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1. Note Available data are related only to faults that occurred after the latest power up sequence Events that occurred before GENSYS has been power cycled are listed in the FAULT pages but NOT among the variables user manual lechnical documentation Chapter Communication buses 91 7 2 CANOPEN EXTENSION MODULES CANopen extension modules can be used to increase the number of digital inputs and outputs of GENSYS Overall max count of added inputs 32 and 32 O They are read written to every 100ms 7 2 1 Hardware Each bus coupler is a slave node that supports up to 64 I O modules that offer different kinds of I O Outputs can be by transistors or relays I Os can be distributed across up to 4 daisy chained couplers TE T Bus coupler PUU pong ong on 950 la FOME gt ONQOE 00 A k 750 3xx d BK5150 LC5100 low cost no VIPAO53 1CA00 isolation ID by DIP switch ID by rotary switch ID by DIP switch ID by DIP switch I O modules 75x 4xx inputs KLXXXX All the digital 1 O VIPA 021 1BF50 inputs 75x 5xx outputs terminals are sup VIPA022 1BF00 outputs ported except the KL15xx KL25x2 KL2692 and KL27x1 terminals The modules are stackable and mounted on a DIN rail Refer to the extension module s user manual for correct wiring on the CANopen module side Check whether the inputs outputs are protected against short circuits If needed connect the d
2. gt Breaker fault Fail to close open the breaker o o Closing 2304 Tult Generator breaker open suddenly Order to close the breaker Generator active power flow 3 6 CYCLES BEFORE MAINTENANCE o o You can program maintenance operations based on counts of cumulated running hours or days Five cycles are based on running hours five cycles are based on running days The counters of the latter cycles are incremented every day whether the generator has run or not In the frame of a maintenance program they are used to call for various maintenance operations the longer the running cycle the deeper the generator inspection The cycles usually imbricate in one another In CRE Config Configuration Maintenance or in the text file set the cycle name and the duration y 3500 3509 Cycle x h d or Meter x h d Cycle duration in running hours h or days d x 1 5 The alarm name shown when the cycle is elapsed will be the label The countdown of left hours days since the latest reset can be read in CRE Config Scada Maintenance cycle monitoring or in Display Maintenance off means that the cycle is not defined It is saved into non volatile memory Reading Label Description 0850 0859 Maintenance hours days n
3. Crank 3 drop out Preheat coolant Speed RPM above which the engine is considered to be started for starter 3 Refer to 3 2 Oil pressure threshold ibidem Air conditioning thresh ibidem Control on CAN2 fault Idle speed Effect of a CAN2 bus fault The engine speeds up from crank disconnect value to idle speed then the Chapter Human Machine Interface 77 1 2 3 Nom speed 1 Nom speed 2 Speed droop First speed set point default Used for protection Second speed set point It can be activated with digital input Droop of the internal speed controller Refer to the chapter 4 4 2 Available according to Speed measurement 2200 Idle speed must be set to nominal speed 1 value 2207 if the internal speed controller is not used Select the menu item Options Advanced If an ECU has been selected set the protections according to the information received by J1939 Control on high speed Protection associated to a high speed Control on very high speed Protection associated to a very high speed Control on high cool temperature Protection associated to a high water temperature Control on very high cool temperature Protection associated to a very high water temperature Control on low oil pressure Protection associated to a low oil pressure Control on very low oil pre Protection associated to a very low oil pressure Co
4. Settings for frequency centering 1 of the deviation corresponds to dead band 47 5 52 5 Hz around 50Hz e g a dead band of 0 1 Hz If the generator changes its speed but has compensated too much or not enough to reach the nominal speed increase 3652 to increase the center frequency control 4405 Load sharing Synchro only GENSYS wants the generator to go faster Maxi f 100 3650 Deadband cererator to go slower oe poo Increase f lt gt T 700 4405 seconds Frequency Frequency centering only GENSYS wants the generator to go slower Dead band 4 ants the generator to go faster Decrease f Increase f Decrease f Increase f 5 4 3 Voltage calibration procedure To calibrate the voltage control execute the same procedure as the speed calibration procedure 3651 Non action range U U in default value O 3653 Delay U U Imp default value O A56 ZO 9 0020 B EN user manual lechnical documentation 5 5 TESTS Make sure that you have the latest power plant schematics and that all the cables CAN bus shielded cables speed governor GENSYS interface are ready The HMI can be either LCD or CRE Config Scada 5 5 1 Individual check Check up 1 Unplug the relay cable connector for safety purpose 2 Check the speed governor settings and AVR control settings 3 Check GENSYS settings according to the desired setup 4 Ask the technician who has wired the power plant to lock the
5. 2 Count of re synchr gee launches Droop In event of CAN loss speed droop and voltage droop are allowed to share kW load and kVAR load respectively As droop is allowed the control does not use any integral Frequency droop The droop is the allowed relative offset Speed Droop Rated no load frequency Base frequency Rated no load frequency In the aggregate the generators were requested to run in proportion to their rated power i e with the same P PO As they are set with the same droop they share the same droop characteristic As the load demand increases they respond to the fall in frequency by increasing their active power outputs simultaneously The increase in the active power output counteracts the reduction in frequency Thus they do not fight one another to control the load no hunting 0 0 isochronous t Speed droop f0 f f0 Droop characteristic 1 P PO Voltage droop uses voltage in place of frequency The droops are set in the GENSYS units not in the ESGs AVRs If 3052 is set to 8 or 9 on all the GENSYS units all the generators fall back to speed and voltage droops It matters that all the GENSYS units be set to the same relative deviations 2204 and 2250 Speed droop for active load sharing Default value 2 Voltage droop for reactive load sharing Default value 2 CAN bus fault 8or9 TM base cl br Delay to close breaker if 3052 8 Default value 15 0s If
6. Raw input 2S ee S Delay oni Delay on pick up drop off Delayed input Chapter Resources for setup amp maintenance 105 Summary INPUT Validity Direction IN OUT Delay on pick up Delay on drop off Function Preset functions Note If a digital input changes a piece of data also to be written by Modbus the latest request takes over the other If 2 digital inputs are assigned to one function the latest change is taken into account Input functions Ref chapter Must be selected if the input is connected default value generally Generator breaker a 3 5 p 39 Generator breaker position feedback 8 4 2 p 114 feedback Remote start stop Remote start stop of generator start stop sequence mode auto 3 1 2 p 25 Allows the engine to run in automatic mode without paralleling nor 3 2 p 27 closing its breaker External temperature monitoring when the coolant is not water External reset Alternative to local fault reset in Fault and Alarm pages 0 p 38 Generator fault request Fault raised by the generator 4 2 AO Regulated preheating For preheating system used with a digital output in automatic mode ibidem permission Prelubrication request For prelubrication pump used with a digital output in manual mode Preglow request For preheating plugs used with a digital output in manual mode Only start generator A56 ZO 9 0020 B EN user manual technical documentation
7. user manual lechnical documentation Chapter Human Machine Interface 87 A56 Z0 9 0020 B EN 7 COMMUNICATION BUSES 7 1 MODBUS TCP 7 1 1 Capabilities The complete list of variables is in the file A56Z0 90030_ xIls Through an Ethernet communication where GENSYS acts as a Modbus TCP server you can e Upload many readings and GENSYS internal variables e Download values for many GENSYS internal variables level Nature Range Access right by nature Readings measurements statuses 0000 1999 Read only 2000 3999 Read Write 2 Modes statuses settings 4000 9999 Read Readings associated with digital inputs 4500 4649 Write subject to activation In addition in order to decrease load on Ethernet the following functions are supported e Reading Bit Fields listed in a dedicated tab of the file and organized in 16 bit words e Reading contiguous configurable data block 7 1 2 Configuration To communicate through Modbus TCP define the following settings e GENSYS IP address set in CRE Config System Network configuration e Modbus TCP port 3014 generally 502 set in CRE Config System Network configuration e Modbus rights see further GENSYS handles up to 4 Modbus TCP connections This can be used for multiple HMIs for example For more details on the Ethernet configuration see the chapter 2 1 p 17 7 1 3 Description RISK OF UNINTENDED EQUIPMENT OPERATION Stop the engine
8. 110 111b QSX15 7 91 512 515 175 182 250 183 168 108 247 102 105 92 513 514 100 110 QSK19 PGI 1 1 8 91 1242 512 515 2432 94 97 157 174 182 3 4 247 50 168 108 102 105 101 92 513 514 22 WY Q 100 1208 110 111b49 9 2 QSK38 PGI 1 1 9 QSK50 PGI 1 1 10 91 1242 512 515 2432 157 174 175 94 182 250 183 184 102 105 101 513 514 100 1208 110 1118 a a askeo Pai 1 1 11 168108977 A 7 GENERIC 0 z Ed jombeere IDEC 1 91 512 515 2432 182 250 183 107 52 106 102 105 101 98100175 184 94 157 174 158 247 173 176 81 92 513 514 109 110 111 1129 8 GENERIC 0 T CATERPILLAR A4E2 C4 4 C6 6 1 91 515 250 157 183 168 158 247 102 105 106 172 92 513 S 9 GENERIC 0 c DEUTZ EMR 1 91 512 188 183 247 102 92 513 100110 FAHR EMR2 2 91 512 183 4 8 174 158 108 247 102 105 92 513 98 100 110 111 EMR3 3 91 512 2432 183 174 94 3 E ond 107 102 105 92 513 514 100 110 111 10 GENERIC 0 boel A ADEC 2000 1 94 158 247 171 174 188 52 102 2433 2434 100 110 175 ADEC 4000 2 189 166 1136 1387 1388 247 1124 5 6 see Appendix MTU ECU8 smart conn 3 515 94 158 66 182 3 8 9 247 50 1136 105 3563 100 109 110 ECU8 SAM 4 11 GENERIC 0 DDEC III 1 DDEC IV 2 91 512 5 188 9 174 94 157 171 182 247 50 183 4 166 8 108 158 52 102 22 101 105 106 ge DDEC X 3 91 512 2432 188 189 166 174 172 107 173 1
9. reduces the deviation between the set point and the actual value By increasing P or I the rise time decreases However the overshoot increases and may also make the system unstable P fast hunting I slow hunting G is a sensitivity adjustment for the other settings Empirical tuning A B C First set G to 50 Set the parameters P and to 0 Increase the value of P until the system becomes unstable From this position decrease the value of P to 60 of the previous value If the system is unstable decrease G if it is too slow increase G A56 ZO 9 0020 A EN user manual lechnical documentation Download the list from CRE Config System PC transmit receive Actions on alarm fault and tick the boxes to show how the alarms faults contribute to severity indication and if any summary outputs grey shade prompts usual choice HH sa ede Pa eles Lale alle els ella se el as lA lalea a A A A A oa al y I I lt I I dl dl ls a el b al oe lt I gt IT O Max kVAR 32Q kW 32RP kVAR 32RQ Max 51 Max In 64G Uneven kW Uneven kVAR Max kW 32P a N w g gt Min KVAR 37Q N Oo Q Y o UN Uv gt O aB s a a ol E Q o ul cls a n in N ZC O Cc gt N O LL Min oil pressure On O O ep C LA 10 5 sl O al gt O E g9 L oO O oO OD E v oO Y a wo S Y S eD
10. stopping of the engine after cooling down time has expired If external protections are installed to report an alarm Stops the engine after cool down GENSYS requires another engine to 4 4 2 Remote fault Help E bol start via a remote start input before stopping itself Remote soft shutdown Activates the gen electrical fault action GENSYS requires another ibidem Help engine to start via a remote start input before stopping itself Stop horn Selective external reset in addition an output must be preset to Horn 0 p 35 Gen breaker Close Remote manual close of generator breaker in manual mode 1 2 manual alternative to front button Gen breaker Open Remote manual opening of generator breaker in manual mode ibidem manual alternative to front button Speed set point2 select Alternative set point Volt set point2 select Alternative set point kW set point2 select Alternative set point MA kW nominal 2 select Alternative active and reactive nominal powers MA Priority generator In power management start stop depends on a priority generator 4 4 3 Unload generator requ External pulse request to stop the generator if stopping the engine ibidem if start stop rule are OK does not overload aggr according to load dependent start stop strategy Remote non essential Order to switch on the load shedding 0 p 54 Heavy consm request n Request to consider powering the heavy consumer n Erreur Source CAN bus inhibition GEn Order to l
11. CATERPILLAR e marathon electric Cosimat N MA329 AEC63 7 AVC63 4 A n A1 Remove shunt between terminal 6 amp 7 of the AVR AVC63 12 DECS32 15 xxx DECS63 15 xxx DECS125 15 xxx DECS300 DVR KVAR PF VR6 CDVR K65 12B K125 10B D510 Use VAR control included in the DECS See drawings AVRout feeds either analog input 0 10V bias input provides a higher range of voltage bias control AVR com is set to 5V R230 448 449 Pot input Pot input Remove the shunt R610 3F 22 23 DVR2010 DVR2000E 1 5V 10 3V 430 MarelliMotori sincro e STAMFORD M40FA640A M40FA644A UVR6 gJ 0 35V 3 0V 4 5V Pot EXTPOT Pot Trim potentiometer V of AVR full EXTPOT counterclockwise Remove shunt Trim potentiometer of AVR fully clockwise 5 4 SPEED VOLTAGE CONTROLLED BY CONTACTS PULSES When digital outputs are connected to speed governor and or AVR the GENSYS PID controllers send speed voltage increments decrements by changing the state of these outputs GENSYS K1 K2 K3 K4 e E Uv 2 gt Uv 2 a o A D Pad D a o x a A g o A digital potentiometer that converts the pulses into analog values has its own settings AUO fsd amp Time A motorized potentiometer a stepper motor with a brake moves the tap Vdc Interposin
12. GENSYS COMPACT PRIME Paralleling unit User manual Technical documentation A56 Z0 9 0020 B EN Technical documentation history June 2015 A Initial edition July 2015 BC First public release Preamble SETTINGS The tables whose header has an orange coloured background describe settings Settings and readings that show only in CRE Config but not on the LCD feature a purple border in the HMI chapter as follows XXXX XXX Can be set in any HMI XXXX XXX Can be set only in CRE Config The setting content is referred to as xxxx In the illustrations e Digital inputs and outputs whether direct or through CANopen whose assignment is preset in the CRE Config software application show as follows the shown position has no meaning Only the inputs Remote start and Generator breaker feedback and the outputs Fuel and Starter No 1 are mandatory in most cases for easing reading they are shown without selector the emergency stop input is also shown without selector e Internal toggles preset through software show as switches with two throws The code xxxx or the name of the setting shows above Function Function Oil pressure fault o Generator ready Coolant temperature fault Digital Digital Protection valid Emergency stop Input output Cooling fan Fault reset Water preheating SYMBOLOGY Denotes a threshold monitoring Denotes a control loop tuning three coefficients G
13. Integral of the phase synchro A56 ZO 9 0020 B EN user manual technical documentation H Control loops H 1 kW control Proportional gain of active load sharing Integral of active load sharing FREQUENCY CENTERING Hz center act Activation of the frequency centering Hz center gain Global gain of the frequency centering 1 Select the menu item Options Advanced 2 This setting can be modified using TXT file or modification by variable number menu 1 by default H 2 kVAR control 2959 P Proportional gain of reactive load sharing 2960 Integral of reactive load sharing H 3 Ramp kW 2913 P Proportional gain of ramp kW H 4 Ramp kVAR 2967 P Proportional gain of ramp kVAR I Modification by variable number This page is very useful when you are familiar with key variable numbers for example the ones you often modify Simply enter the variable number and then enter its value Note You can only change settings 2xxx 3xxx and if allowed 4500 4649 Some are not accessible in regular menus Chapter Human Machine Interface 81 CRE Config EXTRA SETTINGS These settings can still be set changed through the LCD screen I POWER MANAGEMENT SYSTEM LOAD DEPENDENT START STOP 0 Inhibited No automatic start stop of generators according to aggregate load 1 GE number Generators start stop according to the Generator number Load Unl mode E 2 Hours run Gener
14. List of actions on alarms faults Note The file transfer is only possible when the engine is stopped Configuration file Chapter Resources for setup amp maintenance To display the current configuration file in an internet browser select Configuration file In the web browser to save this file right click in the page with the text file and select Save as To edit a new configuration from the configuration file it is strongly recommended to use a configuration file compatible with the installed firmware version 1 Upload the file from GENSYS 2 Modify it 3 Download this new configuration file to GENSYS 101 Log file Upload the file In the web browser to save the file right click in the page with the file and select Save as List of actions on alarm fault By selecting Action on alarm fault a file containing all potential alarms faults and their use is displayed To save this file right click in the page with the text file and select Save as Example RX X X List of actions on Alarm Fault Disable Generator electrical fault Bus electrical fault Alarm Fault Soft shut down Security Hard shut down Fault Soft shut down Help Gen Electrical fault Help Droop Alarm 9 Droop No start if Static paralleling 10 No start if Static paralleling OD 0 Gl q Go Do A Potential alarm fault Actually setup as ANSI C37 2 VO4503 Oil pres fault lvll lt
15. QSK 60 bias input EFC 1 5V OV 8 9 See schematic ECM QST30 18 15 7 75V 1 5 Hz not to DEUTZ EMR 2V 2 5V 24 25 reach EMR FAHR overspeed PEEN ESD5330 5V M G td All other ESD 5V N G ORP GHANA PWC 2000 J G CONTROL E6 B3 Qian KG6 System E6 2 5V 2 5V E3 A3 Voltage converter PANDAROS DC6 2V 2 5V B3 A3 to isolate the signal on the line DC DC 2V 2 5V L C Two different En JOHN DEERE JDEC ES vic d 999 wirings for the LEVEL Ill ET pECe same governor ss A MDEC 4V OV 8 36 amp 7 5V 2 and 12 connected Perkins ECM 1300 2V 2 5V 30 5V iorekterndisenihe EDC IV EDC Ill 1 5V 3V Pot signal 2301A D ILS speed OV 3V 10 11 Shunt 14 16 WwoopwarP without U amp I 25 26 Shunt 26 com on OV 2301D G11 connected to OV 2301A Speed only 4 5V 2 5V 15 16 16 connected to OV EPG System z he sh P N 8290 189 2 5V OV 11 0 6V nc II AE E ane P N 8290 184 etween 11 and 12 Because of the very high sensitivity of Cummins EFC module input use the schematic below to connect GENSYS to the EFC The resistors must be as close as possible to the speed governor terminal This way GENSYS analog speed output can be set higher 2205 according to the resistors used M 2 Battery 4 7 uF 1 Battery AAA z S0 Pi Wye wy Aa E wa 8 Speed input Speed out 150 kQ Speed ref y lt a gt Pa ro wat A te aS TES aaah 5 3 ANALOG AVR AUTO VOLTAGE REGULATOR CONTROL
16. 0 1 0 01 0 001 e Unit among No unit V kV mA A kA Hz kW kWh kVAR kVARh rpm Bar mBar kPa psi C F L Gal s h days Hz s m3 h L h Gal h e Value range in 2 Threshold The input threshold features several attributes preset in CRE Config Configuration Protections Engine Battery Protections or in the text file e Level LV limit value in units it can be a low or high threshold e Delay TM time after which the trespassing is confirmed e Validation CT protection type to which the signal contributes 8 potential values see chapter 3 3 p 34 e Direction SS is it a low 0 or high 1 threshold OUT past threshold OUT protection type Reset Note Do not confuse Validation with Validity engine state that validates a digital input Calibration Calibration is used to estimate a reading from a resistance value by interpolation between 2 wrapping resistance values Negative values are supported for readings Enter a table in CRE Config Configuration Inputs Analog inputs Analog Measure Calibration or in text file Select the Accuracy desired grade of details for tweaking and manual entering 0 001 0 01 0 1 or 1 Enter the limits of reading according to the sensor calibration generally the lower limit is O and the slope is Range Rating Calculate and enter the intermediary readings to get a linear distribution Reference table for Oil Pressure o 34s a87 2120 260 8442
17. O lt Y O O 0 p i D Maximum 200 hours per year STANDBY Allowable average power output RATING over a 24 hour period is 70 of the standby rating No overload Emergency Stand 25h year at 100 by Power No overload changing load 200 h year at 80 TCGEN2 0 no Maximum 500 hours per year paralleling Allowable average power output Limited Time fixed load is 85 of the nameplate rating RUOINE Power MISSION CRITICAL RATING Limited of hours ISO 3046 e Part 1 Power DBR intermittent and MCR Max Continuous Rating GENSYS COMPACT offers the possibility to activate air conditioning and a cooling fan e Part 4 Soeed governor Governor performance classes Speed droop By agreement Regulation stages P PI or PID P Pl or PID Pl or PID Pl or PID Pl and PID regulations require a load sharing device such as GENSYS COMPACT NEC700 and NFPA110 Start in static paralleling to meet the 10s time limit NEC700 Type 10 as per NFPA110 According to NFPA110 Black start is where the stored energy system has the capability to start the prime mover without using energy from another source Such a generator can be used to start a turbine NFA110 defines classes according to fuel tank autonomy it requires that Emergency Power Supply has a manual remote stop A5 6 5 6 NFA110 Fault list includes 15 signals Warning or Shut down NF E37 312 In some public spaces a Generating Safety Source needs
18. The AVR out signal provides the set point for AVR used in voltage control voltage synchronization U U reactive load sharing The components of AVR output are listed in the section 5 1 p 59 The voltage range 10V 10V must be fitted in amplitude and offset to allow GENSYS to vary the AVR set point on a correct range the aim is that GENSYS can control the voltage in the 30V band around the nominal voltage V Amplitude Deviation AVR amplitude AVR offset AVR out AVR common 1 Connect the AVR common wire only 2 In Configuration Generator preset the amplitude and offset as described in the table further AVR amplitude AVR offset V1 Read only Read only Voltage Sum 3 Trim the AVR potentiometer to read 400V 4 Connect the AVR out signal adjust the offset so that the voltage is 400V 5 Start the generator in manual mode by pressing MAN and START buttons 6 Adjust Voltage Sum to 100 with the Shift A keys adjust the amplitude so that the voltage is 430V 7 Return to 0 adjust the offset if needed to get back 400V 8 Adjust Voltage Sum to 100 with the Shift V keys in order to check the variation range till 370V 9 Return to 0 The next table gives both settings for various AVRs For other models contact our Customer service A56 Z0 9 0020 B EN R16 user manual lechnical documentation Mid point of a resistive bridge betw 7 amp 9 10 Ane E Basler Electric
19. Writing to input function registers Writing to Engine counters Writing to Date Time o Bta 8 Default value 1 In CRE Config System Network configuration Modbus access rights just tick a checkbox pit tabel Jue C a Writing to Date Time Synchronization of GENSYS clock See chapter A p 84 Writing to Engine meters Manual adjustment of counters see next table See chapter A p 84 2 Writing to digital input function register EN Reading using Modbus TCP Opens the possibility to grant reading individual permissions EN Writing using Modbus TCP Opens the possibility to grant writing individual permissions The counters encoded on 32 bits include Counters MSB LSB 0080 0079 Generator kWh ef me Sol ef me pl el 0082 0081 Generator kVARh 0084 0083 Engine running hours Bit Fields Bit fields are meant for decreasing communication bus load They pack up to 16 logic variables inside a single register This way a single Modbus request can be used to read a chunk of information Each variable contains the current value of 16 logic variables such as breaker positions faults alarms They are listed out in the Bit fields tab of the document A56Z0 90030_ xls The bit fields 0956 0969 have latched values a reset is required for them to return to O Custom blocks To create your own blocks use the variables 10000 10299 in CRE Config Configuration Modbus There are two ways to configure these
20. technical documentation Ty yo CRE Technology provides a complete range of products aimed at installing your CAN bus P cords wires connectors Please read the document Harness information or contact your local CRE Technology distributor to help you choose equipment that fits your needs MAXIMAL LENGTH amp BIT RATE The maximal length of a CAN bus depends mostly on the communication speed but also on the quality of wires and connectors used The ES table shows the maximal length of a CAN bus depending on the bit rate Bitrate kbis s 10 20 fso fas 250 fso fao Maximallength m 5000 2500 1000 soo 2so 10 so The next table lists the standard bit rate of each CAN protocol that can be used by a CRE Tech unit Bit Seles CANA CRE Technology protocol 125 CAN2 CANopen 125 default Can be selected between 125 250 500 1000 kbit s By CRE Config software or modification by variable number 1939 CANopen 250 Fike oo CAN1 CRE TECHNOLOGY INTER UNITS CAN BUS This CAN bus is used as a communication means between units from a single power plant Features are e Active and reactive load sharing e Automatic load unload e Static paralleling e Dead bus management e Other data exchange Standard CAN bus rules apply here Refer to previous section to connect units properly on CAN bus CAN BUS FAULT CAN communication between CRE technology units is continuously checked by each unit on the CAN bus The count of unit
21. 12663 12142 40 834 1585 3777 4316 6922 10387 8962 80 2014 3945 9674 8892 5402 8111 6102 Chapter Resources for setup amp maintenance 240 6731 20000 30000 20000 678 093 o 280 7911 20000 3000 20000 0 o jo 320 9030 20000 30000 2000 0 jo Jo 111 360 10270 20000 30000 2000 o o Jo 400 11449 20000 30000 2000 o jo Jo Reference table for Water Temperature o sas 1000 aooo 1000 o 1000 rao 96 us 140 fios fao fioa so a oa us a leo frs wle fo sfe fe Summary The attributes show in the text file Validation Direction Function Al 1 level 1 2600 2601 2602 2606 2607 Al 1 level 2 2603 2604 2605 Al 2 level 1 2608 2609 2610 2614 2615 Al 2 level 2 2611 2612 2613 Al 3 level 1 2616 2617 2618 2622 2623 Al 3 level 2 2621 Use of an analog input as a digital input To mimic a digital input connect the input to Power through a switch and select the function to implement in the list CRE Config Configuration Analog inputs Function Refer to 8 3 1 p 105 Use of an analog input as a transceiver input To mimic a 20mA input connect the input and select the function 20mA transceiver in the list CRE Config Configuration Analog inputs Function The non linearity of the sensor can be corrected through a curve Select the tweaking grade the resolution in actual value in accordance with the sens
22. 15 A56 Z0 9 0020 B EN 2 INSTALLATION 2 1 ON DESK ETHERNET SETUP 2 1 1 Setting the PC connection Connect GENSYS to a PC with a 100Q Ethernet Direct connection to PC use a crossover cord cord Connection through a switch use a direct cord a crossover cord such as 3 m long A53W1 is OK if the switch manages it Power up GENSYS using a stabilized power Power supply range 8 35VDc supply Open Windows control panel Click e Local network Windows XP O Network and Sharing Center View status Internet No Internet access Windows Vista Enabled 00 27 12 e Open Network and Sharing Center Change 1 0 Gbps adapter settings Connection to LAN Properties Windows 7 amp 8 Sent A Received om a J Bytes 1 603 976 14 671 317 Properties Disable Diagnose Click Parameters Windows XP or Properties Windows Vista or 7 or 8 Networking Sharing Connect using DY Intel R 82574L Gigabit Network Connection This connection uses the following items 005 Packet Scheduler A Microsoft Network Adapter Multiplexor Protocol d Microsoft LLDP Protocol Driver de Link Layer Topology Discovery Mapper 1 0 Driver de Link Layer Topology Discovery Responder Intemet Protocol Version 6 TCP IPv6 de Intemet Protocol Version 4 TCP IPv4 ARKRIKIKIXSO Install Descrinti Transmission Control Protocol Intemet Protocol The default wide area
23. Crank2 and Crank3 The Starter number depends on the preset output number The starters are attempted according to the starter numbers as far as the engine fails to start Starter alternance type 0 one attempt per starter per round the starters take the token after one 3459 Starter order another In CRE Config select Alternative 1 each starter makes several attempts in a row In CRE Config select Consecutive 3460 1st starter 3461 Maximum count of start attempts allowed by starter Value 0 15 Examples with 3 starters with 1 starter set to 2 and number of start attempts configure to 3 e In alternative mode the sequence will be 2 3 1 2 3 1 2 3 1 e n consecutive mode the sequence will be 2 2 2 3 3 3 1 1 1 Note For each starter s functions starters 1 to 3 in Configuration Engine Start settings there are separate lower thresholds under which the starter drops out The values depend on starter type electric pneumatic 3 2 2 Idle speed To prevent a cold engine to run at full speed GENSYS can run it at idle speed for a short time on startup For this purpose GENSYS feeds a warm up command to an external speed controller with idle speed input when the engine is in states Start Warm up The idle speed is fixed by the speed controller Parameter 3486 allows to command a speed ramp 3468 Idle speed Speed set point in pre start 3 2 3 Smoke limiting To prevent
24. E g 7 amp T EEN Ls ES Fault summary J E a ose Zi D iD o v o 3 E MES N cB a o E AL Gen Electrical Fault summary y O PLC O e Generator fault request E q Excitation fault e Generator E Remote alarm o 8 0 Bus Electrical Fault summary e Alarm summary Auto start Call for maintenance J1939 alarms overspeed oil water module or Ext relay S O A Min Max O x3 ENGINE Fault Fault inhibition battle switch refer to the Appendix Standards for generators NF E37 312 Print amp fill the table at the end of this manual it will help determine the potential causes of a signal Clearing of faults alarms Locally Shift Remotely use the Fault reset input function Protections Fault reset pp J1939 DM3 C A56 Z0 9 0020 B EN 3 5 BREAKER MANAGEMENT user manual lechnical documentation With the breaker feedback failures and unexpected opening ANSI94 ext or manual are signaled A time out 2304 5 0s by def precedes the signaling that the breaker has not opened closed Generator fault request Remote shutdown Internal protections Tripping Order to open the breaker 2304 nt Generator breaker feedback El
25. F 3 Digital outputs The name of each output is displayed with its state active full dot inactive hollow dot F 4 Relay outputs This menu shows the state of the two relay outputs Generator breaker The name of each output is displayed with its state active full dot inactive hollow dot F 5 Analog inputs 1 3 The name of each input is displayed with ts e Value if really analog e Status if digital active full dot inactive hollow dot G Maintenance This page shows the countdown of running hours days since the latest reset if activated The Starting values are set in the Configuration menu or in the software application CRE Config Configuration Refer to the chapter 3 6 p 39 H About These pages show only if you have entered as observer no password Otherwise find it in System About 1 S N serial number Type A56Z0 Version Boot version 2 Host name IP NM network mask GW gateway Refer to the chapter 2 1 p 17 A56 Z0 9 0020 B EN user manual lechnical documentation CRE Config Scada gives access to readings in addition to the preceding ones CLOCKS 4455 4457 4458 4450 Loss of speed sensor 4453 Prelubrication bef crank 4464 Time generator is waiting to warm up before taking the load 4465 Speed amp voltage stabilization Time generator is waiting to let engine speed amp volt stabilize 3469 before taking the load not applicable to static paralleling 4466
26. Filter Mixer Gas Cy Crank 92 Ta shaft 1124 11 513 Tq 1125 1 Ln 1126 1 5 514 To 515 Tq Q cJ 102 P 2434 T 176 T 2433 T 81 P Description Air inlet filter 1 differential pressure first or sole filter 52 Intercooler temperature 106 Air inlet pressure at inlet to intake manifold or air box 102 Intake manifold 1 pressure boost pressure measured downstream of turbo compressor 563 Intake manifold 1 absolute pressure 105 Intake manifold 1 temperature 172 Air inlet temperature 22 Extended crankcase blow by pressure differential pressure across a venturi 101 Crankcase pressure 039 Trip Fuel gaseous fuel consumed during all or part of a run Air 22 Ap 101 P 52 T Exhaust gas PGN FEF6 FEEE FEF6 FEF6 FDDO FEF6 FEF5 FEEF FEEF FEAF 176 Turbocharger oil temperature 173 Exhaust gas temperature alternative to 2433 2434 FEF6 Diesel particulate filter trap inlet pressure FEF6 The ratio of actual engine percent torque indicated to maximum indicated torque available at the Actual percent torque The calculated output torque of the engine The data is transmitted in indicated torque as a percent of reference engine torque The engine percent torque value is not negative and includes the torque 92 Engine percent load at current speed current engine speed clipped to zero torque during engine braking developed in the cylinder
27. Machine Interface 71 6 4 DISPLAY MENU The LCD menu gives access to the following information the letters are the ones that sneak in the LCD A Power plant Generator electrical meter Bus electrical meter Synchronization Engine meters Inputs outputs state Maintenance About only level 0 TOD MOON A Power plant A carousel cycles through power plant loads shared by up to 32 different GENSYS units Power plant status Generator status GE 01 16 kW Percent of nominal active power and value supplied by each generator GE 17 32 kW 16 GEO1 kVAR Percent of nominal reactive power and value supplied by each generator GE 17 32 kVAR B Generator electrical meter These pages display in real time all generator electrical measurements in true RMS B 1 Global view e Phase to neutral voltage of phase 1 e Phase to phase voltage of phase pair 3 1 e Current of phase 1 e Total power kW kVAR coso B 2 Frequency Hz B 3 Phase to neutral V e V1 V2 V3 B 4 Phase to phase U e U31 U23 U12 B 5 Current A e 1 12 13 B 6 Active power kW e P1 P2 P3 B 7 Reactive power kVAR e Q1 Q2 Q3 B 8 Total power kW and kVAR B 9 Power factor e 1 62 63 stands for Inductive C for Capacitive signed as per IEC convention B 10 Total power factor B 11Energy meters e kWh and kVARh A56 ZO 9 0020 B EN user manual technical documentation Notes The frequency is ava
28. O Cc D Bus Underervoltage 27 Bus Overvoltage 59 Min battery voltage Over speed by J1939 nla M an IoD A e alo ELE OO oO olo v oa 2 Ol S a Bus Underfrequency 81H Max battery voltage T a gt O Cc Uv D gt o Uv LL q L w gt O Yn D gt co Generator Overvoltage 59 Max water temperature Low oil pressure by J1939 High water temp by J1939 Malfunction lamp J1939 T sl 00 Ian gt A amp Cc O ap O 2 T a O Uv O gt O o Q v z aD c gt aD Generator Underfrequency 81L Generator Underervoltage 27 me 0 0 1 2 O O O O O O O O 3 O O O O a fi 000 O ty O 5s dT Tt 6 tT tt 7d TTT tT te tt tt 1 Generator electrical Fault 2 Bus electrical fault 3 Alarm 4 Fault soft shutdown 5 Security hard shutdown 6 Fault soft shutdown Help 7 Generator electrical fault Help CAN bus faults are not shown 129 A60 X2 9 0020 BEN user manual technical documentation CRE TECHNOLOGY 130 all e 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 Website www cretechnology com Email info cretechnology com Technical support 33 0 4 92 38 86 86 office hours 8 30AM 12AM 2PM 6PM GMT 1 Email support cretechnology com SKYPE support cretechnology co
29. P I Denotes the need to adjust the amplitude and offset center 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 You can download the most up to date version of this documentation and different other documentations relating to GENSYS on our web site http www cretechnology com Content 1 1 1 1 2 1 3 1 4 1 5 1 6 2 2 1 Lidl 3 2 3 3 3 4 3 5 3 6 Presenta ON AA PP O 11 Generator automatic CONTRO ersin 12 Generator breaker CONTIOL cccsecccsecccssecceececseecceusecsusessueecsueesseceeeceseueeseeseesesessuseeesensesens 12 Human Machine INterface cccccsscccesccceseccsssecaescceuscceueessuseceesessuceeueceeeseeseeessusessuseseueesaases 13 Start and Power Management w sc202cccassussanaseeecoansqneponsseesacaneaussaaaseetnoansannseesirenerereesveewerrscer eres 13 Setting and supervision Utility a tico 14 Associated products for remote metering monitoring and control oocooccocccncncnnnnoccns 15 a 5 17 On desk Ethernet SCtup ccccceccseccsecseccsecenecencceeceneceuceeceseeeuceseeeeceseceseeeeceeeeeeeteeceeeeeneeseetes 17 2 1 1 No o A A PRE OO E 17 2 1 2 Changing the GENSYS IP address susana 18 2 1 3 POSEA AAA A TO EAN E E EE T O ENEN 18 2 1 4 COE A CO E Tr 18 In panel INStallation cccceccseccseccsecsecesecesececesecee
30. Positive pulse 2301 Pulse length Minimum pulse duration Undervoltage coil UV coil rst Coil characteristic pulse hold time after auxiliary contact opening UV coil pre TM Security timeout to wait from the pulse end until the other contact be allowed to close in order to close the breaker Relays output Go a Undervoltage coil L T lt 2302 gt Breaker feedback lt 2303 gt CLOSED OPEN CLOSED To detect the breaker position assign a digital input to a preset function Generator breaker feedback 1 breaker is closed reflected in front led 8 4 3 Related outputs A digital output when assigned to these preset function reports a relay activation Generator breaker close A command closes the generator breaker Generator breaker open A command opens the generator breaker CANopen relay outputs can be used Refer to the chapter 7 2 p 92 A56 ZO 9 0020 B EN user manual technical documentation 9 MAINTENANCE 9 1 UPGRADING THE SOFTWARE First of all e Save the current configuration as a text file refer to chapter References for setup Otherwise the default settings will be enforced except for the IP settings e Stop the generator e Disconnect all the terminals except the Battery connections Then PC side web site GENSYS side Connect to CRE Config System PC transmit receive or to GENSYS web site Select Update firmware Enter password level 1 or 2 Browse to the arc
31. Rotating speed Angle 21 m 27 Hz s 05 kA 11 rpm 17 i 22 mm 28 m h Frequency Percent Mass 23 Gal 29 L h 06 Hz 12 31 kg 30 Gal h A56 ZO 9 0020 B EN user manual technical documentation 8 3 I O LINES 8 3 1 Digital inputs Each input is tagged with a label defined in CRE Config Configuration or in the text file and features several attributes set in the Configuration menu e Validity e Direction e Delay e Function Configurable input label This is the name you give to the input The name shows in the info alarm and fault screens if programmed accordingly Validity Validity is the epoch when the input is taken into account It can take four values Never Never active must be selected if you do not use the input Always Always active input is monitored as long as GENSYS is powered Post Start Input is monitored since the end of the Safety on delay 4852 a Stabilized Input is monitored when the generator is ready for use 1 Set Safety ON time in the Timeout page Direction For each of the inputs two options are available Delays Norm open Used unless the input is used for protection Norm close Normally closed must be selected if the input is normally connected to OV and is opened when active For each input two delays can be defined in 100ms steps between 0 and 6553s Raw input ee nS A a Delay on Delay on pick up drop off Delayed input
32. This page displays some information on module and on Ethernet connection e DHCP status e IP address e Network Mask e GateWay IP address e HTTP port e Modbus port D About This page displays some information on module and on Ethernet connection e Serial number S N e Module reference type e Software version e Boot software version e Hostname e IP address e Network Mask e GateWay IP address A56 Z0 9 0020 B EN CRE Config EXTRA SETTINGS METERS User manual lechnical documentation Meters reset allows you to reset the following meters e kW generator sum kVAR generator sum Running hours Count of starts Event logger Meters preset allows you to preset the following meters e kW generator sum e kVAR generator sum e Running hours e Running minutes SCREEN SAVER Count of starts The page displayed when the user does not interact with GENSYS keys not used is called SCREEN SAVER Information displayed on this page depends on the GENSYS status as described in the following table Some settings can also be used to customize this behaviour Synchronization column Frequency difference bar graph Voltage difference bar graph Phase difference column Frequency match OK NOK Voltage match OK NOK Phase match OK NOK In synchronization state When the generator is ready and the generator breaker is open Generator overview KW in large font Voltage in large font Runni
33. Ul sinp Dead band V KVAR lati Voltage R regulation SUM U AVR amplitude a AVR out Voltage centering droop 4405 is the sum of all applicable speed deviations due to e Frequency and phase synchronization e kW regulation Load ramp e kW sharing e frequency centering e manual command e speed droop in event of CAN bus loss 4411 is the sum of all applicable voltage deviations due to e Volt synchronization e kVAR regulation Load ramp e kVAR sharing e voltage centering e manual command e voltage droop in event of CAN bus loss In fact not all components contribute to the sum at one time the sequencing is Synchronization gt Ramp gt Load sharing centering and can be followed with Reading 4009 0 nothing 1 Synchronization 2 Droop 3 Load sharing 4010 AVR cont mode 4 Ramp 5 Speed Voltage constant very transient Follow strictly throughout the aggregate the scaling procedures amplitude offset to have the best synchronization load sharing and droop 5 2 ANALOG SPEED GOVERNOR OUTPUT The Speed output signal provides the set point for ESG used in speed control frequency synchro nization and active load sharing It is the sum of the components listed in the section 5 1 p 59 The voltage range 10V 10V must be fitted in amplitude and offset to allow GENSYS to vary the ESG set point on a correct range the aim is that GENSYS can control the frequency in the 3Hz band around the no
34. VOZ2364 4 VO4504 Water Temp lvll lt VO2367 4 8 1 2 PC gt GENSYS file transfer This page allows you to send parameters file or language file 1 Click the Browse button 2 Select the file to download 3 Click the Save button When the operation is completed a screen shows on the PC Note Before edition it is recommended to save the current configuration with the GENSYS gt PC page The file transfer is only possible when the engine is stopped 8 1 3 Update firmware It allows you to update the firmware with the latest version Connect CRE Config to GENSYS with the level 2 password Refer to the chapter Maintenance 8 2 TEXT FILE DESCRIPTION 6 2 1 Variable naming The file named A56 ZO 9 0030x xls describes each variable The variable format is VXYYYY X relates to the type of variable e Oand 1 a reading or a real time value Voltage phase 1 CAN bus fault e 2 3 and 4 a setting to store in non volatile memory Generator number Nominal power YYYY is the code of the variable The variables are stored in a non volatile FLASH memory in the unit It is possible to download or upload them with a PC which allows the user to save modify and reuse them later All these values are stored in the text file This chapter describes the layout of the file A56 ZO 9 0020 B EN user manual technical documentation 6 2 2 Text file description The complete unit setup can be contained in
35. X XxX XxX XXX XxX A JOHN DEERE x KX KK KK KR KR KR KR KR XX XXX XX XX XX XxX K K gt x lt L x xX XxX K X x xX KX KK XK A56 ZO 9 0020 B EN user manual technical documentation 8 RESOURCES FOR SETUP amp MAINTENANCE GENSYS handles several files used for setup or maintenance The Configuration file allows you to e Set the value of every setting e Change the units of analog inputs example V mbar psi e Change the accuracy when displaying analog values example 24V or 24 0V e Change the labels of inputs and the screensaver The log file contains the history of time stamped data alarm faults FIFO data as selected in CRE Config Configuration Logger It is used for maintenance The action file contains the list of effects of alarm faults It is a sub file of the text file They are listed out in 8 3 p 105 and 3 3 p 34 The firmware upgrade is a zip file 6 1 FILE TRANSFER These files can be transferred to or from GENSYS Use CRE Config System PC transmit receive OR the web server GENSYS gs i Erase and Reset to factory settings are available in CRE Config for the latter select Options Advanced and connect on level 2 Reset to factory settin ransfer T 8 1 1 GENSYS gt PC file transfer This page allows you to download a file from GENSYS to the PC e Configuration file e Log file e
36. a cold engine from over emitting GENSYS can run it at idle speed for a short time on startup For this purpose GENSYS feeds a smoke limiter command to an external speed controller with smoke limit input when the engine is in states Start Warm up and Nominal speed 3 2 4 External auto start module Some engines are equipped with an Automatic Start Module ASM On start automatic test manuel mode GENSYS empowers it to energize the crank and fuel and to synthesize the engine alarms faults The setup depends on the type of ASM COMMON To inhibit GENSYS internal start sequence activate External start sequence in Configuration Engine In CRE Config Configuration Outputs Digital outputs Connect it to a start request input it replaces preset a digital output to Start request the GENSYS fuel output CRE Config Configuration Inputs Digital inputs Connect it to an engine alarm output preset a digital input to Remote alarm CRE Config Configuration Inputs Digital inputs Connect it to an engine fault output preset a digital input to Remote hard shutdown immediate engine stop or Remote soft shutdown stop after cool down sequence See further As with a GENSYS controlled start the engine start time out 3454 applies ASM with a Generator ready digital output In CRE Config Configuration Inputs Digital inputs Connect it to an engine ready output preset a digital input to Gen
37. a e e e e a ea a 102 8 2 2 lao o ee eee T 103 FOME ada E 105 8 3 1 A O det ltet sla 105 8 3 2 DISA OUTDO UTS aiii lid 107 8 3 3 AMAIOS IMOUCS iia iad edadied Mad e a bed a 111 BGS Ee WOU La 9 cs tnrenre nner tri rN Nee One ee Se eee eT ere 113 8 4 1 Breaker working MOS ada 113 8 4 2 SEGUMGS Ol US eee ceo id 114 8 4 3 Related Output tz 114 VINO NC AU doN oO 115 Uperadine the SOTEW ANS ivan EA AA AAA AAA TA AAA 115 Adding a custom HMI language occoccccccnccncnncnncnoncnanoncnnnnnnonanonnnnnnnroncnnnnnnroncnnnonannacnncnncnonaos 115 MI sesscasenc gone sencsane te ove ees ae oa ene eee 115 APPENDICES usina insenso ninini ini A A ada Et 119 STANDARDS FOR GENERATORS PROTECTION AGAINST SHORT CIRCUITS CAN BUS GOOD PRACTICES MTU J1939 Communications CONTROL LOOP TUNING Index dl nn PP 11 Information page button vaa iia 13 Power management senerallo siria 13 Dynamic paralleling general ccssccsscssscescceccesccesccecccsccusscecccsccussceccescceccesccussceccsccussseceesccusssess 13 Static paralleling ener ss dccesincivusicsesvnacenncewesusicnesisensncseavunsiswsksusisusvwnensnsaneavansseantescounepenenesnunneannaseness 13 RE CONTE NOOK UD ias 14 Text file AEPIOYMENT ccsccscccsccesccsccnsccesccsccnsccesceeccusccesececcecccsccusteuccscceseseccsscuscsuccesscescesccescoess 14 EVN USO ld A dundeaeledeens 15 POSAO a E sr 18 e 22 Biphase installation arrancadas 23 Current transformer 2 phases siccc
38. a simple text file This file can be downloaded from GENSYS to be kept on a PC It can also be manually edited on a PC and sent to GENSYS to fully setup it in a single step This text file is made up of different blocks e Parameter values e Label definitions e Text definitions e Unit and accuracy definitions Parameter definition block The block start is the PARAMETERS statement Each setting 2000 4000 can be found as an input in this block The structure of the input is as follows e The variable parameter number preceded by the letter V Ex VO1006 e The label optional only for user information Ex Gen Nominal kW e The minimal value optional only for user information Ex 00000 e The maximal value optional only for user information Ex 65535 e Unit Example PARAMETERS V02000 2 Nb of gen 00001 00032 VO OOT ik GE number ONO OOO In the example above the generator nominal power is set to 320kW The labels related to a threshold settings are prefixed as follows El IN A LV OUT past threshold TM TON Clock Reset CT C1 1 i OUT protection type The value can be a 4 letter code especially e Validity of digital inputs 2330 2329 2192 2331 see further I O lines e Readings shown in the Information page reading code without E see end of chapter HMI It is possible to modify the values directly in the text file before uploading it into GENSYS The user must be sure that the modified value is
39. activated during preheating Preglow activated during preglow spark plug Warm up activated during warm up Inhibited during emergency start if any Engine not ready activated until the speed set point is reached Generator ready activated as the speed set point is reached and voltage is present Protection valid activated when the protections are enforced expiry of Safety on Note Make sure the speed threshold 3468 is below or equal to 3462 ae Fail to start engine t o aE ad a a a time allocated to start Default value 10 0s Status Label Description Failtostartengine _ Activated if engine has not started until 3453 has expired or 3461 has been passed A56 ZO 9 0020 B EN user manual technical documentation Conditions before start up GENSYS monitors the oil pressure and water temperature 1 Prelubrication check the oil pressure must be ABOVE the threshold 3473 2 Preglow check the water temperature must be ABOVE the threshold 3474 3473 Oil prelubrication Oil pressure low threshold 3474 Water temp Water temp low threshold Digital input Preheating required in auto mode O C If you give them the thresholds the value O the readings from the analog sensors are not checked before start up When both values are OK the output Air conditioning is activated provided an output is preset accordingly When 3454 expires if either reading is below its threshold or the speed is below the set point the
40. and Warm up Activated if start sequence is completed voltage is present in ibidem Generator ready generator In Auto mode the output is activated when engine state is Generator ready Protection valid The protection are enforced ibidem Engine not ready The speed set point is not reached ibidem Excitation cmd Dynamic paralleling activated in Start warm up amp nominal speed ibidem Generator voltage presence Activated if the generator is started and a voltage is detected 3 2 5 p 33 Activated if the generator has completed its start sequence in auto ibidem Available in automatic j The power state 4000 does not signal any fault Generator active power flow Active power direction de activated on Generator reverse power ibidem 3 5 Production request The generator has been elected to start p Dead bus bar 4 Phase seq match Phase sequences are the same for synchronization 4 4 Voltage match Voltages are close enough for synchronization ibidem Frequency match Frequencies are close enough for synchronization ibidem Phase match Phases are close enough for synchronization ibidem Authorization to close breaker ibidem Fail to synchronize Synchronization request denied bide o o wm U 70 A D N U LA A A s S O U D U N 9 o N D q Chapter Resources for setup maintenance 109 Summaries External panel Trigger at least one GENSYS detected fault External panel Trigger at le
41. checking that this will not overload the other generators This input is latched Unlike the inputs Fault Help it does NOT substitute the generator with another one The GENSYS must NOT have been given priority by input The generator restarts automatically Settings across the aggregate 2850 Load Unl mode 0 Inhibited No automatic start stop of generators according to the aggregate load 1 GE number Generators start stop according to the Generator number 2 Hours run Generators start stop according to the GENSYS running hour meter 3 By custom Generators start stop according to my priority number 2863 1 32 2864 Load dep kVAR 0 kW Base criterion kind of power to assess 1 kKVAR 2854 LV Load thres Default 80 Percent of load on the aggregate above which another generator is requested to start and share the load 2857 LV Unload Default 20 Percent of load on the aggregate under which a generator is stopped 2855 TM before load Default 10 0s Delay with power above threshold 2854 before GENSYS requests another generator to start and share load 2858 TM before unload Default 10 0s Delay before deciding to reduce the count of running generators in load unload management Example A 4x100kW aggregate with a load that increases linearly from O to 400kW then decreases to OkW Start threshold 2854 is set to 80 the stop threshold 2857 is set to 20 Generator 1 is permanently r
42. configuration 2003 2805 7 Phase measure Includes A fault is triggered if the breaker does nt Hard x Breaer rault 50BF send proper feedback shutdown An alarm is triggered if the generator Breaker alarm breaker controls do not work correctly Fail to synch The unit cannot synchronize to Bus Uneven kW See 4 4 1 p 45 Uneven kVAR ibidem According to the state of the module a breaker alarm or fault could appear It could be a fail to close breaker fail to open breaker or breaker open suddenly Summary with threshold codes as they show in text file output and action codes on alarm amp fault Gen active power flow kVAR O Setpoint Nominal 2417 Setpoint 2 2420 2456 2424 H 32Q 2426 2414 2460 HH 2462 2450 2427 H 32RQ 2429 2463 HH 2465 2421 L 37Q 2423 2457 LL 2459 Load sharing 3713 A56 ZO 9 0020 B EN user manual technical documentation Load shedding Refer to 0 p 54 Generator is in under frequency in percent 3702 Trip alarm Generator reached a maximum of kW in percent 3705 All trip out 2862 Others Min oil pressure Oil pressure under minimum 2382 Max water Max water temperature over maximum 2385 Sensor lost Triggered if the speed is O and engine has started Hard shutdown Fail to stop Triggered when engine does not stop correctly Hard shutdown Not ready 2 See the section 3 2 1 p 27 Fail to start ibidem Min battery vol
43. ensuing action can be configured as described in 3 3 p 34 Synchronization failure CT Fail synch Alarm 3 by default Soft shutdown 4 Hard shutdown 5 etc A56 ZO 9 0020 B EN user manual technical documentation 4 2 2 Tuning Prerequisite the outputs Speed amp AVR are scaled to match the generator See5 2 p 60 and 5 3 p 62 Settings are settable in Configuration Synchronization 2951 Proportional Frequency P Proportional Integral Phase Angle 2905 P Proportional 70 Tuning process 1 A generator has already started and its breaker is closed 2 Unplug the new generator s breaker connector 3 Start this generator and go to Display Synchronization 4 The generator synchronizes within 5s otherwise isolate the root cause Voltage frequency or phase and adjust e Ina first time the proportional in order to be closer of the set point e Inasecond time if need the integral in order to faster reach the set point 4 3 LOADING AND UNLOADING RAMP 4 3 1 Configuration After a synchronization GENSYS ramps up the generator load soft transfer to avoid overload or an abrupt load kick hard transfer 1 GENSYS calculates the average active and reactive powers from the information conveyed by the Inter GENSYS CAN bus 2 Itstarts a load ramp to reach progressively these values kW and kVAR regulations In the same way when GENSYS must stop an unload ramp is done Vari
44. free protective digital output e they can invoke a fallback plan reconfiguration The action is an attribute of the protection CT settings or of inter module CAN bus loss fallback setting The Droop effect and value 10 are reserved to CAN bus fault prefer 8 or 9 to have some load sharing Triggering events Fail synch CAN bus fault Battery undervolt Water temp excess Oil press default __ o Alarm Targeted protection type Common effects Alarm summar ALARM ALARMS y o Bus electrical fault P Gen electrical fault o Fault Soft shutdown o Security Hard shutdown o Fault Soft shutdown Help o Gen electrical fault Help o Droop Alarm Droop No start if Static paralleling Reporting Annunciator Soft shutdown summary Min Max Analog n Disable no action Fallback Generator electrical fault The protection opens generator breaker and tries to re synchronize again Count of attempts set by 4854 Fallback Bus electrical fault Usual trigger frequency voltage out of range Alarm Alarm Notice as alarm on front panel Security Fault Soft shutdown Generator breaker opens allowing the engine to cool down off load for the duration of the cool down timer then stop Security Security Hard shutdown Generator breaker opens and engine stops immediately without cooling down Serious fault show
45. if an external start module has been selected 2 Not available if an external start module has been selected G Synchronization This page allows setting the synchronization settings used to allow the synch check relay to operate Maximum difference in between generator and bus bar voltage for coupling Voltage match 2811 Freq match Maximum frequency difference between generator and bus bar for coupling 2802 Phase match Maximum phase angle difference between generator and bus bar for coupling 2803 Fail to synch Allocated time to synchronize 2809 C2S dwell time Synchronization dwell time before authorizing to close the breaker Control on fail Selects the action in case of synchronization fails 1 This setting can be modified using TXT file or modification by variable number menu Used to tune the frequency and phase synchronization PID to decrease the synchronization time The built in synchroscope shows and lets you monitor in real time any change made on these settings Voltage Global gain of the voltage synchro P Proportional gain of the voltage synchro Integral of the voltage synchro Frequency G Global gain of the frequency synchro P Proportional gain of the frequency synchro Integral of the frequency synchro Phase Angle Global gain of the phase synchro Proportional gain of the phase synchro
46. is activated when nd by pulse you press the Y key or with an Decrease speed in man meen ea voitaee Idem speed but with Shift key held down and with an Increase volt in man input ibidem ae MOMneRe Idem speed but with Shift key held down and with an Decrease volt in man input ibidem The generator has received a remote start and forwards it to ASM 3 2 4 p 32 Load n to be shed after load n 1 n 1 5 0 p 54 Non essential Load directly shed direct trip n heavy consum Heavy consumer n Erreur authorization Source du Excitation cmd 3 3 p 33 ibidem U N Smoke limit Position limiting y U U 3 7 2 p 40 ibidem Oil filling ibidem U N A56 ZO 9 0020 B EN user manual technical documentation States and reports Function Description Load request 4 4 3 p 49 Unload request idem ibid Fail to close gen breaker Sep Fail to open gen breaker ibidem Generator breaker open suddenly Unexpected opening ibidem Generator breaker close il i ivi 8 4 2 p 114 A coil is receiving a 1 sec pulse to close the generator breaker Generator breaker open A coil is receiving a 1 sec pulse to open the generator breaker ibidem Generator stop Activated if generator is at rest 2 1 p ibidem Activated when engine warms up warm up clock 2061 is running e n manual mode after START is pressed or with Manual start Warm u P request e n auto mode in states Start
47. the function Fault inhibition to force the run even though the oil pressure and water temperature safeties are triggered Some other protections over speed overload etc are still active 119 PROTECTION AGAINST SHORT CIRCUITS The tripping time depends on the duration an alternator winding can endure an over current A IDMT curve is defined by e atype IEEE IEC IAC e ls current for infinite time in type 1 asymptote value type 1 2 is not used e T tripping time for l 10 x Is Definition of TMS Time Multiplier Setting by default 2475 1 Tis the tripping time for I Is 10 Is set point aka threshold TMS 1 corresponds to T 1 5s atl 10x Is courbe CEI type VIT In brief the higher the overcurrent the faster the trip IEC curves k t D TMS x s 5 3 Standard inverse A Very inverse Long time inverse B 13 33 Extremely inverse C 80 2 Preset osos 352 25 Custom The time from T curves must be divided by B to get the time from TMS curves T curves where t 1 for I Is 10 t s curve T 1s N S 1 00 RI inverse time SIT N very inverse time VIT or LTI N S aN A y extremely inverse EIT ultr
48. the generators are not yet started when they lose the CAN bus a downgraded mode is enforced the generator couplings are phased in the generator n cannot close its breaker before 2306 10 7 x n seconds Follow strictly throughout the aggregate the scaling procedures amplitude offset of chapter Commissioning in order to have the best load sharing in droop Call for help GENSYS can call for another generator to take over when an internally detected fault targets a protection of value 6 or 7 refer to the chapter 3 3 p 34 This can also result from the activation of a digital input preset to help forced substitution The two offered functions protection differ by the stop sequence see protections 6 and 7 e Soft shutdown Help GENSYS stops the engine after a cooling down delay e GenElectricalFault Help NO cooling down delay Remote soft shutdown Help Call for CAN help interface Soft shutdown Help Internal a rgeted Stop trigger protection sequence type Gen electrical fault Help Remote fault Help Call for CAN help interface A56 ZO 9 0020 B EN user manual technical documentation 4 4 3 Load dependent start stop Introduction This function selectively phases the start and stop of the generators in an aggregate according to the current load This prevents overload you are advised to run generators between 70 and 85 The CAN bus makes it possible to share load informat
49. the input of a password user manual lechnical documentation Chapter Human Machine Interface 69 6 1 2 HMI status To inhibit some keys or buttons go to CRE Config System Button inhibition This can also be done through 16 bit word E3557 Button inhibit Each bit inhibit one button key when set to 1 Bits numbers For an on demand inhibition of MAN button refer to 3 1 3 p 26 6 1 3 Navigation in LCD Press ESC ENTER and type in the level 1 password as described above to access the top level menu Display Configuration System A black pointer spots the currently selected item setting a white one features other items settings Three main menus are available on the LCD screen and the web client monitor e Display gives information on generator amp busbar displays real time information amp status e Configuration is used to hone the settings done in CRE Config Configuration e System is used to change on the fly the settings done in CRE Config System Date Hour Screen features To cycle through the menus and menu items press Y or A To cycle through the pages of lists of settings readings press gt or lt MENU PAGES LIST OF SETTINGS READINGS 6 1 4 Edition To change a setting 1 Navigate to the setting 2 Press ENTER to switch to Edition mode the current value blinks 3 Press Y or A to get the new value 4 Pre
50. the led goes off 5 5 2 Island mode check When at least two GENSYS units have been successfully tested check the island functions Check the synchronization 1 Unplug the Relay cable connector of the second generator GENSYS Check the bus bar voltage and the bus bar led Start the generator in manual mode MAN then press START Press the generator breaker 0 l button Using the Information screen I button check that GENSYS tries to synchronize mop oS p YY When there is no phase difference anymore synchroscope at noon in Display menu Synchr check the phase sequence and check that all the voltages match upstream and downstream from the breaker If a check is negative check the wiring of the generator voltage and bus voltage 7 When you are sure there is no wiring problem stop the generator by pressing STOP 8 Plug the Relay cable connector 9 Start the generator in manual mode by pressing MAN then START 10 Press the generator breaker 0 I button the two generators are parallelized Note If the synchronization point cannot be reached easily refer to the chapter 0 p 42 Check the loading ramp RISK OF OVERLOAD OR REVERSE kW Check the wiring of the power lines in particular the current transformer inputs Failure to follow this instruction can damage equipment After paralleling GENSYS starts the power management In any case it matters to have power on bus bar to check the voltage measurements In D
51. within the minimum maximum range of the parameter Failure to do so leads to an error message during uploading see chapter 9 3 p 115 It is also possible to write to an incomplete parameter block not all parameters are displayed in the list When uploaded such a file modifies only the parameters which have been entered the others remain unchanged This procedure can be used to upload an old text file into a newer module or to activate special features independently Chapter Resources for setup maintenance Label definition block The block start is the LABELS statement This block is used to define custom labels for CRE Config and the LCD digital I Os analog Is CANopen I Os relay outputs cycles before maintenance Each line of this block contains 2 elements e The variable number of the text preceded by the letter L for label e The text itself LABELS L01130 Sample label Labels are 14 characters long Supported characters include a z A Z 0 9 and the following characters 103 lt space gt lt gt 4_ All other characters are NOT recommended as the display may not be the expected one Note All custom labels apply to all languages Text definition block Each line of this block contains 2 elements e The variable number of the text preceded by the letter T e The text itself This block includes two items for the logo page and one for hostname CRE Technology www cret
52. x Countdown in running hours h or days d x 1 5 At any time you can reset a counter in CRE Config Config Maintenance press counter Reset button When a cycle duration has expired the corresponding alarm is raised Read the alarm page to know which cycle has run out and reset the alarm This resets also the counter of the corresponding cycle 3 7 FILLINGS OF FLUIDS 3 7 1 Presetting GENSYS can monitor the levels of fuel oil or coolant while the generator is running Each fluid monitoring requires either an analog resistive level sensor or two switches one high level and one low level PIPA OO ee Using CRE Config Configuration preset as follows say xxxx fuel oil or coolant Sensor 0 500 2 settings e In Filling preset an analog channel to a sensor input and set thresholds e In Inputs Analog inputs calibrate the corresponding sensor Switches in Inputs Digital inputs preset 2 channels to xxxx low high level xxxx filling Analog input number hj xxxx low level xxxx filling xxxx high level Manual xxxx fill request 3 7 2 Filling up In CRE Config Outputs Digital outputs preset an output to the function xxxx Filling up filling order Automatic mode GENSYS autofills the tank when the low level is reached xxxx level High level Low level Manual mode In Digital inputs preset an input to the fu
53. 2 513 514 100 110 111 GENERIC 0 EMS2 1 94 182 250 247 102 172 100 175 110 EDC4 2 Idem Deutz EMR2 Idem Deutz EMR2 Idem Deutz EMR2 94xGE 3 91 512 188 1013 182 94 250 102 105 92 513 100 175 110 111 124xGE 4 183 97 158 247 1640 2GE 5 91 512 188 1013 182 94 250 102 105 92 513 100 175 110 111 183 158 247 1643GE 6 91 512 188 1013 182 94 250 102 106 107 173 100 175 110 111 183 158 247 92 513 514 D6 7 91 512 188 1013 182 94 250 102 105 92 513 100 110 111 D7 8 183 97 158 247 D13GE Tier3 9 91 512 188 1013 182 94 250 183 97 158 247 102 105 92 513 100 175 110 111 r Perkins Marine Power Aoc 3 GENERIC 0 1100 A4E 91 515 188 174 250 183 247 102 105 92 513 100 110 GENERIC 0 NEF EDC 1 CURSOR 2 CURSOR9 EDC 3 CURSOR11 4 91 512 5 2432 183 4 250 97 174 158 108 247 102 105 173 81 92 513 514 100 175 110 100 110 GENERIC 5 3 NA 6 GENERIC 0 QSX15G8 CM570 1 157 175 183 168 108 102 105 513 CM850 2 QSB5 PGI 1 1 3 QSB7 PGI 1 1 4 91 1242 512 515 2432 157 174 182 3 4 247 50 168 108 97 102 105 92 513 514 100 1208 110 111b QSL9 PGI 1 1 5 Id 512 515 184 94 174 1136 Id 92 101 173 514 Idem 175 109 QSM11 PGI 1 1 6 91 1242 512 515 2432 175 182 250 183 168 108 97 247 102 105 92 513 514 100 1208
54. 3 08 11 07 32 Water temp 2004 0 f To update the page with the latest faults s press Refresh To reset the tripped protections press Reset in the Active faults Active alarms page A56 Z0 9 0020 B EN Note Fix the condition triggering the protection before clearing the alarm failure to do this will trigger the protection again To delete the Faults Active archive in System Date Time Meter Meters reset select Event logger Information At any time and any level you can press the key on the front panel in the browser click the link Information Press the key again to return to the previous page in browser click Back This changes the display and show the information screen Information Power lt Elapsed time gt lt State gt Engine lt Elapsed time gt lt State gt Power 4001 displays the unit current state regarding power management It displays also a state code which is dedicated to the technical support team of your local distributor Engine 4000 displays the unit current state regarding the engine It displays also a state code which is dedicated to the technical support team of your local distributor Custom parameters To display any reading enter its 5 digit code without E As in CRE Config Scada you can customize the information page with 10 readings generally current state or deviations refer to the chapter 5 p 59 They show in the text file with label Info 1 n n 1 10
55. 421018 20 adi cee rE neon to 53 AT 53 Synchronization of EXCITATION ccccsccsccscceccesccsccsccecceccnsccsscecceccesceecceccsccecceccescescceccecceccusceusceccescuscs 54 LO AG SNCOGING siisii EOT E EEE EE EENS 55 Load curtalmenta canada 55 EOC SCC UI OM anaa nisin tre AOTEA uns ETEENI ETATE 55 Nom essentialloads di A A A oO ROS 55 Non emergenty lo dd iuscrnrs rss 55 Phasing OUT the OA i 55 Sealine speed GUL iaa 60 Speed GEMAN OG sansacacseasszescsascunsaucacecsezaessacannenucnceacesesasaccnes cancanacesesasqacnaatuananasausscanngncococasosecesncnecancadcess 60 SCANS AVR GUE E Oea tn 62 Speed demand pu anaconda oia 64 lo A A A ee E 65 A NR mae are ee eee ee reer Dero ote ree ieee nore eee ane tte ate rr EE reer reer ree 69 ACCESS IONE HAMI couse cede ence ince EAA E T es sees seuc sass scsesteeevancecesy 69 INNIDITION OT keys and DUTLONS iii AAA AAA A AA 70 Monitorine CRE Confie laa 71 A AS 71 EleCUCA NM Er NE a oo 72 A OS COD A nn wale se A 73 ENGINE MOTO TINO nera tio 73 Biphase Settine linsnsranannrananarsnna nr 76 Potential Trans TOMO ridad iO EOI NINE 76 Current transformer generator ccccsccesccesccsccesccscccscccsccescceccesccesceccuscceccesececceeccescceseseccscsessssces 76 Speed alternative A O gn nee eer 78 Data 022108 aaa cti e 82 INTOANALON PATO is 87 Access rights via O O 90 BIG TICIGS nad AAA A 90 BOD TUG eta 101 Textensief rana 101 Glearme NOTOR aR eR rem mere RR A 101 Text TNS desc ANA s
56. 713 Generator reactive power is far from the average of all reactive powers If a GENSYS unit does not send any more frames on the inter GENSYS CAN bus all the generators are forced to start and take a load in a natural manner To withdraw GENSYS units from CAN bus communication use either method e set the digital input Inhibit GEn 4557 4588 to 1 e change the variable 4557 4588 via Modbus TCP To disconnect a GENSYS unit from the inter GENSYS CAN bus you must change the count of generators on all the other GENSYS units TUNING Prerequisites e The outputs Speed out amp AVR out are scaled to match the generator 0 p 60 amp 5 3 p 62 e Atleast two generators are synchronized Load sharing P kW sharing Load sharing Share QP Share Q kVAR sharing Once the setting of synchronization and ramp has been done you can adjust the load sharing kW and kVAR share stays within 2 of that power plant average Note The kW kVAR power plant average in as well as the kW kVAR of the genset in can be visualized on the LCD screen during the configuration of the PID You can change e Proportionnal to decrease the correction time le temps de correction e Integral to decrease load sharing difference Note Integral is used only if the frequency voltage centering is set see 4 4 4 4 4 2 Fallback plans On events such as fault CAN bus loss forced substitution each GENSYS ca
57. 76 0 473 1 means Only valid for IEC curves 123 MTU J1939 COMMUNICATION ADEC The Service and Automation Module is used in conjunction with the ADEC 2000 or ADEC 4000 governor The assembly is referred to as ECU7 Disconnect X13 to switch off the power Plug the appropriate lO Plugin Card CCB2 into the SAM slot 3 The ADEC governor SAM and GENSYS communicate over the J1939 CAN bus SAM includes a termination resistor and a CF card eee ee ee A ee Ae y AE A a n A a is tances E The ADEC controls the speed SAM serves as Backup for Engine life data On ECU X1 and X3 connectors are input e the engine start stop requests e the speed demand frequency current or voltage ADEC XI SAM X23 connector CAN High EC Pn E CAN Low ECOS E E CAN ground ESTO EE E speedos AR Speedout FP A56 ZO 9 0020 A EN user manual technical documentation ECU8 Smart Connect is used to e select the speed set point source through a 3 bit code e set the frequency and speed droop e direct the alarms to a display unit USB port OEM CAN S DIASYS DO 90080 Global AO1 AO2 TOP1 TOP2 TOPS GENSYS a e a ia lt 3 Mo aj A K1 Cea Smart Connect S1 X1 Through the K1 connection box the bus connect ECU8 Smart Connect and GENSYS X4 is the Smart Connect J1939 CAN port Basic I O e g Start Stop Speed SAE J1939 PCS 5 125 Kbit MMS Mot
58. 76 92 513 94 97 157 171 182 250 183 18 168 1136 108 158 247 514 109 110 111 112 1 By default the Fuel output is inverted for the SC ANIA engines 95 2 On IVECO engine the ECU is powered by the GENSYS Fuel output The Crank output is activated with settable delay 2s by default 3 Cummins ECU can contain different firmware depending on their provenance Industrial models only G Drive only Fuel circuit and ECU High pressure 157 P pump CP1 Rail pressure senso 97 0 1 91 515 SEA Accelerator CY pedal W 1242 166 Tq 512 2432 Engine speed crank 190 188 9 1013 174 T 94 P 182 Q 250 Q A de Ju J i j gt A e 5 183 cd eS EO a speed am High pressure 184 Q Prefilter Low pressure 108 P Key switch 1136 T 168 V 158 V Battery 9 G Z Description WN U ef 91 Accelerator pedal position 1 run in m e 242 Instantaneous estimated brake power Og 12 Driver s demand engine Percent torque related to maximum engine torque Engine s desired operating speed Indication of optimal speed for the current conditions May include repr the torque generated to accommodate power demands amp exclude dynamic commands from smoke shift D e e e Ie IN WO R U 32 Engine demand percent torque O Engine speed 88 Engine idle speed 89 Engine ra
59. 9 2 Thesynchronization of the elected generator 3 Aload ramp for soft transfer 4 Aload sharing kW kVAR according to the percent of load of each generator 4 2 SYNCHRONIZATION 4 2 1 Configuration Various settings and readings are offered to control and follow the synchronization Voltage match Max difference in of nominal value between generator amp bus bar voltage for coupling Freq match Max frequency difference between generator and bus bar for coupling Phase match Max phase angle difference between generator and bus bar for coupling TM Fail sync Allocated time to synchronize C2S dwell time Synchronization dwell time before authorizing to close the breaker Frequency gap approve to close breaker 0309 Phase gap approve to close breaker 0310 C2S check OK Synchroscope result 1 This parameter can be modified using TXT file or modification by variable number menu GENSYS launches the synchronization only if the bus bar features at least 80 of nominal voltage The bus bar frequency and voltage are the set points of loop controls When the generator and bus bar match GENSYS orders the breaker closing Time chart Allocated time to synchronize 2803 C2S check 0310 IO A ooo Synchronization done C2S dwell time Generator breaker 128091 position If synchronization fails GENSYS stops the generator Another GENSYS is elected if Load Unl mode is 1 2 or 3 the
60. ENSYS sends a reset message DM3 to the ECU If the diagnostic message is not sent by the ECU for more than 3s the corresponding fault alarm is automatically reset to OFF Each of the following J1939 messages alarms can be configured to trigger one of GENSYS protections High speed 3104 CT speed Engine speed above the least severe high threshold Very high speed 3105 CT speed Engine speed above the most severe high threshold High water temper 3106 CT CoolTemp Coolant temp above the least severe high threshold Very high water temp Low oil pressure 3107 CT Cool Temp Coolant temp above the most severe high threshold 3108 CT Oil Press Oil pressure below the least severe low threshold Very low oil pressure Malfunction lamp 3109 CT Oil Press Oil pressure below the most severe low threshold 3110 CT Malfunction Message in presence of an emission related trouble Protection lamp 3111 CT Protection Trouble is most probably not electronic subsystem related E g coolant temp may exceed temp range Amber lamp 3112 CT Amber Trouble where the engine need not immediate stop Red lamp 3113 CT Red Severe enough trouble for the engine to stop To the best of our knowledge the lamp alarms are fully supported by previously mentioned engines ECU of Caterpillar Deutz Perkins Volvo 124xGE broadcast and most Cummins engines and par
61. IES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED IN NO EVENT SHALL THE AUTHOR BE LIABLE FOR ANY DIRECT INDIRECT INCIDENTAL SPECIAL EXEMPLARY OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES LOSS OF USE DATA OR PROFITS OR BUSINESS INTERRUPTION HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY WHETHER IN CONTRACT STRICT LIABILITY OR TORT INCLUDING NEGLIGENCE OR OTHERWISE ARISING IN ANY WAY OUT OF THE USE OF THIS SOFTWARE EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE 2 2 IN PANEL INSTALLATION The unit is designed for panel mounting which provides user with access only to the front panel Ali THE UNIT IS NOT GROUNDED Take all measures against Electronic Static Discharges Do not try to open the unit Failure to follow these instructions may damage the unit Environmental requirements e Operating temperature 30 C 22 F 70 C 158 F LCD display slows down a bit under 5 C 23 F Avoid direct exposure to the sun e Storage temperature 40 C 40 F 80 C 176 F e Altitude up to 2 000 m 6 561 ft on higher altitudes recommended max AC voltage 100VAC 2 2 1 Unpacking Make sure the packaging contains e the unit e four caps screws packaged apart e adelivery bill Unpack and keep the packaging in event of return Make sure the unit does not show scratches or visible defaults Otherwise describe them on the RMA
62. SYS and associated to Gen electrical fault can raise such a fault it can also be raised from outside Generator fault request LS Faults inhibition Excitation command Resynchro Excit restart Stop Engine fault sequence Internal trigger Targeted 88 protection Gen electrical fault type Gen electrical fault summary Generator fault request In event of a generator electrical fault 1 GENSYS opens the generator breaker and restarts the alternator excitation if connected during the time 2052 as long as Excit restart is activated Engine fault is raised 2 If the fault is still present at expiry of 2051 GENSYS commands a hard shutdown and Engine fault is raised again see 3 2 6 p 33 Otherwise GENSYS attempts to re synchronize 2052 Excit rest 10 0s Excitation stop time after electric generator fault 2051 TM max excit 10 0s Timeout for excitation 2806 Re sync delay 30 0s Delay before the GENSYS attempts to re synchronize with bus bar 2807 Nbre synch 3 Maximum count of re synchronization launches before forced stop 2808 TM reset synch 30 0s Time to reset the count of re synchronizations Example with 2807 2 Generator electrical fault Re sync delay Generator breaker position Generator status with respect to ae Isolated coupling Synched Pavals Isolated Synched Paral Isolated Stopped leled leled
63. Timeouts and delays A page describes the settings for the engine start sequence Refer to chapter 3 2 p 27 3455 Prelubrication Time to energize a prelube output for a lubrication pump before cranking 3456 Preglow Time to energize a preglow output for preheat plugs before cranking 3457 Cranking Maximum time for which the crank relay is energized during a start attempt 4459 Crank Rest Time to wait between two cranking attempts 3467 Warm up Time to wait before taking the load to allow the engine to warm up 3469 Stabilisation Time to wait for speed and voltage to get steady 4852 Protection valid Delay before enable protections oil pressure underspeed when starting engine 2203 TM sensor lost Time after a sensor lost security fault will be triggered if no signal is read from speed measurement input 3470 Cooling Time the engine will run without load before stopping 3471 Stop engine rest Delay after which the engine is considered to be not stopped 3472 Rest time after The minimum time the engine will wait before re starting after being put at rest normal stop 3478 Horn delay Drop off delay Refer to O p 35 3453 Fail start to start Time to wait before trigger a fail to start fault Max prelub timer The longest acceptable delay for engine start Refer to 3 2 4 p 32 1 Available
64. Voltage stabilization Voltage stabilization counter for static paralleling 4467 Cool down Time generator is waiting without load before stopping engine 4468 Rest after engine stop Time the engine has been waiting since being put at rest 3472 4469 Fail to stop engine 4476 Fail to start engine 31939 VALUES ETC Time of the current stop sequence Time GENSYS waits a response from an external auto start module since the start request a Chapter Human Machine Interface 75 6 5 CONFIGURATION MENU To access this menu a password is required the LCD menu gives access to the following information A Power plant Generator Bus Engine Protections Timers Timeouts and delays Synchronization kW kVAR control loops Modification by variable n The letters are the ones that sneak in the LCD the settings with a purple left border are for CRE Config only A full index indicates the current selection TOTMOoOCOw A Power plant Number of module 1 32 Number given to this particular GENSYS on the CAN bus Total count of modules 1 32 Total count of GENSYS units installed on the CAN bus Paralleling mode 3 No 0 Standard synchronization carried out by adjusting engine speed and generator voltage Yes 1 Breakers are closed before engine start and generator excitation Deadbus management No 0 An external logic controls dead bus management Yes 1 Dead bus management via inter GENS
65. YS digital CAN bus Voltage schema Monophase 0 voltage system selection Biphase 180 1 Triphase 120 2 1 Select the menu item Options Advanced B Generator B 1 Generator 2105 Nominal kW Generator nominal active power 2107 Nominal kVAR Generator nominal reactive power 2102 Nominal voltage Generator nominal voltage 2106 Nominal kW 2 Second nominal power of the generator activated with logical input 2108 Nominal kVAR 2 Second nominal reactive power of the generator activated with logical input B 2 Generator 2100 PT ratio Ratio of the voltage transformers Ex 20 kV to 100 V type in 200 Default value 1 2101 CT ratio Ratio of the current transformers Ex 100A to 5A type in 20 Maximum ratio is 3250 for e g 3250 1 or 16250 5 Default value 100 A RISK OF BREAKER STATE MODIFICATION Do not switch from one mode to another when the plant is in use Failure to follow this instruction can damage equipment A56 ZO 9 0020 B EN B 3 Generator AVR CONTROL AVR amplitude USO manual lechnical documentation AVR trip Refer chapter 5 3 p 62 AVR offset Middle output voltage to AVR PF nom Power factor set point kW low lim Threshold where GENSYS opens the generator breaker after an unload ramp Enter a value above 2412 refer to the chapter 3 3 p 34 kW nom Generator nominal active power set point kW2 nom Ge
66. a inverse U 1 l s 0 10 100 User manual lechnical documentation TOE iin a AVA MTO SIIT UT WTA CO AFA V A WIA ZA Y AA IA ALI A 11000 TT IA 1100 VANA W A MI ee A poo A UY AD A A eee DAA ALT gt CALLAN A ett SSE q 00 F Z fy VA f am NT Y a A A W VA 2 5 VA D A AAN NN Se NN ee tT YX SE tp O mya 7 MA ty AA TT VT T i i os IA II ARA TA CO TY MAAA ET HH LLL AA spuoo s au 121 Batch of standard inverse curves A56 ZO 9 0020 A EN Inverse curves just above the pick up value not logarithmic abscissae I Is for various value of TMS 100 s 10s 1s 0 1s IEEE CURVES Characteristic curve k o e a O Moderately inverse 0 515 0 1140 19 61 0 491 0 1217 HOW TO DERIVE CURVES BY PARALLELISM Say a curve is known We know tsA s stands for the start curve for IA Is s stands for set point Two curves with same k a and c are parallel K tsA Ts10 tA T This can be used to find tA 1 IA Is 10 l s In the preceding curves in logarithmic plot Ts10 1 For a given I Is first column of next table find K in the row Then ta K x T A56 ZO 9 0020 A EN user manual tec
67. as regular inputs and outputs except the Delay on drop off of inputs refer to the chapter 8 3 Digital inputs 1 32 3200 3231 Function 3232 3263 Delay on pick up 3264 3295 Validity 3296 3327 Direction Digital outputs 1 32 3350 3381 Function 3382 3413 Mode direction 0 normally de energized 1 normally energized On power up the configuration is automatically launched The status 3150 turns to 1 The error time out 3152 is 10 0s by default 7 2 3 Mapping CANopen inputs and outputs are accessed by their code e Inputs 0800 0831 e Outputs 4751 4782 Chapter Communication buses 93 7 3 J1939 COMMUNICATION 7 3 1 Overview 31939 is a CAN protocol used by electronic motors which include an ECU or ECM EMS It allows you to read engine and alternator data measurements positions binary values and send commands start stop speed control Bit rate 250kbit s By default the external sensors are the sources to replace them by J1939 assign the corresponding values as per the schematics in the chapters 1 1 p 12 and 3 2 p 27 The ECU can detect faults and send them to GENSYS Protections can be assigned to these faults see further To use the J1939 communication 1 Enter the Configuration Engine J1939 page In the list select the manufacturer 3100 Select the ECU type 3101 Assign the Alarm fault to a protec
68. ast one GENSYS detected alarm ibidem dawn sumar ESA panel Trigger at least one GENSYS detected ibidem minor fault rela summery dal panel HUESO at least one GENSYS detected 4 4 2 p 46 generator electrical fault External panel Trigger at least one GENSYS detected bus ibidem Bus electrical faults summary electrical fault HMI reflection of the LED state fansen metete Tooo mmeo am A AT A 31939 report of J1939 alarm fault Refer to the chapter 7 3 3 p 99 11939 ig watertemper alarm fr 1835 gh watertemper t e piso Lom o presare rm em ross Lom olpressurefeut O em DoT T T so Diagnostic message DM1 In addition most protection activations can be reported refer to the chapter 3 3 p 34 Ref chapter Min max analog1 Activated if measurement of analog input 1 is under over the threshold 3 3 1 p 34 Min max analog2 Idem for analog input 2 Min max analog3 Idem for analog input 3 A56 ZO 9 0020 B EN user manual technical documentation 8 3 3 Analog inputs In addition to the speed and electrical currents and voltages three analog inputs are available They measure a resistance 0 50002 However they can serve as digital inputs or 20 mA transducer input Input Each input is tagged with a name and preset to a function It features several attributes preset in CRE Config Configuration Inputs Analog inputs or in the text file e Step number of digits after decimal point among 1
69. ators start stop according to the GENSYS running hour meter 3 By custom Generators start stop according to my priority number 2863 1 32 0 kw Load dep kVAR 0 Kind of power used in this strategy 1 kKVAR Percent of load on the power plant above which another engine is LV Load thres Default 80 requested to start and share the load Percent of load on the power plant under which an engine is stopped i 0 LV Unload Dra 20 iced when E2859 0 Delay with power above threshold E2854 before GENSYS requests TM before load Default 10 0s another generator to start and share load Delay before deciding to reduce the count of running generators in TM before unload Default 10 0s load unload management GENERATOR Generator breaker control it can take one of the six values that follow Gen brk ctrl Fail to O C br Timeout before breaker opening closure failure Close pulse Open contact Open contact Close contact Open MNcoil Open MNcoil Close pulse Close contact Open pulse Close pulse Open pulse Close contact For details refer to the chapter 8 4 p 113 GENERATOR ELECTRICAL FAULT Re sync delay Delay before the GENSYS tries to re synchronize with busbar Nb re synch Maximum allowed re synchronization launches before forced stop DIGITAL INPUTS AND OUTPUTS AND CANopen Refer to the chapter
70. avessnebenoueusenenscenudanacesenouscenusanavesenenscenedess 41 Synchronization of networKS ssesessssessssessssececssseososeososeceossseososeossssssseossseossssosossosossseossssososeseoeesso 42 AUTO T E E E T A E A T T E E T A A os becsaveusseoncsesesaserssveceusnsvasncceees 42 e uA TOMI A N E A A AET 44 LOA FAN UOMINICI DIO AA Nan 44 SO TRAS TO ti IA dica 44 Hard tran stor a an seseecaasinesueeeas ees 44 BUTS O edsaduaidedds Wddsdudddideddd wacsdesdddddeds 44 IS VANE INO AAA Un o E A 45 DYNAMIC Dalal CNG ari 45 Parallel cuna 45 Uneven generator OA AAA AA AAA AA a 45 Unbalanced load protection iii A Aia 45 nn SP AREA SR RMA RMR RAMEE a ERC er er Perret rrr rrr errr rer rrtre 48 ROO O RN 48 A a a ae ee a re E oeer er reer er errr Pereer rer errr rer rere errr errr r 48 PREAIANIN AA A O 48 Ali A one E E E 48 E A O 49 PHASING 11 OUL generato Sii nda daa daa iso 49 Start stop a ed al 4 21 10 ge eg Pm VEA AA 49 LOdd UNIO AC a CENECLALON naaa AS a 49 Standard controlo rte load nennen Ria 49 Peer to Peer communications seision aaa teclas 49 Unload cenit LOSS Oli 49 Porty generator oonan ET A T E AA AAA AAA AAA 51 Frequency centering sssesesesececececesesesescececscscsceoecececesesesecescececececesesesecesesesesesoececececesesesesesesseeseeee 52 Voltage CONTAINS ES 52 De droopine principle aaa 52 Optimization Contenido 52 A AEON 53 Static 5 VACATONIZINE is 53 Black Start SVNCNTOMIZALION sii 53 Sg 2d
71. ax watt Water temperature max timer a 2385 CT2 max wat t Action on water temp max passed Manual mode In manual mode the start request is manual the stop is automatic protection manual request If a digital input and a digital output are associated to one function refer to the chapters 8 3 1 p 105 and 8 3 2 p 107 they are interconnected Function Parameter Sensor Prelubrication water temperature Summary A J1939 value has priority over an analog input To dismiss a J1939 analog value set the related switch to the desire analog input GENSYS does not take into account an oil pressure fault during the start sequence Note Preheating with validity Always is used in Auto mode Manual preheat request in manual mode In next illustrations the typical set up is through the switch 3450 3451 Alternately GENSYS receives the fault signal through a digital input whose validity is configured for a given engine state refer to 8 3 1 then to by pass the internal processing set the GENSYS threshold to 0 J1939 Low oil pressure alarm J1939 CAN interface Oil pressure Analog im J1939 Low oil pressure fault input AS number Prelubrication Protective effect CT see Protections Validity Oil pressure fault Never Always pee ee Post starting Stabilized Manual prelub request Man Oil pre
72. before changing settings Failure to follow this instruction can damage equipment Functions GENSYS supports the following Modbus functions Function Description o CS Write single register 16 bit variable 15 OxOF Write multiple logical values multiple coils 16 0x10 Write multiple registers Data 10000 10299 can be read by block See further The 32 bit variables can be written to only with function Ox10 user manual lechnical documentation Chapter Communication buses 89 All GENSYS variables are 16 bit registers Yet it might be useful to consider them as logical values if they are only set to O or 1 to simplify Modbus communication with some external PLC If function 01 or 02 is used to read an internal register that is different from 0 then returned value will be 1 GENSYS registers start from address 0 Depending on your Modbus TCP client equipment software you may need to use an offset of 1 when reading writing registers as addresses may start from address 1 In this case request address register number 1 to access variable 0000 inside GENSYS If a digital input modifies a piece of data also to be written by Modbus the latest request takes over the other Access rights The access rights depend on the parameter nature and on massive and individual permissions To grant massive access rights set to 1 the corresponding bits in the word 3015 Writing using Modbus TCP Reading using Modbus TCP
73. blocks A Configuration in CRE Config Modbus enter the codes of the variables to read the readings on the registers 10000 10299 will be the pointed values B Configuration by an external device this device must request the following 1 Write 1 to 3016 to enter into the configuration mode A56 Z0 9 0020 B EN 2 Write the codes to the desired registers 10000 10299 3 Write Oto 3016 to enter into the read mode 4 Read the register 10000 10299 Then to read your own block you just need to read by Modbus the register 10000 to 10299 Time stamping is done by the master Example If the configuration is as follows E10000 14 E1001 15 E10002 16 the reading by Modbus of the 3 registers will give to you the hours minutes seconds of the GENSYS Later CRE Config can upload the new configuration if needed Modbus communication example The table below exemplifies a Modbus TCP client sending a reading request function 04 of 6 registers starting from variable 0079 Client request GENSYS server response Field Field MBAP header MBAP header Function code Function code Starting register MSB Data bytes 2 x count of requested registers Starting register LSB Value of register 0079 MSB Count of registers MSB Value of register 0079 LSB Count of registers LSB Value of register 0080 MSB CRC32 Value of register 0080 LSB Value of register 0081 MSB Value of register 0081 LSB CRC16 MSB
74. cicscccnsccesccecdiscsinccesctcecssacccucsccstsecdsescesidesenssvovseusdoustoussvsseeusoensteeessee 23 IN o LOPERA CO ooo 25 Stan IMAN iio 25 o AAA e ona 26 Start stop cycle 27 CO Geerecerrrrerrererrrrerreer rere rr rrr rrr rrr rr rrr rr rr ee rrr Te 27 E RA 27 Prote cions ONENE arise ssacsectusesansecestsestusstonstornseepaniessnsesessssseonscisennsseanrsnennsnennresennspeonsesebnssearserennineanss 30 Multiple States enana E TEE 31 SMOKE MUNE aa a a a a li 31 AP 32 INDIO ON iia 32 Protections ZEMELaAl cccscccscssccssccesccsccesccescceccesccesececccsccuscesccuscseccesccussseccesccussseccsccussseccesccusesecs 34 e 34 EAC COMPS AMS in ios dro eo 35 RT 35 ANUNCIOS is 35 REVE O DO WEI sic ree ccoreecaracaducececacccereredssssonarecesccadusecds E E T 36 PANS PP E ounsoanenesenesanenssedvnncensosnvusuanceneonsenavonrsearsaes 36 kW overload protection ccccsscsscssccecceccesccsccsccecceccusccscceccescesceccusccssceccecceccscesscecceccescessescceccuccess 36 BV SAWS TAU Sos E o A 36 A o ooA XAPP A 38 o Ae o IA 38 Breaker signal CiSCOrdance csscssccsccscceccescccccsccecceccnsccsccecceccesccscceccsccecceccescesccsscecceccescsssescecceccess 39 Maintenance schedUl Oss srrirrrirrrirrrorrrrt ttin rinn rran Tenn ET TETEA AAE ees 39 Programmed FVII CIA CO since 39 RUINA desire 39 a Aye q 0 41 Production request ccoo i lalala abi 41 Election among generators sccsssiscicscccsescrssansecssecocsanesiuskesesonss
75. citation command F 8 35VDC si AS Speed out L Speed Speed common aan ii Power H Isolation lt T1939 ECU Shield AVR out AVR AVR common L GENSYS Starter No1 Gen L1 Gen L2 Output 1 Fuel COMPACT Gen L3 Tr Gen N 0 O a Output 2 TT PRIME Gen I1 Output 3 Gen I2 T Output 4 Gen 13 T Gen common Output 5 NO Relay output 1 T Relay Common 1 Output 6 NO Relay output 2 Relay Common 2 Common O Analog input 1 Earth fault Earth common Analog input 2 Z nalog inpu 2 AR Analog input 3 Bus L2 setup Bus L3 Supervision Modbus TCP Bus N Firmware update CAN2 J1939 Extensions _ ima Isolation Digital inputs GND 1 9 CAN1 CAN H Pal Inter GENSYS CAN L RES 4 mm AWG 11 Examples Gen breaker aux Remote start stop Emergency stop Ext electrical fault speed inputs Low water temp Low water level Low fuel level Low oil pressure Charger fault By d
76. cle5 d Duration of cycle 5 in cumulative running days Chapter Human Machine Interface 83 6 6 SYSTEM MENU It gives access to the following pages where with readings or settings to modify A Date Time B Screen setup C Ethernet D About read only Note In CRE Config the buttons are greyed out until the PC is connected to GENSYS A Date Time Date Time allows you to modify the date and the time Year Month Day Day of week Time hh mm Time adjustment H M GENERATOR METER SETTING When GENSYS is not connected to a new generator set in CRE Config the initial values of energies count of starts and running hours B Screen setup Display properties and password Contrast 50 Adjustment of LCD contrast from 0 to 100 when electronic is compatible Backlight 100 Adjustment of LCD backlight from 0 to 100 of the max backlight intensity Backlight 5 min Time in minutes after which the backlight turns off saver timeout Password 5 min Time in minutes after which the display exit menus and show screen timeout saver Screen saver 5 min Time in minutes after which the display backlight is switched off The timeout light is switched on again as soon as a key is pressed Line 1 to Line 2 CRE Tech The two lines of text displayed in the Splash screen saver can be its URL modified on the fly Each line can include up to 21 characters in length C Ethernet
77. digital outputs Link to a PLC or a SCADA via Modbus TCP In this typical setup three GENSYS Compact units communicate over a CAN bus to control three generators in parallel Heterogeneous aggregate of generators in island mode can be controlled by GENSYS Compact modules It is preferred that the alternator winding pitches be identical In any case all the generators must be controlled by similar GENSYS COMPACT PRIME units The engine generator may have an Electronic Control Unit with CAN J1939 interface J1939 and CANopen interfaces can coexist on a second CAN media provided they use the same bit rate According to the settings the engine speed is measured by a magnetic pick up derived from the AC frequency or provided over a J1939 CAN bus Limits on overall active and reactive powers 65 535 kW and 65 535 kVAR A56 ZO 9 0020 B EN Chapter Presentation 11 12 USE Chapter Presentation manual lechnical documentation A56 ZO 90020 B EN 1 1 GENERATOR AUTOMATIC CONTROL Two separate cascade control systems are used Primary control GENSYS Secondary control ESG control ECU or ESG AVR control AVR The generated voltages and currents are measured in true RMS and used to calculate the load demand across the aggregate The synchronization requests and load demand drive the primary control which according to its configuration e produces an analog signal Speed out sends pulses f to digital
78. e of many cranks don t forget to disconnect all cranks 3 4 POTENTIAL ALARMS FAULTS CATALOG The potential alarms faults are listed below e Potential Alarm Fault Alarm Fault label this text shows in the Alarm fault pages e Action on alarm on fault this variable allows you to define the associated protection type 8 potential values target to which the signal contributes This list can be downloaded from CRE Config System PC transmit receive Action on alarm fault ELECTRICAL all trip after a definite time except Short circuit which trips after an IDMT see Appendix Overfrequency Generator is in over frequency 2402 2438 Underfrequency Generator is in under frequency 2405 2441 Undervoltage Generator is in under voltage 2411 2447 Overvoltage Generator is in over voltage 2408 2444 Min kVAR Generator reached a minimum of kVAR 2423 2459 Max kVAR Generator reached a maximum of kVAR 2426 2462 kW Generator is in reverse kW 2420 2456 KVAR Generator is in reverse kVAR 2429 2465 Min kW Generator reached a minimum of kW 2414 2450 Max kW Generator reached a maximum of kW 2417 2453 Max Generator is in over current 2432 1 gt 2468 gt gt Max In Generator is in over neutral current 2435 10 gt 2471 10 gt gt Short circuit Short circuit between generator phases 2477 Over speed Engine is in over speed 2352 2370 Generator voltage measurement is inconsistent with
79. e shutdown switch 2881 Frequency selection Ability to switch the rated speed Switched on a state transition while engine speed is 0 50 60Hz CM570 amp PGI or sources given through a nibble e g see Appendix MTU ECUS 1 GENERIC 0 x Y scania S6 DC16 45A 1 gt re GENERIC 0 PENTA EMS2 1 X x multispeed motors 2 EDC4 2 94xGE 3 124xGE 4 1640 2GE 5 1643GE 6 D6 7 D7 8 D13GE Tier3 9 3 GENERIC 0 x xX KX K gt x XX KX KK gt Perkins x KX X KX KK XxX Xx gt Marine Power 1100 A4E GENERIC 0 narrar 4 NEF EDC 1 CURSOR 2 CURSORO9 EDC 3 CURSOR11 4 6 GENERIC 0 6 QSX15 G8 CMS570 1 CM850 2 QSB5 PGI 1 1 3 QSB7 PGI 1 1 4 QSL9 PGI 1 1 5 QSM11 PGI 1 1 6 QSX15 CMS570 7 QSK19 PGI 1 1 8 QSK38 PGI 1 1 9 QSK50 PGI 1 1 10 QSK60 PGI 1 1 11 7 GENERIC 0 JDEC 1 8 GENERIC 0 CATERPILLAR ADEM A4E2 C4 4 amp C6 6 1 9 GENERIC 0 DEUTZ EMR A FAHR EMR2 2 EMR3 3 GENERIC 0 10 E ADEC 2000 1 ADEC 4000 2 See Appendix MTU ECU8 Smart Connect 3 X ECU8 SAM 4 11 GENERIC 0 DDEC III 1 a DDEC IV 2 DDEC X 3 r 3 Cummins 109G ECU may not support speed control through J1939 ECU with Cummins G Drive firmware should support J1939 spee d control x KX X X X
80. ececeseeeneeeeeeeceseeeeeeeuceseeeeeeeeeteeeeeeeeeeeeeeenees 19 2 2 1 A e oi RDP OOO OR sent seit aaeeennes 19 2 2 2 lares ATI OM AENEA EE EEE EEE E E E nd eelaistiee ai adie E eet 19 2 2 3 A In 20 2 2 4 Connection CIARA ccecceccsececcecceecsececcucceecseeeceeceeeeseeeeeeeeeeeceeeeeeteeeeseeeneeneeeges 24 UO Usa cain N cae ana sacar oe cane hen credo canton ein 25 Operan MO uno 25 3 1 1 Manaa TOC lt aea E A A 25 3 1 2 AUTO MAC MOS ss taa 25 3 1 3 EXternal TEQUESTS ro ee ee ree 26 o Pp ee ee eee 27 3 2 1 Nahees ale relies ds garc 210 0 9 c gt esna 27 3 2 2 lol io o PEET Ue o E EAT E E EAE 31 3 2 3 A e o o oy IA 31 3 2 4 External auto start module occccoccconcnncncnnononononnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnons 32 3 2 5 A e A 33 3 2 6 o AA 33 o EE 34 3 3 1 cn o o A e Un 34 3 3 2 Audio or visual ANNUNCIATOL cccoccccccccnnncnnnnnnnnnnonnnnnononnononnononnononnonnnnonnnnonnnnonannonannonoss 35 31303 Calor nel aaron testo potato enisiejoto rato ininta retorcido ce abaeoa 35 3 3 4 ETSI SUD AAAA 35 Potential Alarms Faults catalOg APPO OU P570 III 36 3 4 1 e e UU e E E In o II A 38 Breaker Wille 2 Oli ON eo E rae eo ooeees 39 Cycles before maintenance rara en ara 39 3 7 4 1 4 2 4 3 4 4 4 5 5 1 5 2 5 3 5 4 5 5 6 2 6 3 6 4 6 5 PIDE SOFTU S OOO O NU NO0N55ggEEI EEN 40 3 7 1 A AA re E ES n EF E E E EE O 40 3 7 2 Eo E O gust goats eemeee
81. echnology com Hostname Texts are 21 characters long at most Units and accuracy definition block The block start is the UNITS statement This block defines what kind of units and accuracy is associated with each analog value You need to define only the unit of the analog input itself All associated parameters thresholds for instance are automatically modified accordingly The table below lists the different units supported by GENSYS Only the three programmable analog inputs have an entry in this block to get the variable number refer to the file A56 ZO 9 0030x xls The structure of a unit accuracy definition consists of the variable number preceded by a letter U for Unit A for Accuracy definition and followed by a code as shown in the examples below The use of unit and accuracy is described in 8 3 3 p 111 The input is as follows CONTES UOUE TOT OO S 00 A00063 2 The table below shows the list of codes which correspond to the supported accuracies and units In the examples above input 0063 is displayed in kW Unit code 07 and with two decimal digits Accuracy code 2 The input 2584 has no specific unit 00 igi Power energy Pressure Temperature Time 0 1 Electrical 07 kW 13 Bar 18 C 24 S 1 0 1 01 V 08 kWh 14 mBar 19 F 25 h 2 0 01 02 kV 09 kVAR 15 kPa Volume 26 days 3 0 001 03 mA 10 kVARh 16 PSI 20 L Time related 04 A
82. ed of the other generators loads through the CAN bus they share the load in proportion to their power rating This strategy is more reliable and accurate than an analog solution The speed control is used to share the active load The AVR control is used to share the reactive load Various readings are available kW GEx Percent of nominal active power supplied by each generator variables 400 to 431 kVAR GEx Percent of nominal reactive power supplied by each generator variables 465 to 496 Nom kW GEx Nominal active power supplied by each generator variables 433 to 464 Nom kVAR GEx Nominal reactive power supplied by each generator variables 498 to 529 The shares taken by the generators are monitored on CRE Config or LCD screen The relative deviation is Generator share Average load Average load When it exceeds a threshold for a given time a fault is raised if set 3708 Uneven kW lvl Threshold in for the generator active power 3709 Unev kW delay Delay before raising fault 3711 Unev kVAR lvl Threshold in for the generator reactive power Unev kVAR dly Delay before raising fault kW kVAR Generator share Average power lvl Deviation Uneven signal The statuses and actions on alarm are as follows the potential actions are listed in the chapter Operation Protections 4263 3710 Generator active power is far from the average of all active powers 4264 Uneven kVAR 3
83. efault the inputs 1 2 and 3 are preset to these functions The diagram shows that the Potential Transformers can be connected in various ways Unom V3 100 V3 Unom 100 Star wye on generator side 1 insulated high voltage terminal per PT the ratio is for example Vee on bus side 2 insulated high voltage terminals per PT the ratio is for example A56 ZO 9 0020 B EN user manual lechnical documentation 3 OPERATION 3 1 OPERATING MODES GENSYS can control the generator in three modes They are activated through buttons Button Led AUTO Refer to chapter Applications MAN Refer to chapter Commissioning Test TEST Used only to check the start sequence of the generator taking the load To exit this mode press either AUTO or MAN 3 1 1 Manual mode 1 Press MAN this lights the associated LED 2 Press START GENSYS starts the engine this is detailed further 3 Press the generator O l button to switch the generator ON the load Depending on the setup the process can include e synchronization if bus bar is live e closing of the generator breaker e loading of ramp if bus bar is live GENSYS manages the load according to the setup 4 Press the generator O I button to switch the generator OFF the load this may imply unloading the ramp paralleling and opening the generator breaker the engine runs on 5 Press STOP e One time to cool the engine down and stop it when the time is up e Two times to stop the engine
84. enerator to start is the one with fewest running hours e On decreasing load demand the next generator to stop is the one with most running hours Note 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 starts Coordination between generators is activated only on a load unload request i e in the next start stop on load request on the CAN bus Start stop by generator priority number If this way is selected on all GENSYS units in the power plant the automatic start stop phasing is based on the generator priority numbers set in CRE Config Configuration Power manag system LDSS 2863 1 The generator with the smallest number will start first and run onwards forcefully 2 On increasing load demand the next starts are ruled by the generator priority number 3 On decreasing load demand the generators are phased out in the reverse order Note If a generator has been started forcefully in manual mode it overrides the smallest priority number It closes its breaker on the bus bar even if there is no load Dead bus management Yes The next generator to start is the one with the next smallest number 4 4 4 Automatic frequency voltage centering Use cases The secondary regulations ESG and AVR might drift e g due to thermal variations To counteract these effects a strategy called frequency centering is applied by default in the ag
85. erator ready 0 Remote start Auto Start 1 Start request gt GENSYS Module Engine ready Engine protections z Remote alarm Enginefault Remote hard soft shutd Oil pressure Electrical control and Crank Water temperature protections Fuel Magnetic pick up When ASM validates the speed it sends the signal of readiness and GENSYS regains the control Stabilization 3469 Safety on E4852 Generator Normal running ready Stop request ASM without a Generator ready digital output No extra presetting In absence of Engine fault at expiry of stabilization timeout 3469 GENSYS declares the generator readiness if the speed and voltage are valid A56 ZO 9 0020 B EN user manual lechnical documentation 3 2 5 Power delivery The sequence depends on the paralleling type refer to the chapter Applications e Dynamic paralleling the excitation generated with the crank output is activated in the states Start warm up and nominal speed e Static engine paralleling the excitation sent apart is activated in the states Engine ready generator ready The succeeding states of the generator can be followed locally in the Information page variables 4000 and 4001 3 2 6 Stop and faults On manual request local or remote GENSYS executes a sequence to open the breaker and cool the engine down soft shutdown the succeeding states can be followed in the Information page In event of a major fau
86. ess TEST Make sure the breaker green led turns on otherwise increase the breaker feedback time out 2304 default value 5 0s Refer to 3 5 p 39 The engine starts but runs above below nominal speed Check the wiring Check the fuel supply Check the speed output Refer to O p 60 No connection with the PC consider deactivating the firewall List of potential error messages when transferring a file to GENSYS ERROR 001 Only when all gensets are in WAIT state An ERROR 002 Unknown file type n ERROR 003 Password must be gt 3 In ERROR 004 Write data or checksum error n r ERROR 005 Parameter file error n ERROR 006 Test production file error n ERROR 007 Langue file error n ERROR 008 Update failed Please restart update n ERROR 009 File exceed the limit size of 64ko n Only for equation level 3 ERROR 010 Variable doesn t exist n ERROR 011 No write right on variable n ERROR 012 No write right on label n ERROR 013 Text doesn t exist n ERROR 014 No write right on unit n ERROR 015 Need password 2 to write on variable n ERROR 016 No right option to write on variableln ERROR 017 Configuration not allowing variable value n ERROR 018 Variable out of range n A56 Z0 9 0020 B EN ERROR 019 ERROR 020 ERROR 021 ERROR 022 ERROR 023 ERROR 024 ERROR 025 ERROR 026 ERROR 027 ERROR 028 ERROR 029 Wrong value for variable n Language file n
87. et the P values 2901 and 2905 high when tuning the synchronization typical values from 80 to 200 Setting for synchronization load sharing Extra setting 3652 Delay f f Imp 3653 Delay U U Imp Pulse width If the generator makes too much or not enough correction during an active phase synchronization load sharing it means that the pulse width is not properly adjusted e Decrease 3652 to reduce the pulse control on the governor e Increase 3652 to have more correction on the governor If the generator oscillates around the set point during an active phase or if it s hard to reach the set point it means that the dead band 3650 is not properly adjusted e Decrease dead band 3650 to improve the accuracy around the set point e Increase dead band 3650 if the generator oscillates in frequency or in load If there is a digital potentiometer between GENSYS and the speed governor set AUO fsd and Time if you don t get the desired compensation check the following points e ls the potentiometer still running when GENSYS sends an output signal e Check that the speed voltage range controlled by the potentiometer is wide enough Note If pulses always generate an over compensation then it may be because the potentiometer is still running even after the GENSYS pulse is finished In this case a shunt resistor on the potentiometer input may correct the problem by ensuring a proper low level at the input when GENSYS issues no pulse
88. evel of control kW and Hz 6 0s Threshold2 delay Delay for 2nd level of control kW and Hz must be shorter than level 1 2 0s TM trip out Min delay before shedding the next load 5 0s They are set in CRE Config Configuration Power management system Consumer functions 2861 thru Modification Using CRE Config Configuration Outputs preset up to 5 outputs to x non essential trip In the same manner as for protections you can trigger an action when the shedding capacity runs out a specific output Trip alarm is signaled if 2862 3 2862 All non essential loads are shed 0 7 refer to chapter 3 3 p 34 Sequence When one of the two levels is reached and its associated delay has expired a trip alarm is set and a five tier shedding starts level 1 or escalates level 2 at the end of a cycle based on 2861 an extra non essential consumer is phased out till the threshold is reversely passed When the kW demand exceeds the supply or when the frequency drops 1 Trip alarm is raised after the related delay as long as either threshold is trespassed 2 The Trip outputs are raised in a sequence after an extra delay they are latched till a manual or automatic reset it can raise an output preset to Non essential direct trip o o 1 non essential trip va o 2d non essential trip o 3 non essential trip o Ath non essential trip 5h non essential trip kW Targeted demand o protec
89. fault ENGINE not ready appears Max prelub t o Max time allocated to engine to prestart Default value 10 0s Prelub timer 4453 Associated digital output Notready Activated if no pre start until 3454 has expired Engine not ready A Oil pressure Prelubrication a a Fail to start Success prelubrication can be resumed later manually or on external fault see next time chart Failure the starting sequence stops Protections GENSYS can activate protections e below the oil low threshold or above the water high threshold the ENGINE not OK information shows e the attribute CT of the threshold determines the protection type 8 values see Protections to which the signaling contributes A digital output can be configure according to this protection rr pressure low threshold The output shows the status with incremented decremented when a MO 2364 CTminoil Action on oil pressure min passed After threshold has been trespassed for its 2380 LV2 min oil Oil pressure very low threshold stabilis delay TM 2381 TM2 minoil 2382 CT2 min oil Action on oil pressure min passed OUT past thresholds 2365 LV max wat t Water temper high threshold d MN 2366 TM max wat t Water temperature max timer OUT protection type MN 2367 CTmaxwat t Action on water temp max passed Always 2383 LV2 max wat t Water temp very high threshold CT 8 potential effects 2384 TM2 m
90. g relay Governor AVR Pulse Vdc motorised potentiometer 5 4 1 Setup In Configuration Outputs Digital outputs assign to outputs a function Increase Decrease speed voltage by pulse Select the direction output normally energized i e at state 1 or de energized i e at state 0 refer to the chapter 8 3 2 p 107 As detailed in the section 5 1 p 59 e 4405 is the sum of all speed deviations positive or negative e 4411 is the sum of all voltage deviations positive or negative The dead band is the range centered on 0 of them where no correction pulses are sent 3650 NonAction f f 3651 NonAction U U Dead band percent of 4405 4411 Preliminary step 1 Adjust the resistance at mid value or set the potentiometer tap in the mid position or the tapper in the mid position unless the connection GENSYS governor AVR is direct 2 Show the sum of all deviations 4405 4411 The components of total deviation are split in two as they are compensated in different ways Finally the compensations will be added A56 ZO 9 0020 B EN user manual technical documentation 5 4 2 Speed calibration procedure e Set 3650 to 50 which is about 1 percent of deviation dead band on 4405 e Set 3652 to 2 which corresponds to a 200ms pulse width e Remove the component of the synchronization control set 2906 and 2902 to O Note To get the best results during synchronization it s often useful to s
91. generator breaker open 5 Check the fuel input 6 Check the battery voltage Check the protections Make sure that at least these protections are properly set Overspeed Overvoltage Oil pressure if available Water temperature if available Reverse kW Start the generator NA PS Start the generator in manual mode MAN and press START Navigate to Display Inputs outputs state Digital outputs where the states show in real time If you want to simulate the sequences of starter amp fuel switching disconnect the related outputs Check the activation of the starter crank and of the fuel pump Check the generator readiness led is on Check that the engine speed and the generator voltage are stable and adequate e g 1500rpm 50Hz 400VAc the data is available in Display Gen electrical meter Global view Gen On the screen Engine Generator make sure the speed voltage increases when pressing Shift A Press STOP to stop the generator Check the control of the generator breaker on dead bus bar SS a a Plug the relay cable and make sure the breaker feedback input is connected Start the generator in manual mode MAN and press START Press the generator breaker 0 1 button Make sure the breaker closes control OK displayed and the Breaker status led lights up Apply a dummy load active and reactive on the bus bar and check the powers currents volts Press the generator breaker 0 1 button Make sure the breaker opens and
92. gregate The same applies to voltage the voltage centering can counteract a voltage drift When it is used to counteract the droop created by the ESG AVR this strategy is called de drooping Settings Settings across the aggregate Hz center act Activation 1 enabled Hz center gain Central frequency gain of lead GENSYS 1 U center act Activation of central voltage 1 enabled Procedure 1 Adjust the generator speed to get 49Hz by tuning the speed governor offset When the breaker is closed the frequency must return to 50Hz within 5s Adjust the Hz centering gain 2926 to adjust the time if needed Adjust the generator speed to get 50Hz by tuning the speed governor offset Repeat the steps for all generators Test the load sharing by changing the nominal frequency of one generator to 49Hz To do so e Start a generator at 50Hz and close it breaker e Synchronize the generator at 49Hz e Check that the bus bar frequency comes back to 50Hz and the kW load sharing is correct ays 2 a Note load sharing integral is used only if the frequency voltage centering is set Functioning Using the CAN bus the aggregate elects a leader among the generators on bus bar The centering is applied only to the leader and requires no extra communications whether digital or analog For information the leader number is indicated in 357 variable The centering is a slight proportional correction that slowly brin
93. gs back the frequency and voltage to their nominal value As a result the leader takes more of the load Through the load sharing loop of the other generators the load balance is regained If the default tuning cannot counteract the drift hone the tuning A56 Z0 9 0020 B EN User manual lechnical documentation 4 5 ADDITIONAL CAPABILITIES 4 5 1 Start by static paralleling Use cases e Starting a full plant with multiple generators in an emergency on dead bus the generators are ready to take load in the shortest possible time without warm up e Installation with a high voltage transformer as the generators start the transformer core is magnetized progressively without peaks no transient short circuit Conditions On equipment e The alternators are identical in particular same winding pitch e The AVRs are set for static paralleling they wait for excitation command on their first start e All breakers must be powered by continuous voltage like 24VDc so as to close before AC is available On GENSYS e A digital input is preset to Remote start e A digital output is preset to Excitation command Shunt excitation Courtesy of Leroy Somer E X E t e r lt Courant alternatif Courant continu Bobinage auxiliaire D tection de tension ES Remote start ye Emergency O start o Breaker T O relay Static paralleling 2050 Paralleling Dynamic Static to show the set
94. hereas the protections are inhibited This concerns all engine protections Main start phases 1 The engine is considered to have started when the speed reaches the crank drop out The engine gets ready 3 The generator gets ready the protections are activated unless the Safety on delay 4852 is set to protract inhibition SPEED START POST START Thresholds Default values Time outs delays Waiting Pre start Preglow Start Waiting Preglow Start Warm up Engine state 4001 Speed 1orSpeed2 setpoints O LLL LL 7 SSS CCC Os a 10s 10s 105 10s 10s 10s o oaos 10s 30s Y Y 7 i ple pi pa O a 4 Prelub Preglow Crank Crank rest Preglow Crank Warm up Stabilisation speed volt Safety on Cooling Rest 3455 3456 3457 3458 3456 3457 3467 3469 2004 3470 3472 Nominal Engine Cool speed ready down Digital outputs if preset Air conditioning Starter No 1 Warm up Excitation command Generator ready Protection valid Digital inputs can be preset to Start related functions Only start generator run without paralleling nor closing breaker Start inhibition no start whatsoever even in manual mode Digital outputs can be preset to states Generator stop activated as long as the engine is in state Waiting Prelubrication activated during prelubrication Water preheating
95. hite strip when using a CRE cable i 100Hz to 10kHz Voltage limits between and 2 40VAC Pickup Speed measurement for speed regulation crank drop out and over speed Better option than alternator voltage An over speed shutdown device independent of GENSYS is required the alarm can be generated by ECU refer to the chapter J1939 Communication or by GENSYS refer to the chapter Protections Pickup RISK OF EQUIPMENT DAMAGE Switch off the unit before plugging or unplugging the CAN bus connector or disconnecting wires Failure to follow this instruction can damage the CAN transmitter receiver Note Crank dropout the unit survives for 70 ms at 24V and 20ms at 12V Other systems of voltage If Biphase 180 is selected in CRE Config connect voltages and currents to terminals L1 L3 and N resp 11 13 and common If Monophase is selected connect voltages and currents to the terminals L1 N resp 11 and common Current measurement by only two CTs The 3 phase system must be balanced therefore 13 11 12 and only two identical CTs are required GENSYS 12 CT Gen common This is used in middle high voltage applications The 13 value is less accurate Chapter Installation 23 2 2 4 Connection diagram A56 ZO 9 0026 Examples pulses to speed goy Visual audio alarm Generator breaker trip Lubrication pump Reverse power Ex
96. hive Compact version number zip Click Save Wait until Update firmware successful shows Alarm and Fault LEDs blink Alarm and Fault LEDs are off At last restore the settings from the text file 9 2 ADDING A CUSTOM HMI LANGUAGE By default 4 languages are available English French Spanish Italian In addition to English up to 10 languages can be embedded in GENSYS To add your own language Translation Ask for the Excel file Fill in the columns for the new language labels meant for your GENSYS model Option fill in the labels and variable names for CRE Config software Return the Excel file Downloading When you receive the related bin file in CRE Config System PC transmit receive select Upload file to GENSYS Compact OR in the website select PC gt GENSYS browse to this file Wait until Download successful shows Chapter Maintenance Note Unless the contrary is expressly stipulated CRE Technology reserves the right to use your translation for other uses 9 3 TROUBLESHOOTING To get a history of alarms faults stop the generator connect to CRE Config System PC transmit receive Download log file from GENSYS Compact and click Download To restore factory settings into CRE Config navigate to CRE Config System PC transmit receive Reset factory settings and click Reset Message Sensor lost fault on start In Configuration Engine Speed control settings check that the speed measurement origin i
97. hnical documentation I Is SITIEC A VIT LTI EIT UIT RI IEEE MI IEEE VI IEEE El IEC B IEC C not av EC D IEC E IEC F 1 0 1 1 24 700 90 0000 471 4290 330 606 1 2 12 901 45 000 225 000 545 905 157 946 21 5 5 788 18 000 79 200 179 548 55 791 2 0 3 376 9 000 33 000 67 691 23 421 2 5 2 548 6 000 18 857 35 490 13 512 3 0 2 121 4 500 12 375 21 608 8 970 3 5 1 858 3 600 8 800 14 382 6 465 4 0 1 676 3 000 6 600 10 169 4 924 4 5 1 543 2 571 5 143 7 513 3 903 5 0 1 441 2 250 4 125 5 742 3 190 5 5 1 359 2 000 3 385 4 507 2 671 6 0 1 292 1 800 2 829 3 616 2 281 6 5 1 236 1 636 2 400 2 954 1 981 7 0 1 188 1 500 2 063 2 450 1 744 7 5 1 146 1 385 1 792 2 060 1 555 8 0 1 110 1 286 1 571 1 751 1 400 8 5 1 078 1 200 1 390 1 504 1 273 9 0 1 049 1 125 1 238 1 303 1 166 9 5 1 023 1 059 1 109 1 137 1 077 1 000 1 000 1 000 1 000 1 000 0 979 0 947 0 906 0 885 0 934 0 959 0 900 0 825 0 787 0 877 0 941 0 857 0 754 0 704 0 828 0 925 0 818 0 692 0 633 0 784 0 910 0 783 0 638 0 572 0 746 0 895 0 750 0 589 0 518 0 712 0 882 0 720 0 546 0 471 0 682 0 870 0 692 0 508 0 430 0 655 0 858 0 667 0 473 0 394 0 631 0 847 0 643 0 442 0 362 0 609 0 836 0 621 0 414 0 334 0 589 0 827 0 600 0 388 0 308 0 571 0 817 0 581 0 365 0 285 0 555 0 808 0 563 0 344 0 265 0 540 0 800 0 545 0 324 0 246 0 527 0 792 0 529 0 307 0 229 0 514 0 784 0 514 0 290 0 214 0 503 0 777 0 500 0 275 0 200 0 492 0 770 0 486 0 261 0 188 0 482 0 763 0 474 0 248 0 1
98. ie mneeeeseweeernes 40 Applications oE EEE EEEE EE E EEE 41 TREE EE gL A eae ere ee ee EEA E A A AA AA A A A A AA NEA EA A 41 YERO IONE EE 42 4 2 1 Ea aA BETOL A CAAA E EEE o lataen 42 4 2 2 TUI EEEE E A AA E E E E 43 Loading ana UNLOADING TAMD roser rert aa 44 4 3 1 CONT SUP ATION ias 44 4 3 2 ACUI o e o 0 o TU In 44 POWErMa na SE bans a 45 4 4 1 PACTS Dea CWI rte at ll 45 4 4 2 O o o A ae 46 4 4 3 loaddependentistarUSto ore enn ate en aE OR OnE SRT ONES Sete men mt N Stn wt n oe nner tn ee rE aaa 49 4 4 4 Automatic frequency voltage Centering cccccncccnonocnnonocnnnncnnonacanonarononanononarononanananos 52 AdditionakcapaDiitiES acertacete cer eder E A EE ea n eane eene 53 4 5 1 Start DY static Pporalle WING ares 53 4 5 2 Esad heat O aa 55 COMMISSIONING crianca ninina iasa ara datada 59 Arodu ON A A mn E E E O 59 Analog Speed COVEMION OUT E rasreucaee e E ea a e ee ae 60 Analog AVR Auto Voltage Regulator control o ccoccccncncncncncnnncnnoninonononcnonononacnnacnnacnnninono 62 Speed voltage controlled by contacts pulses cccooccccncncnocnnnncnnnacinonononaconnananonnnonanonnnnnnannnnno 64 5 4 1 o A Ue esed a a a a a O A 64 5 4 2 Speed calibration procedure vilct TETEE 65 5 4 3 Voltage CallDFatlOn Procedure oerna e e e ee e aa e a ea a TE 66 E S SUS E A A oie 67 5 5 1 VCO CI GCC creire E ans va suleuscbal icine nd ied ede ranean 67 5 5 2 bland MODE Cela 68 Human Machine Intel ace sisictccsicccdsacdecsdecadarc
99. ilable if the phase to neutral voltage exceeds 15VAc These pages fit the preset voltage system see further C Bus These pages display in real time all bus electrical measurements C 1 Global view e Phase to neutral voltage of phase 1 e Phase to phase voltage of phase pair 3 1 C 2 Frequency C 3 Phase to neutral V e V1 V2 V3 C 4 Phase to phase U e U31 U23 U12 Note These pages fit the voltage system selected see further C 5 Total power kW amp kVAR e Measure by CAN bus D Synchronization This page displays e Synchroscope phase difference e Differential frequency and voltage bar graphs E Engine meters E 1 e Oil pressure e Water temperature e Engine speed RPM e Battery voltage Note This screen is the screen saver during start E 2 e Running hours e Total count of starts Note Oil pressure water temperature amp engine speed can be measured by an analog input pickup J1939 If the unit is connected by J1939 to the engine some extra pages are available to display the measurement received from the engine Refer to the chapter 7 3 p 94 F Inputs outputs state F 1 Digital inputs 1 5 The name of each input is displayed with its status active full dot inactive hollow dot Chapter Human Machine Interface 73 1 Raw is the status of the physical input 2 Processed is the status after conditioning delay F 2 Digital inputs 6 9 Idem
100. installing the unit Use a properly rated voltage sensing device to confirm the power is off Do not use renewable link fuses in fused switch Failure to follow these instructions will result in death or serious injury General procedure 1 Make sure the cable connectors are NOT plugged Take on protective gloves Connect the wires on each cable connector in accordance with the National Wiring Regulations 2 3 4 Plug each cable connector onto the related connector 5 Plug a direct Ethernet cord RJ45 male male 100 m max 100 a crossover cable such as 3 m long A53W1 is OK if the switch manages it or if the link to PC is direct and lock the rear door Recommendations Wires section 2 5 mm AWG13 To avoid ElectroMagnetic Interferences shield cables appropriately for CAN bus see the Appendix CAN bus Good practices Segregation keep the power cable separate from the CAN bus cables The latter can be installed in the same duct as the low level DC I O wires under 10V If power amp communication cables have to cross each other do it at right angles to avoid crosstalk gt 10cm 4 in SASN39 1934 rt aE 7 l m LA E uri A56 Z0 9 0020 B EN Breaker commands 3 WAR EA Epa 5A 250Vac AC voltages J4 Bus voltage 80 500VAC 35 75 Hz CRE TECHNOLOGY FRANCE technology www cretechnology com 30 C 70 C 40 C 70 C Operating Storage Front protectio
101. ion amp coordinate the actions Conditions required by automatic start stop e The Remote start input must be permanently active on each GENSYS unit i e connected to OV otherwise the generator cannot start This is the prime trigger e Atleast 2 generators must be equipped with a GENSYS unit all with identical LDSS settings e All the GENSYS units must be in AUTO mode The settings are in CRE Config Configuration Power management system LDSS Principle Each GENSYS unit is susceptible e To start its generator if the aggregate threshold 2854 has been exceeded during 2855 e To stop its generator if the aggregate is under the threshold 2857 during 2858 Loading request Aggregate load lt 2855 Unloading request 2854 2857 2858 Running prime force This includes two stages in the CAN interfaces decision to load unload and generator selection 28 D Plant load y Unload request selection Stop request 1 E on number of gen on Q kVAR o 0 gt 5 Y lt Load request gt generator ne o 79 N gt 3 YW 3 z D gt Y Y D O o He zZ 2 lt Cc gt O E p Unload gen Q if LDSS OK 2 an Start and S z F nchronisation O Y Generator number sy Remote start Production request A digital input preset to Unload gen if LDSS OK can be used to stop the related generator after
102. isplay Generator electrical meter Global view generator check that the consumed powers by phase are positive and balanced Otherwise check the wiring During the ramp engine state 4 if power is reverse or the load remains low increase the gain 2912 in Configuration Control loops Check the load sharing On both GENSYS units adjust the gain 2916 2958 to have a load in proportion to the generator rating In event of uneven load sharing 1 Check the wiring direction of the current transformers and the power measurements The power by phase must be balanced and positive 2 Check the speed control is correctly configured and performs the same action on all speed governors 3 Check that all engines are stable If one or more engines oscillate in frequency even slightly this oscillation affects the load sharing Note To improve the function refer to the chapter 4 4 1 p 45 If the load sharing is steady but one generator always takes more load than another adjust the off load speeds engine started no paralleling on the ESG A56 Z0 9 0020 B EN 6 HUMAN MACHINE INTERFACE GENSYS offers several interfaces for setup and monitoring the built in LCD screen CRE Config software application interface a PC web browser mobile phones monitoring in conjunction with BSD On these interfaces the pages are organized similarly The CRE Config software is outlined in a specific manual specific pages are described fur
103. le s to your needs 2 1 3 Hostname You can assign an alias to GENSYS in addition to the IP address enter it in CRE Config to get connected To change this alias in CRE Config navigate to System Network configuration Maximum length 16 characters With Windows the last character defines the type of service 0 is the usual value Allowed characters reduced ANSI set and are allowed except at the start and end 2 1 4 Copyright GENSYS Ethernet communication uses the open source IwIP TCP IP stack Read copyright disclaimer below More details on IwIP Web site http savannah nongnu org projects lwi Copyright 2001 2004 Swedish Institute of Computer Science All rights reserved Redistribution and use in source and binary forms with or without modification are permitted provided that the following conditions are met 1 Redistributions of source code must retain the above copyright notice this list of conditions and the following disclaimer 2 Redistributions in binary form must reproduce the above copyright notice this list of conditions and the following disclaimer in the documentation and or other materials provided with the distribution 3 The name of the author may not be used to endorse or promote products derived from this software without specific prior written permission THIS SOFTWARE IS PROVIDED BY THE AUTHOR AS IS AND ANY EXPRESS OR IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANT
104. lt GENSYS immediately hard shutdown opens the breaker and stops the fuel Any other internal protection can trigger either process through assignment of an action provided an output is preset is connected and feeds back the related remote shutdown input for more details refer to the section Protections The various potential external events show on the following diagram Manual stop request Remote start stop Soft shutdown Remote soft shutdown sequence Breaker command Remote hard shutdown Breaker fault Speed gt 0 Energize to stop Sensor lost Engine fault Fail to stop Emergency stop Damper Assignment of a direct or remote digital input or output in CRE Config If the relay has to be energized to stop the generator use the output Energize to stop GENSYS stops the air feeding Damper output if the proper digital output is connected and preset to Damper function 3 3 PROTECTIONS 3 3 1 General Protections are triggered by internal and external events alarms faults digital inputs CAN bus loss To protect the process the engine or the alternator you must associate one of the predefined actions to each such event These actions or effects are of various kinds e they can just raise an alarm notice shows on the front panel ANSI30 a summary can be reported e they can secure the equipment the engine stops the breaker trips safe and can activate a
105. m voice only A worldwide coverage E Head Office FRANCE EJ Official Distributors C Agents Check our entire distributors list around the world on our Web site http www cretechnology com CRE TECHNOLOGY has provided the engine and generator industry for over 25 years with standard products and dedicated solutions for engine control generator protection and paralleling All application fields where power is the core resource of performance are covered by CRE TECHNOLOGY The company is a reference in the industrial marine and defense businesses Our very strong situation allows us to invest feeding our ambition to be always more advanced always closer to you The coming years will see the broadening of our distribution network and of our innovative products portfolio BECOME A CRE TECHNOLOGY DISTRIBUTOR NEW WEB SITE W W W C relechnolosy com YOUR ACCOUNT amp YOUR PRICES By creating your account you ll have access to all your personal data All the prices of the new CRE TECHNOLOGY website correspond to your business rates GET INFORMATION THE WAY YOU WANT IT Fill your cart by choosing the products you want and get all the information you need EVERYWHERE WITH YOU The new CRE TECHNOLOGY website is designed to be responsive to smartphones and touch tablets It allows you to consult the documents related to the CRE TECHNOLOGY s ranges of products
106. minal frequency V Amplitude Deviation ESG offset Speed out Speed common Reminder to change a setting select it black index adjust it and press Enter 1 Connect the speed common wire only GENSYS Governor Common 2 In Configuration Engine preset the amplitude and offset as described in the table further if not listed contact CRE Technology ESG amplitude ESG offset F Read only Engine Speed Read only Speed Sum 3 Trim the governor potentiometer to read 50Hz or 60Hz 4 Connect the Speed out signal adjust the offset so that the frequency is 50Hz or 60Hz 5 Start the generator in manual mode by pressing MAN and START buttons 6 Adjust Speed sum to 100 with the Shift A keys adjust the amplitude so that the frequency is 53Hz 7 Return to 0 adjust the offset if needed to get back 50Hz or 60Hz Select the Speed Sum and adjust it to 100 with the Shift V keys in order to check the variation range till 47Hz 9 Return to 0 The next table gives both settings for various ESGs For other models contact our Customer service A56 ZO 9 0020 B EN user manual technical documentation with analog input 0 5V OV ILS input AV BARBER 0 5V OV ILS signal ILS 2 5V Fea F COLMAN cs e tuning depends DPG 2201 ILS signal Digital supply 5V a ee ILS signal BAT ECM for QSK23 11 Barber QSK40 QSK45 2 5V OV Colman Freq 06 5V QSX15
107. n m1 Digital input 8 35VDC Digital Os Upper blocks IO user CT inputs Analog inputs J6 MY Generator voltage Earth fault Generator current COD A E GRA GENSYS COMPACT PRIME Speed output AVR common N 100 480VAc measure range 35 75Hz 100mA max accuracy 1 fs N GeneratorN Option S CT inputs ee These lines must be protected externally against short circuits A C S Earth fault Stator earth current Protection on earth fault not implemented yet Don t hesitate to contact CRE Technology for more information Gen current 13 Generator 13 Gen current 2 Generator l2 Gen current l1 Generator I1 Gen common Analog inputs Common Input 3 Input 1 input 2 Freeinput These lines must be protected externally with 100mA 600Vac fuses Use two PTs of 2VA Phase to phase These lines must be protected externally with 100mA 600Vac fuses 1VA Phase to neutral O 5A Maximum rating 15A during 10s Burden 1VA Keep the lead length short to preserve accuracy up to 0 5 full scale deviation External CT max ratio is 3250 i e 3250 1 or preferably 16250 5 Optionally connected to CT For a 2 CT setup see further 0 50 CommectittoBattery S manual technical documentation Chapter Installation 21 Block and mark Note Shield GND Ground plane Lower blocks RISK OF EQUIPMENT DAMAGE As a protection against polarity reversal install a 6A fuse bet
108. n invoke a plan to recover or downgrade the load sharing Generally one plan is adopted across the aggregate setting 3052 These plans are a subset of the actions that can be enforced when a protection trips refer to 3 3 p 34 Plan Generator electrical fault The protection opens generator breaker and tries to re synchronize GENSYS calls another generator on duty via the CAN bus GENSYS waits till the backup is connected to the bus bar GENSYS opens its generator breaker lets the engine cool down off load for the duration of the cool down timer then stops the engine Fault Soft shutdown Help GENSYS opens the breaker and tries again to synchronize See previous section Droop Alarm Only available for 3052 i e in event of CAN bus loss Droop No start if Static ldem CAN inter GENSYS only paralleling No start if Static paralleling Idem CAN inter GENSYS only In static paralleling Parall mode 1 see 4 5 1 the effect of 9 10 depends on when CAN bus is lost GENSYS calls another generator on duty via the CAN bus GENSYS waits till the backup is connected to the bus bar 7 Generator elec fault Help K Abortion 9 or 10 4 Droop 9 or No load sharing at all 10 Load sharing NO generator can start as their AVR never gets the information on when to send the excitation order A56 ZO 9 0020 B EN user manual technical documentation Resynchronization after generator electrical fault A fault detected by GEN
109. nction Manual xxxx filling up request It is interconnected with the digital output preset to xxxx filling After pressing MAN press the external push button till the desired level is reached the upper threshold is not enforced A56 ZO 9 0020 B EN user manual technical documentation 4 APPLICATIONS In island operation each generator in the aggregate is controlled by a private GENSYS unit All GENSYS units are CAN connected A typical configuration for paralleling is the following t Aenote start Starting from the default settings just enter the installation 2000 Count of gen 1 lt N lt 32 2001 GE Number 1 to 32 differs for each GENSYS on one bus The default settings are in bold 2050 Paralleling mode Dynamic 0 Static 1 2002 DeadBus manag No 0 Yes 1 2850 Load Unl mode No 0 To change it see section 4 4 3 p 49 4 1 FIRST START All the GENSYS units with an activated Remote start input start in AUTO mode The fastest generator s GENSYS makes sure that the bus bar is unpowered dead bus bar closes its breaker and takes the load The others synchronize with the bus bar Then if 2850 0 all the generators remains on duty If 2850 1 2 or 3 depending on the load demand the aggregate decides which generators must stop Messages are interchanged over the inter GENSYS CAN bus Calling a generator for production requires 1 An election based on load demand see 4 4 3 p 4
110. nerator nominal active power alternative set point Load ramp timer Time to ramp up from lower limit 2851 to nominal Unload ramp timer Time to ramp down from upper power limit 2852 to lower power limit Resynchronization timer Refer to the chapter 4 4 2 C Bus Max nb of resynch 2150 PT ratio Ratio of the potential transformers D Engine 2205 ESG amplitude 0 10 0V Refer to the chapter 5 3 p 62 2206 ESG offset 10 0V 10 0V 3452 Auto start seq Internal start sequence 0 GENSYS manages the start sequence External auto start module 1 An external module manages the start sequence CRANK SETTINGS This menu does not show if an external start sequence has been selected in CRE Config Configuration Engine Start settings Speed measurement If Magnetic Count of teeth on flywheel is required default value 2 If Alternator Pole pair number is required default value 2 3461 Starts attempts Count of start attempts Default value 3 3100 31939 If installed on engine select the engine manufacturer and ECU type Count starters Starter order Crank 1 drop out Speed RPM above which the engine is considered to be started for starter 1 3463 Crank 2 drop out Speed RPM above which the engine is considered to be started for starter 2 temperature threshold
111. net connection to communicate with a PC Please contact your network administrator to configure router and module s according to your need 3012 DHCP select 1 Enable DHCP protocol dynamic IP address enabled Disable fixed IP address 3000 3003 IP Address 192 168 11 1 Fixed IP address of the unit DHCP disabled or in fault 3008 3011 IP GW address 0 0 0 0 Gateway IP address DHCP disabled 3004 3007 IP NM 255 255 255 0 Network mask DHCP disabled 3013 Port HTTP 80 TCP communication port 3014 Port Mod TCP 502 Modbus TCP communication port 1 Only available if DHCP protocol is disabled Note modification of port numbers is taken into account during power on sequence Restart GENSYS DEDICATED PAGES The dedicated pages include e The faults page e The alarms page e The information page Faults and alarms At any time and any level click the link Faults or the link Alarms in the browser or press the key FAULT or ALARM on the front panel To return to the previous page click lt on the browser or press again the button The latest 30 faults and 30 alarms show They are time stamped as follows dd mm yy hh mn ss protec label XXXX On or Off XXXX is the variable number With the keys navigate between the pages of active faults alarms 1 3 faults alarms 4 7 faults alarms etc Faults 1 3 20 03 08 11 07 38 Input 4 2009 00Fr 20 03 08 11 07 32 Input 4 2009 0n 20 0
112. network protocol that provides communication across diverse interconnected networks User manual technical documentation Chapter Installation 17 Select TCP IP or TCP IP v4 and click Properties General You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator for the appropriate IP settings Obtain an IP address automatically e Use the following IP address IP address 192 168 11 10 Subnet mask 255 255 255 O Default gateway Parar agddeann a bra IS server address automatically Mo Server agacress automaUcCcally 0 Use the following DNS server addresses Preferred DNS server Alternate DNS server _ Validate settings upon exit Enter a PC address that differs from the one of Last number 0 255 avoid O and 255 as they are the GENSYS only by the last number amp click OK often taken for other purposes 2 1 2 Changing the GENSYS IP address To change GENSYS IP address in CRE Config or on LCD navigate to System Network configuration resp About GENSYS supports the DHCP function in this case GENSYS must be connected on a network with a DHCP server During the power on sequence GENSYS is assigned an IP address by the DHCP server If DHCP process fails the fixed IP address is used factory setting 192 168 11 1 Note Contact your network administrator to configure your router and modu
113. ng hours in large font When the generator breaker is closed When the generator breaker is closed Engine overview Water temperature Oil pressure Battery voltage Engine speed In start and fault states When you press START or in fault state Customized screen PASSWORD 2 custom lines Current date and time In waiting state the engine waits for a start request In other cases This page allows you to change passwords from level O to the currently connected level Passwords are limited to 8 characters maximum Refer to this chapter s beginning Chapter Human Machine Interface 85 LANGUAGES English Francais Language of the menus displayed on the PC and the Espanol LCD Italian Language Note It is possible to add a custom language Refer to chapter Maintenance COMMUNICATION PORTS CONFIG INTER GENSYS CAN This isolated communication port is dedicated to inter unit data communication using a proprietary protocol This bus is designed for synchronization load sharing active and reactive dead bus management automatic load unload data broadcast Action to be performed upon CAN bus fault 3052 occurrence can be set select menu Options Advanced CANopen J1939 This bus is used for communication with CANopen remote I O modules Beckhoff Wago or electronic engines communication 31939 ETHERNET This page allows you to configure the Ether
114. ntrol on DM1 smoke Protection associated to an emission related trouble code active Control on DM1 engine protection Most probably not electronic subsystem related For instance engine coolant temperature may exceed its prescribed temperature range Control on DM1 warning Protection associated to problem where engine needs not immediate stop Control on DM1 alarm Protection associated to a severe enough condition to trigger engine stop A56 ZO 9 0020 B EN E Protections All protections Generator and Engine Battery work with e Athreshold triggering level of protection e Atimer time before triggering the protection e Anaction to do when the fault is present Over speed User manual lechnical documentation Under speed Min oil pressure Max water temp Min battery voltage Max battery voltage Over frequency Under frequency Over voltage Under voltage Mini kW Maxi kW Reverse kW Mini kVAR Maxi kVAR Reverse kVAR Over current Over neutral current Uneven load sharing 1 Must be under the DBR intermittent and MCR Max continuous rating curves Refer to Appendix Standards ISO3046 See curves in Appendix Uneven kW Uneven kVAR Short circuit Chapter Human Machine Interface Standard inverse IEC curve c 0 Default value 79 F
115. ogically withdraw from CAnbus the GENSYS whose number is n 4 4 1 p 45 8 3 2 Digital outputs Each input is tagged with a label defined in CRE Config Configuration or in the text file and features several attributes set in the Configuration menu e Direction e Function the output 1 is usually set to Starter 1 function the output 2 to Fuel function Chapter Resources for setup amp maintenance Directions Each output can be e NE normally energized the output is de energized when its function is activated e ND normally de energized the output is energized when its function is activated 107 Output functions Orders Ref chapter ibidem ibidem ibidem bidem ibidem ibidem Static paralleling energizes the AVR excitation relay in states engine ready generator 4 5 1 p 53 ready wait after stop request cool down Dynamic paralleling see further Reports External fuel relay if it has to be energized to stop the engine Energize to stop n manual mode the triggers are STOP button the input Manual stop request or the output Fuel being deactivated Order to close Alternative to generator breaker relay output open or close Can be used to signal a 1 2 p 12 generat breaker tripping Soft shutdown Another GENSYS unit called for help this output is associated with input Remote Help Soft shutdown Help 4 4 2 Generator elect Another GENSYS unit called for help this output is as
116. or Management System 125 CAN BUS GOOD PRACTICES This chapter describes rules to be used to ensure reliable CAN communication These rules must be applied to all CAN communications including inter GENSYS CAN bus and ECU remote I O CAN bus In an EMI environment use a shielded cable to connect CAN bus The table below lists the standard CAN wiring Terminal Standard CAN Mandatory Reserved CAN L CAN GND Reserved CAN SHLD optional GND optional CAN H Reserved CAN V optional SHIELD CABLES A RISK OF EQUIPMENT DAMAGE Switch off the unit before plugging or unplugging the CAN bus connector or disconnecting the wires Failure to follow this instruction can damage the CAN transmitter receiver Cables used must be selected to respond to CAN bus specificities Always use shielded twisted wire pairs Deploy the CAN bus in a bus no mesh ring or star topology as shown below Both ends of the CAN bus must be terminated with a 1200 resistor The next figure gives the example of three units connected through a CAN bus Do NOT install any resistor in the middle unit and connect the incoming wire and the outgoing wire on the same terminal max 1 5 mm or AWG16 use preferably the same section for both termina termi nal Daisy chain it is recommended that the cables draw reversed curves as illustrated Wye rather than Vee A56 ZO 9 0020 A EN user manual
117. or accuracy A56 Z0 9 0020 B EN 6 4 RELAY OUTPUTS 8 4 1 Breaker working modes GENSYS is equipped with two NO relays to control the generator breaker one for opening and one user manual lechnical documentation for closing These outputs allow you to control various types of breakers Fail to O C br Refer to 3 5 p 39 Breaker max opening timeout max time to get the feedback from breaker Nb br close Min time keeping breaker closed If GENSYS has required to close the breaker it will not try to open it until the time has elapsed Unit tenth of second Gen brk ctrl Continuous contact to open Positive pulse to close Control type of the generator breaker relay See below Continuous contact to open Continuous contact to close Undervoltage MN coil opening Pulse to close CLOSED Undervoltage coil opening Continuous contact to close A N CLOSED 4 Breaker without under voltage coil Pulse to open Pulse to close CLOSED RISK OF BREAKER STATE MODIFICATION Do not switch from one mode to another when the plant is in use Failure to follow this instruction can damage equipment Pulse to open Continuous contact to close A CLOSED Chapter Resources for setup amp maintenance 113 8 4 2 Settings of pulses Several settings can be modified in Configuration Modification by variable n
118. ot for GENSYS Compact n Too much languages already download n Wrong language file version n Label doesn t exist n Unit doesn t exist n Wrong accuracy value on 0 1 2 or 3 n Wrong unit value on from O to n No header in language fileln No filename found or too long n Wrong accuracy on parameter n WARNING 001 Wrong size of label n WARNING 002 Wrong character entered in label n WARNING 003 Wrong size of text An WARNING 004 Wrong character entered in text An WARNING 005 Too many errors n WARNING 006 No unit specify on unit An WARNING 007 No value specify on parameter n WARNING 008 No text specify on text n WARNING 009 No label specify on label n user manual lechnical documentation Chapter Maintenance 117 A56 ZO 9 0020 A EN user manual technical documentation 10 APPENDICES STANDARDS FOR GENERATORS ISO 8528 1 CLASSES AND POWER DESIGNATIONS Various load duration profiles are defined Here is the correspondence between classes and powers Fun 50 designa rows destin conien Gnral Allowable average power output Prime Running Overload max 1 h GENSYS PRIME RATING over a 24 hour period is 70 of Power changing over a 12 h period COMPACT the prime rating 10 overload load total 25 h year PRIME CONTINUOUS RATING base Continuous load rating Operating Power ACGEN2 0 fixed load no paralleling Yn _ gt
119. ous settings are used in ramping up down 2851 Gen low lim 10kW Wattage lower limit 50kW 2853 Loading ramp time 10 0s Time to ramp up power from 0 to nominal power 50s slope 10kW s 2856 Unloading ramp 10 0s Time to ramp down power from nominal power to0 22s slope 23kW s time Example Nominal power 500kW Load kW 300 350 Active power set point 200 150 100 50 Low limit Time to ramp up Time to ramp down 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 Before isolating and stopping a generator its GENSYS unit decreases its load from the current value to the low limit where it opens the breaker and the load drops to 0 If a breaker fails to open at the end of an unload ramp the generator continues to share the load as described further GENSYS raises a breaker fault 4 3 2 Tuning Prerequisite the outputs Speed out and AVR out are scaled to match the generator See O p 60 and 5 3 p 62 If the generator is in reverse power or does not takes enough load set P in menu Configuration control loop Ramp kW or kVAR 0 200 Note On LCD screen you can visualize during the ramp the kW kVAR setpoint and the kW kVAR measure 2913 Ramp kW P Proportional of kW ramp 2967 Ramp kVAR P Proportional of kKVAR ramp A56 ZO 9 0020 B EN user manual lechnical documentation 4 4 POWER MANAGEMENT 4 4 1 Load sharing GENSYS is inform
120. outputs or writes to J1939 bus e produces an analog signal AVR out or sends pulses U to digital outputs 1 2 GENERATOR BREAKER CONTROL When GENSYS has synchronized the generator and bus bar it closes the breaker relays coupling this can also be done manually locally front button or remotely if configured so All the related digital inputs and outputs are configurable Two coils can be controlled simultaneously 1 3 HUMAN MACHINE INTERFACE AAA Back lit auto off LCD GENSYS COMPACT The led blinks after a fault arises Acknowledged by pressing the lower button FAULT The led blinks after an alarm arises Acknowledged by pressing the lower button Press to switch to automatic mode Led is lit when this mode is activated Press to switch to test mode starts the gen amp closes breaker Led is lit when mode is activated Press 19 to access the Fault page if new fault occurred Fault blinks the Alarm page if new alarm occurred Al blinks pages with 2 statuses Power and Engine and 10 readings of special interest Press again to return Led Gen ready Navigation Edition In manual mode Closes opens generator see below breaker Breaker status led Bus status led lit when closed lit when live Keyboard A Y Cyclic navigation through menu amp settings list Used to change the value of a setting Hold down to change faster lt gt Cyclic navigation through pages when an item i
121. rain to the DIN rail Make sure there is a resistor of 12002 between CAN H and CAN L on both ends of the cable For details refer to the Appendix CAN bus good practices Available bit rates 125 250 500 kbps 1 Mbps Note CANopen can be used in parallel with J1939 at 250 kbit s A56 Z0 9 0020 B EN 7 2 2 Configuration CANopen config User manual lechnical documentation 8 inputs 8 outputs of coupler ID 1 whose default ID is O 16 inputs 16 outputs of coupler IDH 1 32 inputs 32 outputs of coupler IDH 1 Custom configuration defined by more settings CANopen ID 1 CANopen IN 1 CANopen OUT 1 Identifier of the first coupler Count of inputs on the first coupler Count of outputs on the first coupler CANopen ID 2 CANopen IN 2 CANopen OUT 2 Identifier of the second coupler Count of inputs on the second coupler Count of outputs on the second coupler CANopen ID 3 CANopen IN 3 CANopen OUT 3 Identifier of the third coupler Count of inputs on the third coupler Count of outputs on the third coupler CANopen ID 4 CANopen IN 4 CANopen OUT 4 So lo ao 10 o 9jo o 9 Identifier of the fourth coupler Count of inputs on the fourth coupler Count of outputs on the fourth coupler The assignment of I Os is done in the order of couplers and the lower variable number is associated to the lower message number configured The CANopen inputs and outputs have the same attributes
122. right away Generator is ready Pressing STOP when the generator breaker is CLOSED starts the standard unload sequence opens the breaker and stops the engine after cool down 3 1 2 Automatic mode The automatic mode is subjected to a digital input assigned to the function Remote start of generator start sequence Until the digital input is activated and any delay expired the Auto mode does not prevail To set delays refer to the chapter 8 3 1 p 105 If the input is de activated GENSYS is considered as unavailable 3 1 3 External requests You can substitute the front panel buttons for external buttons PLC commands connected to a pair of digital inputs The external requests control the Led in the same manner as the local buttons The last request external or front panel override the others MAN AUTO If both signals contradict each other the Manual mode request overrides the Auto mode request START STOP and Increase Decrease Regardless of the mode you can start stop the engine or increase decrease the speed voltage Local buttons Substitute function START STOP Manual start stop request Shift A y Increase decrease speed in man OR Increase decrease voltage in man A56 ZO 9 0020 B EN user manual technical documentation 3 2 START SEQUENCE E Internal Start sequence During the start sequence GENSYS controls the prelub preglow crank and fuel outputs when proper conditions are met w
123. run at full capacity nan Bottom line full plant availability in less than 10s typically This meets the NEC700 requirements As long as there is a voltage on the bus bar the dynamic paralleling prevails even if static paralleling is configured A56 ZO 9 0020 B EN user manual technical documentation 4 5 2 Load shedding Introduction The load shedding is the ability to disconnect less important consumers if the aggregate is overloaded even when the full capacity is engaged this prevents a blackout Any GENSYS generally one in the aggregate can take care of excessive demand If the kW demand exceeds the aggregate capacity and or the frequency has dropped below a threshold for a given time the dedicated GENSYS unit activates outputs to shed non essential loads Using two levels of thresholds and delays you can setup your system to react more or less rapidly depending on the severity of the situation Settings Under freq valid Enables disables under frequency monitoring for load shedding 0 Underfreq thresh1 1st level of under frequency monitoring 96 0 Underfreq thresh2 2nd level of under frequency monitoring must be lower than level 1 90 0 Max load valid Enables disables overload monitoring for load shedding 0 Max load thresh1 1st level of kW overload monitoring 95 0 Max load thresh2 2nd level of kW overload monitoring must be higher than level 1 100 0 Threshold1 delay Delay for 1st l
124. s accurate Speed measure Magnetic or Alternator or J1939 If it originates in the alternator check the voltage presence on terminals Gen L1 L2 L3 N If it originates in a magnetic pick up check that the engine speed increases up to 1500rpm 115 If the speed does not reach this value on time the engine stops increase the sensor lost time out 4203 default value 5 05 This time out is set in CRE Config Configuration Time out and delays Message Oil pressure fault on start Check the related connections Check the related settings mainly delays and directions of digital analog inputs Message CAN bus fault Check the related connections including the one of internal resistor jumper Refer to the Appendix For inter GENSYS bus check the related settings count of generators number of each generator No J1939 communication Check that the ECU is powered Check that the configuration correspond to the engine ECU Check that the wiring is correct Refer to the Appendix Power cycle GENSYS and ECU Check that the ECU and its settings are consistent with the J1939 standard Note Some ECUs do not provide information if the engine is on stop Start the engine Message Breaker fault Check the type of breaker against the selection in CRE Config Configuration Outputs Breakers Stop the other generators Make sure the digital input Gen breaker feedback is connected Start the generators in manual mode or just pr
125. s 8 3 p 105 and 7 2 p 92 FIFO DATA LOGGER GENSYS can save up to 2 000 pieces of data In addition to Engine state and Power state up to 10 readings statuses can be selected This includes archived alarms and faults They are archived on change of value Format jj mm aa_ hh mn ss 100ms label XXXX YYYY XXXX parameter number YYYY value A56 Z0 9 0020 B EN In CRE Config Configuration Logger User manual lechnical documentation e Tick the box Log on off to enable the data logger e Enter the codes in the text area using the spin is NOT recommended as you have to scroll a lot The records can be downloaded from CRE Config or the web site RUNNING HOURS CYCLES This page allows you to e set the duration of five cycles in hours and five cycles in days e reset the cumulative duration Refer to the chapter Operation Running cycles Cycle1 h Duration of cycle 1 in cumulative running hours Cycle2 h Duration of cycle 2 in cumulative running hours Cycle3 h Duration of cycle 3 in cumulative running hours Cycle4 h Duration of cycle 4 in cumulative running hours Cycle5 h Cycle1 d Duration of cycle 5 in cumulative running hours Duration of cycle 1 in cumulative running days Cycle2 d Duration of cycle 2 in cumulative running days Cycle3 d Duration of cycle 3 in cumulative running days Cycle4 d Duration of cycle 4 in cumulative running days Cy
126. s as information Fallback Fault Soft shutdown Help See chapter Fallback plans Fallback Gen electrical fault Help ibidem Fallback Droop Alarm ibidem Fallback Droop No start if Static paralleling If already started the generator runs on otherwise no Degraded No start if Static paralleling ibidem The actions are configured in CRE Config Numerical values 0 10 show only in text file See 8 2 p 102 A56 ZO 9 0020 B EN user manual technical documentation 3 3 2 Audio or visual annunciator To trigger an external annunciator whenever a protection trips connect it to an output preset to the Horn function the signal duration is modified by 2478 alternately an input can be used for remote reset Protection PA PETN Stop horn 2478 Horn delay Duration of ring Default value 10s O means the horn will buzz until being manually stopped 3 3 3 Call for help A help protection calls another engine for help and contributes to a summary Soft shutdown or GE electrical fault See Fallback plans 3 3 4 Emergency stop The emergency stop function can be done in two ways e Connecting a normally closed mushroom type button to the digital input Emergency stop This is a pure software solution Hard wired solution where the button also disconnects power supply from the controller outputs like Fuel and Crank Note In cas
127. s connected to CAN bus must be the same as the count of units declared inside each unit count of GENSYS units Otherwise a CAN bus fault is triggered This may also occur if e Two or more units share the same unit number e 120 termination resistors are not used correctly see previous section e CAN bus cable is not properly connected This CAN bus fault can only be reset when the correct count of unit is seen on the CAN bus As with every protection the way to handle a CAN bus fault can be selected If a remote start occurs on a GENSYS working in automatic mode and set up to manage Dead bus and a CAN bus fault has already been triggered GENSYS starts its engine and closes its breaker if there is no voltage on the bus bar after a delay that depends on the generator number If there is a voltage on the bus bar GENSYS synchronizes the generator before connecting to the bus bar Note If you disconnect a GENSYS from the inter GENSYS CAN bus change the count of generators on ALL other GENSYS units of the power plant 127 CONTROL LOOP TUNING Each control is carried out by two actions Proportional and Integral l Set point amp Command Measurement G global gain P proportional gain l integral gain P adjusts the rise time time needed for the system to reach its set point for the first time Using only the P factor always leaves a static error between the set point and the actual value
128. s required to overcome friction Nominal friction percent of reference torque Torque that compensates the engine pumps losses FED 124 Alternator winding 1 temperature 125 Alternator winding 2 temperature 1126 Alternator winding 3 temperature FEEE FOO4 mn m E N Chapter Communication buses 97 Oil and Coolant circuits NA Filter 111 L Expansion tank 112 Ap lt TB E 175 T y LE 99 Ap ADA 1 Pump 110 T 109 P PA i 1208 P 98 L Description Oil level ratio of sump current volume to required volume Oil filter differential pressure 100 Oil pressure Oil temperature 1 1208 Oil pressure upstream the pre filter Coolant pressure 110 Coolant temperature 111 Coolant level ratio of current volume to total volume Coolant filter differential pressure These measurements show in Display Engine meters A measurement not sent by the ECU shows dG ass Notes To get the measurements through the Modbus TCP port refer to the related section A56 Z0 9 0020 B EN 7 3 3 Faults user manual lechnical documentation GENSYS can monitor diagnostic messages DM1 from the ECU Only relevant diagnostic messages are taken into account and used in the GENSYS fault alarm system GENSYS can understand and interpret messages for display process and protection When you activate the internal GENSYS RESET RESET button or remote reset G
129. s selected in a menu and validated Shift Used with AY to in decrease LCD luminosity When in manual mode and breaker is open used with AY to Used with lt gt to adjust LCD contrast increase decrease speed command on Speed control page voltage command on Voltage control page Used with to reset alarms and faults Esc Return to parent menu 3 times to home or Setting change rejection and return to the Navigation mode preceding menu Page opening switch to Edition mode Validation of the new setting and return to Navigation mode 1 4 START AND POWER MANAGEMENT GENSYS units in an aggregate share information through CAN bus communication Various start strategies can be implemented to match your needs e In dynamic paralleling the generators are selectively started and synchronized to the already running units Then they can be stopped and restarted according to the load demand Load Dependent Start Stop e In static paralleling emergency start the generators are started simultaneously and the warm up is by passed A56 ZO 9 0020 B EN Chapter Presentation 13 14 user manual lechnical documentation A56 Z0 9 0020 B EN Chapter Presentation 1 5 SETTING AND SUPERVISION UTILITY A Windows PC with the software application CRE Config 2 50 or later must be connected on the rear Ethernet socket generally via a switch in a star network This allows you to preset all the GENSYS units when
130. sheet downloadable from CRE technology Web site 2 2 2 Installation Preparation 1 Cut out the panel to 220x160 mm minimum 8 7 in x 6 3 in 2 Make sure the cut out is smooth and clean Mounting o Tool cross head screwdriver size 1 Pass the unit through the panel 4x11 mm gt In the rear cover each of the four 0 16x0 42 in spacers with a cap Screw a cap against the panel Repeat on the diagonally opposite spacer 5 Repeat on the other diagonal and tighten equally do not overtighten GENSYS A56 ZO 9 0020 B EN user manual technical documentation Chapter Installation 19 2 2 3 Wiring the unit Tool insulated screwdriver 2 5 mm 0 1 in tightening torque 0 8 Nm 7 Ib in max Accessories 4 5 6 8 15 amp 18 terminal cable connectors protective gloves carpet if the floor is wet THE UNIT IS NOT PROTECTED Use external fuses Bus bar and Generator phases 100mA 600Vac Battery positive 5A 40Vpc Install the fuses as near as possible the unit in a place easily accessible to the user The disconnection device must NOT be fitted in a flexible cord Failure to follow these instructions may damage the unit HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH The unit must only be installed and serviced by qualified electrical personnel Apply appropriate personal protective equipment PPE amp follow safe electrical work practices Turn off power before installing or removing fuses and before
131. sn E A 102 Vabdity of digital Input aaa 105 Cal IU OIT ara EE EN ENEE E EEE T E 111 Accuracy analo INDUUS ui 111 UNdernvolta ECO aaa E A EEE EN 114 EATE Eo M EESE To AAAA E REE EEE BEEE R E EEEE TOE AE A 114 NO VOMITO Coil sion cocoo coi 114 Snuntco iMac 114 e EAEE r 114 o osas 114 ISO Sstandard lense re nr reer rere rere Serer ener ee ere E errr Terre rere cree OO OOE 119 Black Stare CETINITION corr ninio 119 BORIC NE exter sets scenes es ne cose sansa ies da 128 1 PRESENTATION GENSYS Compact is a panel mounting electronic unit meant for the control of a fuel single two or three phase low voltage generator The Prime model is mainly designed to control a generator that operates in an aggregate of generators up to 32 multiple sets with prime mover and standby sets in parallel island mode with load sharing Various generator powers are specified for various usages Refer to Appendix Standard for generators GENSYS Compact capabilities include Start and monitoring of the engine three 2 wire resistor inputs Acquisition of the engine speed and the generator AC currents and voltages Generator electrical protections PID control in various modes isochronous speed and voltage droop frequency volt centering Control of actuators it is compatible with most speed governors ESG and AVR regulators Synchronization before coupling Extension by CANopen units Wago Beckhoff VIPA etc up to 32 extra digital inputs and 32 extra
132. sociated with input Remote faults Help Fault Help External speed controller with smoke limit input Activated on start e In manual mode after START is pressed or with Manual start request e In auto mode in states Start Warm up and Nominal speed External horn or flashing light Activated whenever a protection triggers The output is Horn l s 0 p activated when one or more of summary outputs is activated and reset on acknowlgt Air conditioning Air conditioner activated by input Cool temp fault when coolant is not water Cooling fan Air fan activated by input Coolant temp fault or high water temperature ibidem Damper Damping flap activated in stop sequence if there is an engine fault bidem 4 4 2 a External fuel pump in conjunction with Fuel low level and Fuel high level or Fuel tank filling n sii E enii Manual fuel fill functions assigned to digital inputs Compressor in conjunction with Coolant high level and Coolant low level or Coolant filling Manual air fill functions assigned to digital inputs External oil pump in conjunction with Oil high level and Oil low level or Manual oil fill functions assigned to digital inputs Increase speed Speed regulator requiring contacts In manual mode the output is activated when errr by pulse you press the A key or with an Increase speed in man P Decrease speed Speed regulator requiring contacts In manual mode the output
133. ss ENTER to validate the new value ESC to reject it GENSYS returns to Navigation mode It is also possible via the bus Modbus TCP Refer to the chapter 7 1 p 89 A56 ZO 9 0020 B EN user manual technical documentation 6 2 SUPERVISION If you keep the PC connected you can monitor the generator from CRE Config Scada through GENSYS E Scada Generator power meters 4 Generator electrical meters Global view generator Generator e meters Generator energy meters b Mains bus electrical meters Synchronization b Engine meters Digital inputs outputs Analog inputs Active timers Maintenance cycle monitoring Faults Alarms Information display ____ aS Device Name 192 168 11 1 amu Password o Connect An alarm faults handler is built in Note In the handler the buttons are greyed out until the PC is connected to GENSYS 6 3 WEB SERVER The GENSYS web server provides a very easy and efficient way of loading downloading configuration file Downloading alarm fault log events Update firmware Visualize alarm fault To do so 1 Connect GENSYS to your PC using an Ethernet direct cable 2 Start a Web browser such as Firefox or Internet Explorer 3 Type in the IP address factory setting http 192 168 11 1 or GENSYS hostname 4 When the GENSYS password page appears enter your password In the browser the only soft key is ESC used to return to the parent menu Chapter Human
134. ssure Water J1939 High water temperature alarm J1939 i o ee eae 3 temperature J1939 High water temperature fault Analog 3 o 2 Input 2 o 1 L 3474 Water preheating 73 number 1 0 fij 419365 MN Protective effect CT Regulated preheating permission Never 3451 see Protections Way ene gt Post starting _ Stabilized Preheating request Never Always L__ Sy Post starting Stabilized Water gt 1 temperature Validity Cooling fan TE Never o Al s Coolant temp fault e a Stabilized Assignment of a direct or remote digital input or output in CRE Config Usual validities are shown They are preset in CRE Config at the same time as the function Refer to 8 3 1 p 105 Cooling fan is also actuated in manual mode if the engine runs A56 ZO 9 0020 B EN user manual technical documentation 3473 Oil pressure threshold Lubrication pump run below this low pressure threshold Set to O to bypass prelubrication 3474 Preheat coolant Preheating pump run below this low temperature threshold Set to 0 to bypass temperature threshold preheating 3475 LV cooling Air fan is activated when water temperature is over this threshold default value 40 C Air fan is not active when engine is stopped Crank With multiple starters preset digital outputs to
135. tage To set the thresholds refer to E p 76 Max battery voltage idem CAN1 bus fault Communication problem on the inter unit CAN 3052 CAN2 bus fault A J1939 CANopen bus error is detected See 7 3 p 94 3053 Overspeed Extreme Over speed detected by J1939 3104 3105 Low Oil P Very Low oil pressure detected by J1939 3108 3109 High Cool T Very High water temperature detected by J1939 3106 3107 Malfunct lamp See 7 3 p 94 3110 Protect lamp ibidem 3111 Amber lamp ibidem 3112 Red lamp ibidem 3113 1 For an external start module the alarm fault 4473 Engine not ready corresponds to a loss of generator ready signal 3 4 1 Synthesis The faults and alarms are synthesized as follows The specified action selection is depicted as a selector in the middle of the illustration External relays can contribute to Generator protection Fault inhibition NI Fail to stop Overspeed Overcurrent Z Remote hard shutdown Remote soft shutdown help Auto start o module or Ext relay o Forced run Speed sensor Breaker fault _ FAULT Hard Shutdown summary o O Y o PLC POWER ENGINE A Serious fault Auto start module or Ext relay Remote fault help Security Fault Soft Shutdown summary Protections run a ne e E 3
136. ted speed max rotational velocity of engine crankshaft under full load conditions ninin injin nN m im im OJO O og Iov m Io Jo O m im u A J D 66 Engine rated power net brake power at rated speed y n m gJ N 013 Trip maximum engine speed since latest trip reset n m UI 171 Ambient air temperature n m m o 182 Engine trip fuel fuel consumed during all or part of a run 0 UN Engine total fuel used 8 84 Engine fuel rate Engine instantaneous fuel economy covered distance fuel consumption Engine fuel delivery pressure as delivered by supply pump to high pressure pump EN EA Battery potential Power input FE nm iim im imn in m im m im m nm imin imn iim T Im IN IN IIO o 7 Water in fuel indicator binary signal m OU UU 157 Engine injector metering rail 1 pressure 174 168 158 136 08 387 nN m m m Engine fuel temperature 1 at injector inlet Battery potential Power input1 m m N Key switch supply potential alternative to 168 CU temperature gJ arometric pressure m inn m im m o Imp O W ressure auxiliary sensor 1 Ea 388 Pressure auxiliary sensor 2 247 Engine total hours of operation n m m UI A56 ZO 9 0020 B EN user manual technical documentation Air and Exhaust gas circuits Gas is optional Alternator 1039 Q 3563 P 172 T 106 P 107 Ap 1040 Q 105 T Compressor 1390 P
137. tesaitssseecdecanes aaecctecanex oa EENEN EAEE 69 Security and operations through the front panel ccoocccccccccnccncncnnnncnoncnnoncnnoncnnononnoncnnnncnnnos 69 6 1 1 Security level and password aeeie ernes Erer En EEEE rA rR EAR EAER AA NE IRA ARNASA 69 6 1 2 HIVES tt seene a E EEEO EEEE ONONE NAS 70 6 1 3 NEVA A 70 6 1 4 AA ata titatatatata a a 70 SUE VISION irte A IIA IAS ii 71 We SENO aiii AA NN 71 DISPLAY MENU AAA AAA A 72 CONFIGURATION MEN ias Na 76 6 6 7 1 7 2 7 3 8 2 8 3 8 4 9 9 1 9 2 9 3 10 FENE EN ea a cece ese ee tubebabenubobsboeebceute wee use 84 Communication BUSES currada dida oido 89 Modbus TE caia 89 7 1 1 CDI as 89 7 1 2 CONFESIONES 89 7 1 3 PSS CEI A e e A e uaa eeenee 89 CANopen extension modules turca 92 7 2 1 AI ds 92 7 2 2 CONEA ca 93 7 2 3 Wie DDI rra AAA 93 ESA so IA 94 1 31 OVE OW araea E R RR e a aa Eana 94 7 3 2 Measuring points and positions ooccoccoccconconnnnoncnncnncnnoncnnonconcnnononcnnroncnnronaroncnncononos 94 7 3 3 UU tii iii AAA Aa 99 7 3 4 sn E EEE ew sew Su OE 100 Resources tor setup amp maintenance iii RR 101 Filetrans te eneee eE AEE EEEE AEREE EA e s ool icalos sata tots tsulalos a tatelaettocrceovaeeeee 101 8 1 1 EIS See ENIE ANS Nels ean esta iar a iia iaa 101 8 1 2 PCES GENSYS letran Te cep cscs ias 102 8 1 3 Update firmware ssssotoe thote eL re e o E Fah Baal Deans nd Tad eee 102 Texte CESEMIOTOM eiet tt 102 8 2 1 V AF a DIC namine a a
138. ther The splash page text is customized in CRE Config System Display properties 6 1 SECURITY AND OPERATIONS THROUGH THE FRONT PANEL 6 1 1 Security level and password GENSYS features password protected access levels to define which menu and items can be accessed Default password Authorization Accessible pages and items B fault this level i t d No password Press ENTER Alo Save S elit DISPLAY menu pages only protected but you can implement one 1 digit ONE User level settings and commissioning All three menus ES 1234 Used to change advanced settings All items CRE Config only 2 The password can be changed in CRE Config System Display Configuration System To access the Display menu press ENTER To access the Configuration and System menus the padlock must be released 1 2 Press Y to select Configuration Press ENTER to switch to password input mode as for other settings the first character is represented by a black rectangle Scroll the character set by pressing till you get the desired first character and press ENTER to validate it Shift to the next character pressing gt select the value pressing A and press ENTER to validate it substitutes for each character entered Repeat for other characters To validate the password press ENTER To log out wait for the time TM password set in the System menu default value 5 min then the home shows and configuration is subjected to
139. they are on desk a text file that reflects the first GENSYS unit s configuration can serve as a template to deploy the setup to the other GENSYS units in the cluster The CRE Config multi tabbed interface makes it easy Once all GENSYS units are mounted CRE Config can be used to set them up and monitor the generators The CRE Config features a Scada section that can be used in particular as an event console to GENSYS NN GENSYS CRE Config Scada 0h00 Breaker fault Power e Prod request Cc O pa O q 1 6 ASSOCIATED PRODUCTS FOR REMOTE METERING MONITORING AND CONTROL The readings and alarms faults raised by GENSYS can be transmitted over a wired Ethernet network through the CRE Technology boxes BSD Plus see preceding illustration it embeds a website or BSD2 0 illustrated herein it uses the laaS cloud technology h l a E l a aa o l The data server stores the data and forwards e mails to notify alarms faults SMTP Antennas provide wireless capabilities e 3G GSM GPRS insert a SIM card into the slot SMS service is supported by BSD Plus e GPS geo localization geo fencing is supported by BSD 2 0 The alarms faults can be remotely reset and the generator started in any mode The writing rights are those defined for Modbus TCP Trend analysis and tunneling direct connection to GENSYS are available with BSD 2 0 Refer to the dedicated manual A56 Z0 9 0020 B EN Chapter Presentation
140. tially by MTU and Scania engines not supported All thresholds are those set in the ECU In addition of these known diagnostic messages GENSYS shows the latest five unmanaged SPN what is wrong FMI Failure Mode Identifier e error type combinations it has received with the diagnostic message DM1 These SPN FMIs are backed up in registers Register Description 0664 0665 0666 31939 SPN LO 1 31939 SPN HI 1 31939 FMI 1 Latest SPN FMI received by GENSYS 0667 0668 0669 31939 SPN LO 2 31939 SPN HI 2 31939 FMI 2 Second latest SPN FMI received by GENSYS 0670 0671 0672 31939 SPN LO 3 31939 SPN HI 3 31939 FMI 3 Third latest SPN FMI received by GENSYS 0673 0674 0675 31939 SPN LO 4 31939 SPN HI 4 31939 FMI 4 Fourth latest SPN FMI received by GENSYS 0676 0677 0678 J1939 SPN LO 5 J1939 SPN HI5 J1939 FMI 5 Fifth latest SPN FMI received by GENSYS SPN LO corresponds to LSB SPN HI to MSB Note In any case a fault alarm is activated on reception of an unknown SPN FMI if the Red 3113 Amber 3112 control has been set It is deactivated by Reset Chapter Communication buses 99 7 3 4 Controls SPN Description Details ss PGN 898 Requested speed Engine speed which the engine is expected to operate at if the speed control mode is active OR which the engine is not expected to exceed if the speed limit mode is active Start Stop Engin
141. ting in CRE Config tick Options gt Advanced mode 2051 TM maxexcit 10 0s Timeout for excitation This parameter must take care of the timer prelubrication preglow starter speed stabilization See sequence further 2053 Excit speed 90 0 Speed low threshold in of nominal speed before waiting excitation Must be identical in all GENSYS units 2054 Excit volt 20 0 Voltage high threshold in of nominal voltage to validate closing breaker in static parrallel It relates to the remanent voltage of the alternators Must be identical in all GENSYS units 2056 TMVoltstab 5 0s Voltage stabilization timer after excitation order before to pronounce as engine ready Must be identical in all GENSYS units During this stabilization the unit working in droop mode The generators are synchronized together through the CAN bus Exroration OWO ai 400V 2053 ES 2 Waiting Voltage 2054 f BOM Locman 3 4 5 step Sequence 1 Any signaling of bus voltage loss activates the Remote start inputs All the GENSYS units close their breaker and start their engine The remanent voltage appears The fastest generator s speed reaches 2053 The slowest generator s speed reaches 2053 before 2051 expires then CAN bus orders all the GENSYS units to simultaneously activate their excitation output as a result e the nominal voltage is reached immediately at the same time on all generators e the plant can
142. tion type Actual frequency 5 digital outputs Enable Remote non essential load Non essential direct trip The next time charts show the trip alarm and trip outputs depending on the generator load or frequency Load kW Delay 2 kW 2 kW 1 Trip Alarm 5th non ess load TM trip out Ath non ess load 3rd non ess load 2nd non ess load 1st non ess load Trip counter The trip counter sums the times during which at least one consumer is shed It is reset at the same time as the alarm A56 ZO 9 0020 B EN user manual technical documentation Freq Hz Hz 1 Hz 2 t Trip rarm 7 A56 ZO 9 0020 B EN user manual technical documentation 5 COMMISSIONING 5 1 INTRODUCTION Each function produces a speed or voltage deviation based on its own GPI coefficients GENSYS feeds the sum of deviations to the output stage either as analog signals Soeed out and AVR out or as pulses train or J1939 frames speed G p Speed droop ESG amplitude F Frequency Speed out centering ESG offset E nn S Pulse width f a G Load sharing kW f UI cos Dead band kW regulation z 5 CAN interface J1939 C F b a U Synchronization H U ar U U Pulse width a Y Load sharing kVar U A
143. tion see below Connect the engine ECU and the GENSYS J1939 port oP ey The pair manufacturer ECU determines the following settings e GENSYS address on the CAN bus e ECU address on the CAN bus e Speed control through J1939 or by analog output pulses e Start stop control through J1939 or by crank and fuel digital outputs GENSYS can communicate with a large number of J1939 engines As the engine list accrues please contact CRE Technology or your local distributor if your engine is not mentioned in this document In any case if your ECU does not belong to the following list try 1 Toselect the generic ECU from your manufacturer 2 Toselect the GENERIC manufacturer then modify the GENSYS and ECU address according to the ECU documentation 7 3 2 Measuring points and positions The next table lists out the measuring points whose values are conveyed over the CAN bus and taken into account by GENSYS The J1939 standard assigns each of them an SPN Suspect Parameter Number as it will be used to label the alarms Refer further to the three schematics amp tables for description and location Legend P a t t mR a a ov w Diff pressure Flow Rate Voltage Power To be conveyed they are grouped in frames each frame is identified by a PGN Parameter Group Number A56 Z0 9 0020 B EN GENERIC 0 user manual lechnical documentation S6 DC16 45A 1 91 512 188 183 184 247 102 105 9
144. unning When load increases above the start threshold generator 2 starts to supplement generator 1 then generator 3 amp generator 4 start As the load decreases the generators are phased out in the order 4 3 2 100 80 60 GE1 40 20 0 100 80 60 GE2 40 20 0 100 80 60 GE3 40 20 HA IO 0 100 80 60 GE4 40 20 0 A56 ZO 9 0020 B EN user manual technical documentation Start stop by generator number If this way is selected on all GENSYS units in the power plant the automatic start stop phasing is based on the generator numbers set in CRE Config Configuration Power 2001 1 The generator with the smallest number will start first and run onwards forcefully 2 On increasing load demand the next starts are ruled by the generator number 3 On decreasing load demand the generators are phased out in the reverse order Note If a generator has been started forcefully in manual mode it overrides the smallest generator number It closes its breaker on the bus bar even if there is no load Dead bus management Yes The next generator to start is the one with the next smallest number Start stop by running hours In this way the generator to start stop is auto selected according to the GENSYS running hour meter e On increasing load demand the next g
145. ween Battery positive lug amp terminal 8 35VDC Connect battery negative to GENSYS terminals 8 35VDC with 2 5 mm AWG13 cable Failure to follow this instruction can damage the controller Block and Mark Note 8 35VDC VA NOT protected against polarity reversal Power supply 8 35VDC consumed current 130 mA at 24V standby amp operation Power supply 2 5mm AWG13 Generator chassis Shield Digital outputs GND 1 Starter n1 generally 2 Fuel generally Free solid state output State 1 at the supply voltage max 2A Protected against short circuits A reactive load is supported Not isolated from power Other free outputs Digital inputs 1 Gen bk fb generally Free digital input with 10kQ pull up Accepts NO or NC contact to OV Not isolated from power Other free inputs CAN2 11939 Extensionsy Isolated CAN bus 11939 CANopen Twisted pair See CAN appendix _ Shield Speed __ Compatible with most speed governors Isolated from power Out 10V analog output to speed governor A56 ZO 9 0020 B EN user manual lechnical documentation Block and Mark Speed reference Twisted pair length lt 5m 16ft if unshielded lt 50m max if shielded ave __ Compatible with most regulators Isolated from power CANA Inter GENSYS Isolated CAN bus use twisted pair Refer to the CAN appendix CANL O White wire with a blue strip when using a CRE cable CANH Blue wire with a w

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