown enable
Under speed threshold
0-3600RPM
Under speed delay
0-60s
Over speed threshold
1000-4000RPM
Over speed delay
0-20s
Low battery volt action
Low battery volt threshold
0-20V
Low battery volt delay
0-1800s
High battery volt action
High battery volt threshold
12-40V
Page 29 of 39
SEDEMAC
Level 0
Level 1
Charge
alternator
monitoring
Preheat
Maintenance
Oil filter
Air filter
Fuel filter
Electronic
governor
(Optional)
General
Generator PID
Parameters
Engine PID
Parameters
Level 2
Possible Value
High battery volt delay
0-1800s
Charge alternator fail action
Charge alternator fail threshold
0-12V
Charge alternator fail delay
0-60s
Preheat timer
2-900RPM
Temp limit enable
0, 1 (Disable, enable)
Temperature limit
25-60°C
Alarm action
0, 1 (None, Warning)
Engine hours
100-65000 hours
Alarm action
Engine hours
100-65000 hours
Alarm action
Engine hours
100-65000 hours
Actuator speed
1-10
Actuator direction
0, 1 (Anticlockwise, Clockwise)
Paralleling mode enable
0, 1(Disable, Enable)
RPM for 0 volt
500-4000
RPM for 5 volt
500-4000
Cranking steps
50-5000
Target speed
500-4000 RPM
Proportional gain
0-1000
Integral gain
0-2000
Derivative gain
0-1000
Friction set off
0-1000
Gain schedule trigger
0-1000
Loading factor
0-1000
Unloading factor
0-1000
Target speed
500-4000 RPM
Proportional gain
0-1000
Integral gain
0-2000
Derivative gain
0-1000
Friction set off
0-1000
Gain schedule trigger
0-1000
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SEDEMAC
Level 0
Active Profile
(Optional)
Level 1
Active profile
Level 2
Possible Value
Loading factor
0-1000
Unloading factor
0-1000
Active profile
0-10
Alternator configuration
0, 1 (1 Phase, 3 Phase)
Mains monitoring
0, 1 (On, Off)
10.1.2 Table 2 - Input Sources Selection
Value
Source
0
None
1
User configured
2
Low fuel level switch
3
Oil pressure switch
4
High temp switch
5
Water level switch
6
Emergency stop
7
Remote start
8
Reserved parameter
9
Simulate “Start”
10
Simulate “Stop”
11
Simulate “Auto”
12
Close generator / open mains
13
Close mains / open generator
14
Simulate mains
15
Paralleling enable
16
Reserved parameter
10.1.3 Table 3 – Activation choices
Value
Activation choices
0
Never
1
From start
2
From monitoring on
3
Always
10.1.4 Table 4 – LOP Sensor Calibration
Resistance(Ω)
0-1000(R1-R10)
Pressure(Bar)
0-10(P1-P10)
Page 31 of 39
SEDEMAC
10.1.5 Table 5 – Eng_Temp Sensor Calibration
Resistance(Ω)
0-1000(R1-R10)
Temperature° C
25-150(T1-T10)
10.1.6 Table 6 – Fuel_Level Sensor Calibration
Resistance(Ω)
0-1000(R1-R10)
Level (%)
0-100(L1-L10)
10.1.7 Table 7 – Output Source Selection
Value
Output source
0
Disable
1
Audible alarm
2
Battery over volts warning
3
Battery under volts warning
4
Charge alt shutdown
5
Charge alt warning
6
Close genset contactor
7
Close mains contactor
8
Mains failure
9
Common alarm
10
Common electrical trip
11
Common shutdown
12
Common warning
13
Cooling down
14
Digital input A
15
Digital input B
16
Digital input C
17
Digital input D
18
Digital input E
19
Digital input F(ANLG_IN LOP)
20
Digital input G (ANLG_IN ET)
21
Digital input H (ANLG_IN FLS)
22
Emergency stop
23
Stop solenoid
24
Fail to start
25
Fail to stop
26
Fuel relay
27
Generator available
Page 32 of 39
SEDEMAC
28
Generator over voltage shutdown
29
Generator under voltage shutdown
30
Generator over current
31
High coolant temperature
32
Low fuel level
33
Low oil pressure
34
Main high voltage
35
Mains low voltage
36
Oil pressure open circuit
37
Open generator contactor
38
Open mains contactor
39
Over frequency shutdown
40
Over speed shutdown
41
Start relay
42
Temperature sensor open circuit
43
Under frequency shutdown
44
Under speed shutdown
45
Oil filter maintenance due
46
Air filter maintenance due
47
Fuel filter maintenance due
48
Stop mode
49
Auto mode
50
Manual mode
51
GSM reset
52
Preheat output
10.1.8 Table 8 – Modbus baudrate Selection
Value
Baudrate
0
1200
1
2400
2
4800
3
9600
4
19200
5
38400
6
57600
7
115200
Page 33 of 39
SEDEMAC
11 Module Operation In Manual Control Mode
11.1 Starting The Engine
First Press STOP Key
11.2 Stopping The Engine
Then, Press The START Key
To Crank The Engine.
While Engine Is Running,
Press STOP Key To Stop
Engine. To Stop Engine
Immediately Press STOP
Key Twice.
Page 34 of 39
SEDEMAC
11.3 Acknowledging The Alarms
Press The UP
Key To
Acknowledge
Alarms
And Warnings
Note: This is to acknowledge the “Audiable Alarm Output” if configured.
11.4 Clearing The Alarms
While On
Alarms Page,
Press
STOP Key
To
Clear The
Alarms
And Warnings
Page 35 of 39
SEDEMAC
11.5 Accessing Event Log
While In
Configuration
Mode,
Press And Hold
UP & DOWN
Key
To Enter
Into Event Log
12 Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Sr.
Fault
Possible Causes / Remedial Actions
No.
Normal Mode
1
Controller not powered ON.
•
•
•
•
Check that the battery voltage is within
operating voltage.
Check DC power line fuse.
Check continuity between battery +ve and
controller pin # 2.
Check continuity between battery ground and
controller pin # 1.
2
Controller stuck on same page.
•
Reset the controller.
3
Controller fails to crank the engine when
commanded.
•
•
•
•
Check “START” led is glowing.
Check battery voltage
Check the “START” output configuration.
Check configured output is working correctly
by measuring the voltage at controller pin.
Check the configuration of crank disconnect
methods.
Check “Oil Switch” polarity is correct.
Check Oil switch/sensor and wiring.
•
•
•
4
Emergency stop alarm when “Emergency Stop”
not pressed.
•
•
Check the “Emergency Stop” connection.
Check the “Emergency Stop” polarity in the
configuration.
5
Shutdown alarm/s.
•
Check the respective switch/sensor and
wiring.
Check the configuration threshold.
•
Page 36 of 39
SEDEMAC
Sr.
No.
6
Fault
Warning alarm/s.
•
•
7
Charge fail alarm.
•
•
•
8
A) Controller shows genset “ON” while
genset is at rest.
B) “Fail to stop” alarm when genset is at rest.
Check the respective switch/sensor and
wiring.
Check the configuration threshold.
Check the charge fail input connections.
Check the current supplied by controller when
the pin is grounded through current meter.
(Should be equal to 220 - 270 mA.)
Check charge alternator.
•
Check the oil switch/sensor and wiring.
Check oil switch/sensor polarity in
configuration.
Check oil switch input configuration.
•
•
9
Controller issues “Start” command after power on.
•
•
•
Check “Start mode” configuration.
Check crank output polarity.
Check crank connections and wiring.
10
Engine runs but controller shows genset “OFF”.
•
•
Check MPU signal/voltage signal(R phase).
Check “Oil pressure” sensor/switch and
wiring.
Measurement Issues
11
Controller displays incorrect PF value.
•
Check wiring of the respective phase and the
CT.
12
Controller displays incorrect voltage.
•
Check wiring of the respective phase.
13
Controller displays incorrect KW.
•
CT.
Check CT ratio in the configuration.
•
14
Controller displays incorrect current.
•
•
CT.
Check CT ratio in configuration.
15
Controller displays incorrect LOP/fuel/Temp sensor
value.
•
•
Check respective sensor and its wiring.
Check the calibration for the respective sensor
in configuration.
16
Controller displays incorrect RPM.
•
Check the MPU connection and configuration
(if enabled).
Check R-phase and neutral wiring.
Check frequency and voltage on R-phase.
•
•
Communication Issues
17
Unable to connect with computer/laptop through
USB.
•
•
•
•
18
Unable to connect with computer/laptop through
CAN.
•
Check the controller is in “Programming”
mode.
Check for correct and updated drivers are
installed in computer/laptop for controller.
Check the cable.
Check PC USB port.
Check that correct and updated drivers are
installed in computer/laptop for controller and
Page 37 of 39
SEDEMAC
Sr.
No.
Fault
•
•
19
Controller fails to start/stop genset after
commanded through SMS.
•
•
•
•
CAN device.
Check the cable/device.
Check computer/laptop USB port.
Check the controller is in “Auto” mode.
Check the controller is receiving the SMS(If
controller receives SMS it will send an
acknowledgement).
Check the wiring of the communication port.
Check the wiring of GSM module.
AUTO Mode Issues
20
Controller does not receives “Remote start”
command.
•
•
•
21
22
Controller does not receives “Remote stop”
command.
While in Auto mode, controller issues “Start”
command even if the mains present.
Check the wiring of the remote start.
Check the configuration for the remote start
input.
Check that the controller is in “Auto” mode.
•
Check the wiring of the remote stop.
Check the configuration for the remote stop
input.
Check controller is in “Auto” mode.
•
•
Check the mains wiring.
Check the configuration for mains monitoring.
•
•
•
Check the actuator connections.
Check mechanical linkage assembly.
Check the configuration parameters for egovernor.
Check the PID control gains.
•
•
E-Governor Issues
23
A) Controller not able to maintain the target
RPM.
B) Engine RPM is not stable
•
24
Engine cranks but does not start the engine.
•
•
•
•
Check that the actuator moves to full throttle
position when engine cranked.
Check the actuator connections.
Check mechanical linkage assembly.
Check the configuration parameters for egovernor.
Disclaimer: Due to continuous development, the details provided in this document are subject to change without any
prior notice.
Page 38 of 39
SEDEMAC
SEDEMAC Mechatronics
C9-10, C Block, MIDC Bhosari,
Opp Faurecia Ltd, Pune 411026.
Support over email:
Email: [email protected]
Support over phone:
+91-8551039888
+91-8551041888
+91-8551043888
Page 39 of 39

Operation Manual For GC1200 Series Genset Controllers SEDEMAC DOC # ENG-PD-APPKIT-GC1200-002

Transcription

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