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Manual

HM1016ER1

Control and Operation Instruction

Harsen

®

Page 15/54

4.9 Flow chart for start and stop

T1

－

start delay

T2

－

crank time

T3

－

pre-heat time

T4

－

safety-on delay

T5

－

idle time

T6

－

Stop delay

NOTE:

If T4 is longer than T5, oil pressure protection is ignored during T5.

If T4 is shorter than T5, oil pressure protection becomes effective after T4

in T5.

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Summary of Contents for GU641B

Page 1: ...Manual GU641B Genset Controller HM1016ER1 Harsen ...

Page 2: ...ardous situation which if not avoided could result in death serious personal injury or property damage CAUTION A CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment or property NOTE A NOTE provides other helpful information that does not fall under the warning or caution categories ...

Page 3: ... with possible personal injury loss of life or property damage The over speed shutdown device must be totally independent of the prime mover control system An over temperature or low pressure shutdown device may also be needed for safety as appropriate CAUTION BATTERY CHARGING To prevent damage to a controller that uses an alternator or battery charging device make sure the charging device is turn...

Page 4: ...Manual HM1016ER1 History Harsen III History No Rev Date Editor Validation Changes 1 HM1016ER1 2011 1 1 P L New ...

Page 5: ...nsion Drawings and Controller Wiring 3 Panel Operation 4 Control and Operation Instruction 5 Measure and Display Data 6 Pre alarm and Shutdown Alarm 7 Parameters Setting 8 Installation Guide 9 LCD displays and Menu System 10 Technical Specification 1 2 6 7 16 17 21 41 50 53 ...

Page 6: ...e outputs of configurable auxiliary control relays More configurable isolated digital inputs Buttons on control panel are used for selecting control modes starting and stopping the operating procedure displaying data and modifying the parameters LED indicators are used for indicating the operation mode of controller and the running status of Genset and LCD displays each measuring parameter and sta...

Page 7: ... Dimension Drawings and Controller Wiring Harsen Page 2 54 2 Outline Dimension Drawings and Controller Wiring 2 1 Following Details Module Dimensions W192mm H144mm Panel Cutout W174mm H126mm Thickness D56mm without connection ...

Page 8: ...CB close open N O contact 3A 30Vdc configurable 1 1mm 21 Relay output 4 MCB close open N O contact 3A 30Vdc configurable 2 1mm 22 Relay output 5 N O contact 3A 30Vdc configurable 3 1mm 23 Relay output 6 N O contact 3A 30Vdc configurable 4 1mm 24 charger excitation power output if not used do not connect to negative 1mm 25 Configurable digital input signal 1 low level is active 1mm 26 Configurable ...

Page 9: ...Manual HM1016ER1 Outline Dimension Drawings and Controller Wiring Harsen Page 4 54 2 3 Typical Wiring Diagram A fuse with the rating of 1A shall be provided external to the equipment ...

Page 10: ...buzzer continues to sound Press and hold this button for 2sec all LEDs illuminate simultaneously AUTO Mode Button LED Value Increase The push button is used for selecting auto mode When the controller is running in AUTO mode the LED above the button is illuminated The activation and deactivation of the remote start signal input and Mains Failure controls the starting and stopping of the Genset Whe...

Page 11: ... immediately If failure occurs press this button the shutdown alarm lockout can be cleared When in parameters setting mode this button is used to move to next parameters setting position C O Button There are 2 C O buttons respectively beside the Mains and Gen icons They are used to close open the switches of Mains and Gen when controller is running in MANUAL mode Shutdown Alarm FAILURE LED The LED...

Page 12: ... are within the range of preset value the Mains Normal LED illuminates the timer for Mains ON delay is activated when it times out the MCB close open relay closes the transfer switch switches on Mains the Mains Aux Switch s contact feeds back the signal to a configurable input on our controller The MCB closed LED illuminates WARNING The Mains Normal LED illuminated means that both voltage and freq...

Page 13: ...ngages and begins to crank When the engine speed reaches the crank cutout RPM the start relay output is de energised and the safety on delay starts When the safety on times out if the controller detects that the parameters of the Genset such as voltage frequency oil pressure coolant temperature are normal and no other failure is detected this indicates the Genset has successfully started and runni...

Page 14: ...inputs has been configured as Gen Aux Switch Closed and connects the switch s N O Aux contact signal to this port If you do not configure an input as Gen Aux Switch Closed then the GCB closed LED illuminates is only an indication that the GCB close open relay should have been closed If you have selected idle function the idle relay will be closed at the same time as the crank relay is closed the i...

Page 15: ...ns and the timer for Stop delay begins If the controller detects that the voltage of the generator or oil pressure or the speed of engine is greater than the cutout values or LOP switch is open when it times out the failure LED illuminates and the LCD displays Fail to stop NOTE After stop failure the controller will not energise the crank relay output if the failure has not been removed and the co...

Page 16: ...ator starting sequence Pressing START button the fuel relay energises and operates the fuel solenoid of engine After 300ms delay the start relay output is energised the start motor engages and begins to crank when the engine speed reaches the crank cutout RPM the start relay output is de energised and the safety on delay starts When the safety on times out if the controller detects that the parame...

Page 17: ...ing normally then Gen will be on load Test without load GCB close open relay will not be closed after the generator is started successfully and running normally the Mains remain on load 4 5 The start and stop Sequence of engine whose fuel solenoid is N O type There are two kinds of fuel solenoids for an engine one is N C type the valve of this solenoid is closed when the engine is in standby and i...

Page 18: ...t energises Mode 2 during preheat time preheat relay output energises until the successful ignition Mode 3 during preheat time preheat relay output energises until safety on delay times out Mode 4 one of the configurable inputs is defined as Preheat preheat relay output energises when this configurable input is active and de energises when configurable input is inactive For preheat mode 1 to 3 ple...

Page 19: ...the holding time on the button Safety on timer begins after it has successfully started The other processes and protections are the same as for a normal start Second method when controller is running in MANUAL mode configure the EX Crank permit as 1 shown as schematic below a PB switch is externally mounted to control cranking Close PB switch engine cranks when the speed reaches 150RPM or generato...

Page 20: ...low chart for start and stop T1 start delay T2 crank time T3 pre heat time T4 safety on delay T5 idle time T6 Stop delay NOTE If T4 is longer than T5 oil pressure protection is ignored during T5 If T4 is shorter than T5 oil pressure protection becomes effective after T4 in T5 ...

Page 21: ... L1 N L2 N L3 N Gen 3 phases VPh Ph L1 L2 L2 L3 L3 L1 Gen frequency Hz L1 Gen 3 phases current I1 I2 I3 Gen total apparent power A Gen total active power P Gen power factor PF AV Engine speed RPM signal derived from magnetic pick up or generator Hz Engine oil pressure Bar signal from engine LOP sensor Engine coolant temperature signal from engine HET sensor Battery voltage Vdc Genset Running Hour ...

Page 22: ...olt preset as 28 2V when battery voltage exceeds this value LCD flashing high value icon LOW OIL PRESS If controller detects that the engine oil pressure has fallen below the Oil P low preALM after the safety on timer expired the pre alarm LED illuminates and the buzzer sounds LCD displays For example Oil P low preALM preset as 2 2BAR when engine oil pressure falls below this value LCD flashing lo...

Page 23: ... high value D INPUT If one of Configurable D inputs has been configured as pre alarm when D input is active the pre alarm LED illuminates and the buzzer sounds LCD flashing D Input icon GCB FAILURE If GCB close open relay is closed the timer for GCB closing is activated when it times out if the controller does not receive the feed back signal from Gen Aux Switch s contact then Gen fail to load ala...

Page 24: ...has expired engine stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays low oil press icon ENGINE HIGH TEMP if controller detects that engine coolant temperature has exceeded the Coolant Alarm or HET switch closes engine stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays engine high temp icon OVER SPEED if controller detects that engi...

Page 25: ...open Genset stops the Shutdown alarm LED illuminates and buzzer sounds LCD displays NOTE If engine speed signal is derived from generator output voltage frequency it is used for control and failure protection parameters for convenience of user some data is expressed by RPM RPM Hz 60 pair of poles NOTE While the Genset is running if there is high coolant temperature low oil pressure or over speed f...

Page 26: ...999 1 12 Firmware update Menu descriptions CT Ratio The current is derived from CT on generator Secondary current on CT is fixed at 5A Used to calculate for GEN KVA KW and PF Used for shutdown alarm over current overload etc VT Ratio The voltage is derived from VT on Gen and Mains Used to detect frequency of Gen and Mains Used to calculate for GEN KVA KW and PF Used for shutdown alarm over under v...

Page 27: ...Manual HM1016ER1 Parameters Setting Harsen Page 22 54 Voltage type There are 5 kinds of voltage input type Y 3P4W 3P4W 3P3W 1P3W 1P2W 1 Y 3P4W 3 phases 4 wires star 2 3P4W 3 phases 4 wires angle ...

Page 28: ...Manual HM1016ER1 Parameters Setting Harsen Page 23 54 3 3P3W 3 phases 3 wires 4 1P3W single phase 3 wires 5 1P2W single phase 2 wires ...

Page 29: ...sed to configure the cycle of page scroll When parameter is configured as 0 manually scroll page via button Start to scroll automatically 30 seconds after not pressing any button Default settings Some parameters are resumed to default setting Password There are 3 levels of password CL0 CL1 CL2 for different users CL0 for the operator who can read parameters start and stop controller The default se...

Page 30: ...with load Menu descriptions GEN V under preALM Used to configure Gen under voltage pre alarm value the GEN V under preALM is inactive when parameter is configured as 0 Expressed by percentage Rated Ph N voltage x GEN V under Alarm Used to configure Gen under voltage alarm value the GEN V under Alarm is inactive when parameter is configured as 0 Expressed by percentage Rated Ph N voltage x GEN V ov...

Page 31: ...ED illuminates and buzzer sounds if over current happens Genset will not shutdown LCD displays over current icon When parameter is configured as 2 the Shutdown alarm LED illuminates and buzzer sounds if over current happens the Genset will be shut down LCD displays over current icon Loading Voltage Used to configure the voltage trigger value of the GCB close Expressed by percentage use Rated ph vo...

Page 32: ...sed 3 19 Idle time 0 1 to 9999s 0 not used 3 20 Pre heat mode 1 1 to 4 3 21 Pre heat time 3s 1 to 9999s 0 not used 3 22 Safety on delay 10s 0 to 600s 3 23 Cool down mode 0 0 full speed 1 idle 3 24 Cool down time 300s 0 to 600s 3 25 Stop delay 20s 0 to 60s 3 26 Under SP preALM 1440RPM 1 to 9999 RPM 0 not used 3 27 Under SP Alarm 0 1 to 9999 RPM 0 not used 3 28 Over SP preALM 1600RPM 1 to 9999 RPM 9...

Page 33: ...ter of MPU input as 0 Start the Genset choose Set pickup now from the menu after the Genset running normally the parameter of fly wheel teeth will be automatically calculated at that time Configure the parameter of MPU input as 1 to finish the setting NOTE This function is only used for the debug of the controller and Genset Please do not implement this function when no RPM signal input Pair of Po...

Page 34: ...T 50 60 70 80 90 100 110 120 130 140 150 R Ω 322 221 155 112 93 62 47 37 29 23 19 Datcon T 40 50 60 70 80 90 100 110 120 130 140 R Ω 900 600 400 278 200 141 104 74 50 27 4 Murphy T 40 50 60 70 80 90 100 110 120 130 140 R Ω 1029 680 460 321 227 164 120 89 74 52 40 PT100 T 100 50 0 20 40 60 80 100 150 200 300 R Ω 60 81 100 108 116 123 131 139 157 176 212 Pre set 1 T 20 30 40 50 60 70 80 90 100 110 1...

Page 35: ...nsor is used to measure the oil pressure its accuracy is very important to the protection of the Genset so please match the right type of the sensor or configure the right curve of the senor Otherwise it may cause engine damage The parameters appendix of LOP sensor VDO 5 bar P Bar 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 R Ω 11 29 47 65 82 100 117 134 151 167 184 VDO 10 bar P Bar 0 0 1 0 2 0 3 0 4 ...

Page 36: ...e how many times the controller repeat to crank the engine this value is equal to the maximum crank times Crank time Used to configure the maximum time permit of engine cranking Crank time add Used to adjust the maximum time permit of the repeat cranking The second time of crank time is equal to the first crank time plus the extra time For example crank time set at 5s Crank time add set at 3s then...

Page 37: ...recovers to open after the idle time has expired When parameter is configured as 0 idle function is inactive Pre heat mode Used to configure the mode of preheat Optional 4 pre heat modes details refer to the description of 4 7 preheat function Pre heat time The preheat duration before engine crank When parameter is set as 0 pre heat function is inactive Safety on delay Used to configure the period...

Page 38: ...d alarm value for the engine When parameter is set as 0 this function is inactive Over SP preALM Used to configure the over speed pre alarm value for the engine When parameter is set as 9999 this function is inactive Over SP Alarm Used to configure the over speed alarm value for the engine When parameter is set as 9999 this function is inactive Oil P low preALM Used to configure the low oil pressu...

Page 39: ...rvolt Used to configure the low battery voltage pre alarm When parameter is set as 0 this function is inactive Batt overvolt Used to configure the high battery voltage pre alarm When parameter is set as 99 9 this function is inactive Alt low preALM Used to configure the low charger voltage value Voltage signal is derived from the excitation winding of charger When parameter is set as 0 this functi...

Page 40: ... active When it is active generator stops shutdown alarm LED illuminates and buzzer sounds 3 Pre alarm 1 Low level is active When it is active after safety on delay pre alarm LED illuminates and buzzer sounds 4 Alarm1 Low level is active When it is active after safety on delay generator stops shutdown alarm LED illuminates and buzzer sounds 5 LOP switch low level is active 6 HET switch low level i...

Page 41: ...reheat relay 6 Reserved 7 Reserved 8 Reserved 9 GEN running 10 Auto mode 11 Test mode 12 Manual mode 13 Reserved 14 Idle relay N O 15 MCB failure 16 GCB failure 17 Start failure 18 Stop failure 19 MCB close open 20 GCB close open 21 KW overload pre alarm 22 Charge failure 23 Over current pr alarm 24 Battery Under voltage 25 Battery Over voltage 26 Reserved 27 Reserved 28 Low oil pressure pre alarm...

Page 42: ...served 48 GEN under voltage alarm 49 GEN over voltage alarm 50 KW overload alarm 51 P Sensor open alarm 52 Configurable D input1 active 53 Configurable D input2 active 54 Configurable D input3 active 55 Configurable D input4 active 56 Configurable D input5 active 57 Reserved 58 Reserved 59 Buzzer sounds alarm 60 Air flap control 61 Reserved 62 Test without load mode 63 Test with load mode 64 Emerg...

Page 43: ...arm value the Mains V high Alarm is inactive when parameter configured as 999 Expressed by percentage use Rated ph voltage as factor Mains Hz low Alarm Used to configure low Mains frequency alarm value the Mains Hz low alarm is inactive when parameter configured as 0 Mains Hz High Alarm Used to configure high Mains frequency alarm value the Mains Hz high Alarm is inactive when parameter configured...

Page 44: ...value display of GEN Phase 1 voltage Reference to the Rated ph voltage GEN V2 offset Used to modify the measured value display of GEN Phase 2 voltage Reference to the Rated ph voltage GEN V3 offset Used to modify the measured value display of GEN Phase 3 voltage Reference to the Rated ph voltage Current I1 offset Used to modify the measured value display of Phase 1 current Reference to the Rated c...

Page 45: ...he Rated voltage Mains V3 offset Used to modify the measured value display of Mains Phase 3 Voltage Reference to the Rated voltage Pressure offset Used to modify the measured value display of LOP sensor Temperature offset Used to modify the measured value display of HET sensor Batt V offset Used to modify the measured value display of battery voltage ...

Page 46: ...ion of the mounted controller meet IP65 the cutout dimension on the panel must be correct A readily accessible disconnect device shall be incorporated external to the equipment 8 2 Wiring Please refer to the above 2 3 Typical Wiring Diagram for connection 8 2 1 Grounding Protection Make sure the connection between terminal 34 of controller and protective earth is good the cross section area of cab...

Page 47: ... or fuse for over current protection between power supply and controller must be mounted the recommended capacity is 1A When powering the controller will generate significant instantaneous peak current the maximum instantaneous peak current is relative to the power impedance You must consider the peak current when choosing a switch or fuse for over current protection 8 2 3 The installations of LOP...

Page 48: ...f the common port is connected to the power supply negative The sensor shell and engine must be well connected and do not use insulated material on sensor screw thread when installing single pole sensor 8 2 4 The installation of MPU NOTE The measuring accuracy of magnetic pick up is related to fly wheel teeth Accuracy 120 fly wheel teeth RPM As the above formula more fly wheel teeth leads to highe...

Page 49: ...generator winding 3P4W 3 phases 4 wires Measure and Display Data Mains 3 phases VPh N L1 N L2 N L3 N Mains 3 phases VPh Ph L1 L2 L2 L3 L3 L1 Mains frequency Hz L1 Gen 3 phases VPh N L1 N L2 N L3 N Gen 3 phases VPh Ph L1 L2 L2 L3 L3 L1 Gen frequency Hz L1 Gen 3 phases current I1 I2 I3 Gen apparent power A Gen active power P Gen power factor PF ...

Page 50: ...res CT measure at Gen side Measure and Display Data Mains 3 phases VPh Ph L1 L2 L2 L3 L3 L1 Mains frequency Hz L1 Gen 3 phases VPh Ph L1 L2 L2 L3 L3 L1 Gen frequency Hz L1 Gen 3 phases current I1 I2 I3 Gen total apparent power A Gen total active power P Gen power factor PF ...

Page 51: ... phase 3 wires CT measure at Gen side Measure and Display Data Mains VPh N L1 N L2 N Mains VPh Ph L1 L2 Mains frequency Hz L1 Gen VPh N L1 N L2 N Gen VPh Ph L1 L2 Gen frequency Hz L1 Gen phase current I1 I2 Gen apparent power A Gen active power P Gen power factor PF ...

Page 52: ...Page 47 54 1P2W single phase 2 wires CT measure at Gen side Measure and Display Data Mains VPh N L1 N Mains frequency Hz L1 Gen VPh N L1 N Gen frequency Hz L1 Gen current I1 Gen phase apparent power A Gen phase active power P Gen power factor PF ...

Page 53: ... negative terminal 33 inside the controller The maximum acceptable resistance for each input is 10KΩ it means whether the switch of loop circuit is closed or not the status monitored by controller are all open when the resistance in loop circuit exceeds 10KΩ status monitored by controller are all close when the resistance in loop circuit falls below 10KΩ To avoid error monitoring of switch status ...

Page 54: ...it is connected to power positive The output current for each relay can not exceed the rated current of respective relay the total output current for 6 relays from RL1 to RL6 can not exceed 16A A switch or fuse for over current protection must be mounted between power and terminal 17 the recommended capacity is 16A In practical application controller output will generate instantaneous peak current...

Page 55: ...HET sensor or LOP sensor is set as not used LCD will not display the related data 9 2 Setting running parameters Press and hold button 2sec to enter into parameter settings menu then use or to scroll page in the same menu list press enter into submenu press can return to upper menu go to menu 1 11 to key in password first or select the required item press enter into modify mode press or LCD displa...

Page 56: ...he password is correct change at 100 then LCD displays Press to confirm then press then LCD displays Press or press and hold 2sec will quit parameter settings menu then LCD displays For example setting controller crank attempt at 2 Operation Description Press and hold 2sec enter into parameters setting menu then LCD displays Press 36 times and then press then LCD displays Press or button it prompt...

Page 57: ...n press for exiting parameters setting For example configure controller at online program mode Operation Description Press and hold 2sec enter into parameters setting menu then LCD displays Press 11 times then LCD displays Press button it prompts to key in password the password is 3132 press move to desired modify number Press again enter into program mode Use the communication cable and the softw...

Page 58: ...urement True RMS Measuring current 5A Accuracy 1 Display 0 to 9999A Max power wastage per line 0 01W 10 4 Power supply Range 12V 24V 8 35V continuous Max operating current 12V 300mA 24V 150mA Max standby current 12V 90mA 24V 45mA Cranking dropouts 0V for 80ms assuming dc supply was at least 10V before dropout and recovers to 5V Accuracy 1 Display 0 to 40V 10 5 Configurable digital inputs Number 5 ...

Page 59: ...to 70V Max frequency 10000Hz Fly wheel teeth 5 to 300 10 10 Ambient parameters Operating ambient temperature Standards 20 to 70 IEC60068 2 1 and IEC60068 2 2 Storage ambient temperature Standards 30 to 80 IEC60068 2 1 and IEC60068 2 2 Humidity Standards 60 95 RH 48 hours IEC60068 2 30 Electro Magnetic compatibility EMC Standards EN 61000 6 4 and EN 61000 6 2 Vibration Standards EN 60068 2 6 Shock ...

Page 60: ...Service Hotline 4008883388 More technical support Please browse our website www jnhharsen com ...

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