SEDEMAC GC1100 User Manual Download

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MANUAL FOR

GC1100:

GENSET

CONTROLLER

Product Manual Version #0.00

ABSTRACT

This manual is intended as
an information guide for
operating SEDEMAC's GC1100
genset controller

Doc #SED-MAN-GC1100-002

Date: 20-Apr-2018

Summary of Contents for GC1100

Page 1: ...L FOR GC1100 GENSET CONTROLLER Product Manual Version 0 00 ABSTRACT This manual is intended as an information guide for operating SEDEMAC s GC1100 genset controller Doc SED MAN GC1100 002 Date 20 Apr...

Page 2: ...by their respective companies SEDEMAC Mechatronics Pvt Ltd reserves the right to change the contents of this document without prior notice For permission requests and applications to reproduce any par...

Page 3: ...nerators produce high electrical voltages direct contact with it can cause fatal electrical shock Prevent contact with terminals bare wires connections etc while the generator and related equip ment a...

Page 4: ...used by electric shock immediately shut down the electrical power source If this is not possible try to release the victim from the live conductor Avoid direct contact with the victim Use a nonconduct...

Page 5: ...gital Input ENG TEMP Engine Temperature ETS Engine Temperature Sensor FLS Fuel Level Sensor GCU Genset Control Unit Genset Generator Set GND Ground HMI Human Machine Interface HSD High Side Driver HWT...

Page 6: ...etic Pick Up Input 7 Digital Outputs 7 D CHG ALT 8 Sensor Common Point 8 Deep Sleep Mode Feature 8 Communication Ports 9 Installation 10 Dimensions 10 Mounting on panel 10 Terminal Description 12 Typi...

Page 7: ...485 MODBUS Based Protocol 43 Connection Details 43 Precautions 44 Function Code Used 44 Register Map 46 Protocol for CAN Based Communication 51 Connection Details 51 Structure of Communication 51 Pack...

Page 8: ...igure 9 GC1100 genset controller from backside 12 Figure 10 GC1100 genset controller power circuit used in the Auto Mains Failure Mode 14 Figure 11 GC1100 genset controller control circuit used in the...

Page 9: ...ble 15 Sensor common point 8 Table 16 Communication ports 9 Table 17 Details of GC1100 terminals 12 Table 18 Screens of engine status and operating mode 16 Table 19 Control keys in different modes 19...

Page 10: ...nd from MODBUS master for Function 3 45 Table 37 Normal response from genset controller slave for Function 3 46 Table 38 Register map for input registers 46 Table 39 Register map for holding registers...

Page 11: ...MAC s Smart Config All parameters can also be configured using the keypad of the genset controller 1 1 Key Highlights of the Product Genset controller with configurable 5 digital inputs 4 analog input...

Page 12: ...mperature Range deg C 20 to 65 Ingress Protection with Optional Gasket IP65 Sensor Common Input with 2V Sensing Range Y Warning auto clear enable disable Y Fuel reference selection input Y On the fly...

Page 13: ...SM Part Number Female Mating SM Part Number Quantity Nos 4 Pin 5474274 SM0003195 5453499 SM0001163 2 Phoenix Phoenix Contact I Pvt Ltd 5 08 mm pitch connectors suitable for 2 sq mm wire Figure 3 Conn...

Page 14: ...V DC Battery voltage measurement accuracy 1 full scale Battery voltage measurement resolution 0 1 V Maximum current 0 2 A 12 V DC Excluding all current loads for the high side driver s output and Rot...

Page 15: ...ent Transformer CT 2 5 Mains Voltage and Frequency Measurements Following table gives a brief overview of Mains voltage and frequency measurements Table 8 Mains voltage and frequency measurements Cont...

Page 16: ...tch and many more Please refer Table 21 2 7 Analog Resistive Sensor Inputs Following table gives a brief overview of analog resistive sensor inputs Table 10 Analog resistive sensor inputs Controller s...

Page 17: ...oltage range 200 mV to 45 V AC RMS 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 2 10 Digital Outpu...

Page 18: ...an electrically sound point on the engine body This point on the engine body should serve as a common reference point for all analog sensors such as those for measuring lube oil pressure engine temper...

Page 19: ...rial Port Half Duplex Max Baud Rate 115200 Data connection 2 wire Termination resistor of 120 is provided between output pin A B Common mode operating range and bus pin fault protection upto 70V Maxim...

Page 20: ...igure 6 Dimensions of the GC1100 genset controller Recommended mounting panel cut out dimensions 118 mm X 93 mm 4 2 Mounting on panel To mount the controller into the panel use the fixing clips provid...

Page 21: ...ll the fixing clips backwards towards the back of the module Ensure that the fixing clip is properly fitted inside the slot provided on the controller Fix the screws and tighten the screw turn clockwi...

Page 22: ...enix Female Mating Connector Part No 1 GND Power Supply Ground 5441980 2 BATTERY Power Supply ve 3 OUT A High Side Driver A 5441430 4 OUT B High Side Driver B 5 OUT C High Side Driver C 6 OUT D High S...

Page 23: ...oltage Input From Gen Phase B 29 GEN_V IN Y Voltage Input From Gen Phase Y 30 GEN_V IN R Voltage Input From Gen Phase R 31 MAINS_V IN NTRL Voltage Input From Mains Neutral 5453499 32 MAINS_V IN B Volt...

Page 24: ...ing Diagram Auto Mains Failure Application The typical wiring diagram of GC1100 for Auto Mains Failure application on engine with mechanical fuel system Figure 10 GC1100 genset controller power circui...

Page 25: ...GC1100 SEDEMAC Page 15 Figure 11 GC1100 genset controller control circuit used in the Auto Mains Failure mode...

Page 26: ...ns 5 1 Monitoring Mode In monitoring mode screens will scroll automatically after a configurable time which can be configured in configuration menu or you can use the Navigation UP DOWN Keys to scroll...

Page 27: ...visible only if configured for 3 phase genset LOAD CURRENT GEN ENERGY The Y B phase will be visible only if configured for 3 phase genset MAINS STATUS ENG SPEED ENG RUN TIME BATTERY VOLT ENG TEMP LUB...

Page 28: ...ler s configuration AUTO EXERCISE 2 CONTACTOR STATUS This screen will be visible only if Event 2 is enabled from Auto Exercise 2 in controller s configuration This screen will be visible only if outpu...

Page 29: ...Manual Start Starts the engine 2 Manual Auto Enters Auto mode Stop Stops the engine when engine is running Stop long pressed Enters configuration mode Stop Down long pressed Enters Programming mode 3...

Page 30: ...view the configuration press STOP key of the GCU If you wish to change the configuration press START key of the GCU Figure 14 Configuration mode authentication page screen The GCU will ask for passwor...

Page 31: ...EP SLEEP MODE Disable Enable Load Histogram LOAD HISTOGRAM Disable Enable Auto Clear Warning Alarm WARNING AUTO CLEAR Disable Enable Language LANGUAGE English Chinese Display DISPLAY Contrast CONTRAST...

Page 32: ...ource SOURCE Refer Table 21 Polarity POLARITY Close to Activate Open to Activate Action ACTION None Notification Warning Electrical Trip Shutdown Activation ACTIVATION Never From Engine Start From Mon...

Page 33: ...Digital Activation DIG ACTIVATION Never From Engine Start From Monitoring On Always Digital Activation Delay DIG ACTIVATION DELAY 1 60 sec FLS Low Fuel Level Shutdown SHUTDOWN Disable Enable FLS Low F...

Page 34: ...ning Threshold WARNING THRESHOLD 0 2 10 0 bar LOP Circuit Fault Action OPEN CKT ACTION None Notification Warning Electrical Trip Shutdown LOP Lube Oil Pressure Sensor Calibration Table Refer Table 24...

Page 35: ...Start Delay AUTO START DELAY 0 43200 sec General GENERAL TIMER Safety Monitoring Delay SAFETY MONITOR DELAY 10 60 sec Mains Detect Delay MAINS DETECT DELAY 1 300 sec Alternator Detect Delay ALT DETECT...

Page 36: ...OLT MONITOR Under voltage Shutdown UNDER VOLT SHUTDOWN Disable Enable Under voltage Shutdown Threshold UV SHUTDWN THRESHLD 50 295 V Ph N Under voltage Warning UNDER VOLT WARNING Disable Enable Under v...

Page 37: ...Reserved 0 900 1 100 CT Location CT LOCATION On Load Cable On Alt Output Cable Load Monitoring LOAD MONITOR Generator Rating GEN RATING 0 8000 kW Over load Action OVERLOAD ACTION None Notification Wa...

Page 38: ...348 V Ph N Under frequency Monitoring UNDER FREQ MON Enable ENABLE No Yes Trip TRIP 10 0 59 0 Hz Return RETURN 11 0 60 0 Hz Over frequency Monitoring OVER FREQ MON Enable ENABLE No Yes Trip TRIP 26 0...

Page 39: ...sable Enable Under speed Threshold UNDER SPD THRESHOLD 0 3600 rpm Under speed Delay UNDER SPD DELAY 1 60 sec Over speed Threshold OVER SPD THRESHOLD 700 4000 rpm Over speed Delay OVER SPEED DELAY 1 20...

Page 40: ...10 65000 hour Alarm Due Date ALARM DUE DATE DD MM YYYY Miscellaneous Settings MISC SETTINGS PASSWORD 1 0 9 for each digit PASSWORD 2 0 9 for each digit RESET COUNTERS MAINS RUN TIME In numbers MAINS...

Page 41: ...sistance Fuel level 0 1000 R1 R10 0 100 L1 L10 Table 24 LOP sensor calibration Resistance Pressure Bar 0 1000 R1 R10 0 0 10 0 Bar V1 V10 Table 25 LOP sensor 4 20mA calibration Current mA Pressure Bar...

Page 42: ...UV Shutdown 32 Y Phase Over Voltage Shutdown Y Phase OV Shutdown 33 Y Phase Under Voltage Shutdown Y Phase UV Shutdown 34 B Phase Over Voltage Shutdown B Phase OV Shutdown 35 B Phase Under Voltage Shu...

Page 43: ...voltage or frequency or RPM or lube oil pressure is detected then engine will be on Controller will latch the genset contactor when genset loading voltage and frequency are above the minimum healthy...

Page 44: ...genset contactor when controller confirms that all the engine and genset parameters are within the configured thresholds When the preconfigured input is deactivated the controller will open the genset...

Page 45: ...Exercise mode In AMF mode if the mains is unhealthy or cutoff or when the genset is running in Exercise mode genset will first run Exercise and then genset will continues to run in AMF mode Load will...

Page 46: ...er will start DG off time After completion of DG OFF time DG ON time will start and this cycle will continue until mains is detected healthy During any of the times if mains is detected healthy both t...

Page 47: ...GC1100 SEDEMAC Page 37 8 2 Manual Mode Figure 19 SMD for manual mode...

Page 48: ...ng genset s operation in genset ON condition The genset cannot be started without acknowledging the warning alarms 3 Electrical trip In this alarm action type load is taken off from the genset engine...

Page 49: ...utdown is required Shutdown 13 Fail To Stop Indicates that genset has not stopped after sending Stop command Shutdown 14 Fail To Start Indicates that genset has not started after the pre set number of...

Page 50: ...shold is configurable percentage value of over speed threshold Shutdown 30 Under Speed The engine speed has fallen below the pre set RPM Shutdown 31 Extended Over Load Trip Indicates that there was 10...

Page 51: ...rates unnecessary Shutdown Alarms or Warning Alarms Check the respective switch sensor and wiring Enter configuration mode in the controller and verify the respective threshold configuration 5 The con...

Page 52: ...MPU connection and configuration if enabled Check wiring of the main alternator s R phase and neutral to the controller 12 The controller screen freezes or hangs up Reset the controller power Possible...

Page 53: ...shielded twisted pair cable The transmission mode used by GC1100 controller is MODBUS RTU not MODBUS ASCII The byte format for communication is 1 start bit 8 data bits with without parity bit and 1 s...

Page 54: ...eads one or more 16 bit from the slave device of read write location 16 Write holding register Writes one or more 16 bit registers to the slave device Supported functions and respective command respon...

Page 55: ...to 255 5 Number of registers to write low byte 6 Number of data bytes to follow n 7 Value at first register 6 n Value at last register 7 n 8 n Error check CRC Table 35 Normal response from genset con...

Page 56: ...check CRC 12 4 Register Map The register map for input registers is as shown in Table 38 Table 38 Register map for input registers Register Address Parameter Scale Factor Unit Interpretation Bits Sign...

Page 57: ...1 kVA Unsigned 35 Load L1 var 0 1 kVAR Unsigned 36 Load L2 var 0 1 kVAR Unsigned 37 Load L3 var 0 1 kVAR Unsigned 38 Load total var 0 1 kVAR Unsigned 39 40 Generator cumulative energy 0 1 kWH Unsigne...

Page 58: ...or high frequency 1 16 4 16 67 Alarm 4 Generator high current 13 16 16 16 Generator overload 9 16 12 16 Unbalanced load 5 16 8 16 Emergency stop 1 16 4 16 68 Alarm 5 Charge alternator failure 13 16 16...

Page 59: ...tation 5 16 8 16 Mains phase rotation 1 16 4 16 75 Alarm 12 Fuel level Open Circuit 13 16 16 16 V belt broken 9 16 12 16 Extended over load trip 5 16 8 16 High oil pressure detected 1 16 4 16 76 Input...

Page 60: ...ctual value Observed value on MODBUS interface multiplied with scale factor The register map for holding registers is as shown in Table 39 Table 39 Register map for holding registers Register Offset D...

Page 61: ...oller Response to the commands is a part of the data that is broadcasted Table 42 shows the structure of the broadcasted message Table 41 Structure of communication Register Offset Page No Value for G...

Page 62: ...8 Load total VAR 1 kVAR Unsigned 39 40 Page 13 Generator cumulative energy 0 1 kWh Unsigned 41 42 Page 14 Generator cumulative apparent energy 0 1 kVAH Unsigned 43 44 Page 15 Generator cumulative reac...

Page 63: ...0001 S 0011 0011 13 16 16 16 Over speed E 0001 0001 S 0011 0011 9 16 12 16 Fail to start E 0001 0001 S 0011 0011 5 16 8 16 Fail to stop E 0001 0001 S 0011 0011 1 16 4 16 66 Alarm 3 Reserved 1111 13 1...

Page 64: ...Battery low voltage E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011 0011 13 16 16 16 Battery high voltage E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011 0011 9 16 12 16 Temperature Circ...

Page 65: ...0100 S 0011 0011 1 16 4 16 72 Alarm 9 Auxiliary input e E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011 0011 13 16 16 16 Auxiliary input f E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011...

Page 66: ...Circuit E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011 0011 13 16 16 16 V belt broken E 0001 0001 N 0101 0101 W 0010 0010 E 0100 0100 S 0011 0011 9 16 12 16 Extended over load trip E 0001 000...

Page 67: ...6 DG fail to start True 1 False 0 6 16 Gen available True 1 False 0 5 16 Common shut down True 1 False 0 4 16 Common electric trip True 1 False 0 3 16 Common warning True 1 False 0 2 16 Common notific...

Page 68: ...r each of 1 Bytes Bits Sign 1 Start Stop command 0x01 Start DG 0x02 Stop DG Command Status is updated in status register Unsigned 2 Operating mode change command 0x01 Toggle Current mode of operation...

Page 69: ...GC1100 SEDEMAC Page 59 Notes...

Page 70: ...ect to change without any prior notice SEDEMAC Mechatronics Pvt Ltd Technical Centre C9 10 C Block MIDC Bhosari Pune 411026 India Manufacturing Plant G 1 MIDC Phase III Chakan Industrial Area Nighoje...

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