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A53 Z0 9 0020 EN - Technical ducumentation

1. Fichier Editon Affichage Favoris Outils S o E 2 E Pr c dente Gurvante Arr ter Actualiser D marage Rechercher Favoris Adresse E http gensys d010 htm Liens Engine meters AI oil press 0029 1000 mBar o M ooo AI water temp 0030 46 c o ZT iso Batt voltage 0041 23 0 o MT sooo Engine speed 0033 0 rpm o FI 43 2500 Faults p Applet d marr e Alarms Information im OG Site de confiance Variables from MDEC 3 http gensys d011 htm Microsoft Internet Explorer Fichier Editon Affichage Favoris Outils e gt A ad i Pr c dente Suivante Arr ter Actualiser D marrage Rechercher Favoris Adresse A http gensys d011 htm v Liens gt Engine meters Engine Speed sat N A Lube Oil pressa j4 N A Coolant temp M00 N A Lube Oil compat N A Engine ee ee N A HTUID PV110104 390 N A MTUID Pvi10119 395 N A MTUID PV1102 19 444 N A HTUID pyii0226 445 N A RED Alarm 343 N A lt lt gt gt Esc Faults Alarms Information p E Temn 11 O Sitesdeconfian e 2 FIGURE 86 MDEC SCREENS 6 Additional information In the standard configuration GENSYS 2 0 can display all the MDEC variables available on the CAN bus thanks to the screen seen above These variables are displayed as is without any further processing except for certain faults If you need
2. 1 and 4 Parameter to be stored in non volatile memory Ex Genset number Nominal power 2 and 3 General purpose variable Ex Alarms PLC variables The next 3 digits YYY give the number of the variable A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 147 All the parameters Variable from 1000 to 1999 and from 4000 to 4999 of the module are stored in a non volatile FLASH memory within the module It is possible to download or upload these parameters with a computer thus allowing the user to save modify and reuse these parameters later All these values are stored in a text file The following chapter describes the layout of the file The file can be exchanged between a PC and module as described in 19 4 6 and 19 4 7 It can also be exchanged with the SD card as described in 17 7 3 16 3 TEXT FILE DESCRIPTION The complete module configuration can be contained in a simple text file This file can be downloaded from the module to be kept on a computer It can also be manually edited on a computer and sent to a module to fully setup this module in a single step This text file is made up of 5 different blocks SG Parameter values Label definitions Unit definitions PLC initializations PLC equations NSG SG SG SG 16 3 IGENERA TING AN EMPTY TEXT FILE TEMPLATE The module can generate an empty template that contains the minimum requirem
3. It is possible to modify the values directly in the text file before uploading it into the module The user must be sure that the modified value is within the minimum maximum range of the parameter Failure to do so will lead to an error message during uploading Compilation result VARIABLE It is also possible to write an incomplete parameter block not all parameters are displayed in the list When uploaded such a file will only modify the parameters which have been entered the others remain unchanged This procedure can be used to upload an old text file into a newer module or to activate special features independently 16 3 3 LABEL DEFINITION BLOCK The beginning of this block is shown by a LABELS statement This block is used to define custom labels Only the spare analogue inputs the digital inputs the virtual digital inputs the maintenance cycle and the lines in the Logo Page can have an input in this block The table below shows the correspondence between the LABEL number and its associated value Identifier LOO29 LOO31 LOO32 L2804 to L2805 L2020 to L2024 L2913 L2914 L2283 to L2302 L2565 to L2584 L1442 to L1446 Factory label Al oil press Al water temp Al spare 1 Al spare 2 Spare Input J4 Spare Input J15 Output C1 Output C5 Relay A1 Relay A2 Virtual in 1 Virtual in 20 Virtual in 21 Virtual in 40 Cycle 1 h Cycle 5 h A53 Z0 9 0020 N EN
4. Trip Out 5 E2728 Trip Out 4 E2727 Trip Out 3 E2726 Trip Out 2 E2725 Trip Out 1 E2724 Trip timer E2730 RESET FIGURE 74 NON ESSENTIAL CONSUMER TRIP ON KW A53 Z0 9 0020 N EN Technical documentation Chapter Advanced marine functions 144 Freq Hz Timer_1 e E a Hz 1 E E1909 E1903 Hz 2 i Timer 2 lt a E1910 EE Trip Alarm J H E2729 FIGURE 75 NON ESSENTIAL CONSUMER TRIP ON HZ t Chapter Advanced marine functions 145 A53 ZO 9 0020 N EN Technical documentation 15 3 CONNECTING MULTIPLE UNITS TO THE SHORE Diagram below is an example showing how to connect a two engine power plant run by GENSYS 2 0 units to a shore through the use of a SELCO T4000 auto synchronizer The output of this module is connected to analog input G1 G3 of both GENSYS 2 0 units set up as a 10V input and used as a speed adjustment input SELCO T4000 AUTO SYNCHRONIZER FIGURE 76 SHORE CONNECTION USING SELCO T4H000 A53 Z0 9 0020 N EN Technical documentation Chapter Advanced marine functions 146 16 TEXT FILE amp PLC 16 1 INTRODUCTION A NZ Cx GENSYS 2 0 LT doesn t support custom equations feature References to equation in this chapter DO NOT APPLY to GENSYS 2 0 LT units The core system of the module is based on a list of predefined variables These variables can be used in a proprietary programming language
5. E1457 Water temp sign E2283 Virtual input 1 alarms inhibition Or TEST E2011 EQ 1 THEN BLOC E1457 0 E2283 1 E1274 2208 TEST E0033 GT E1712 THEN E1456 0 ELIF E0033 LE E1714 THEN E1456 1 TEND E1273 2208 BEND Chapter Additional functions ELSE BLOC E1456 E2812 E1457 2813 E2283 0 E1273 1 E1274 1 BEND TEND BEND 124 A53 Z0 9 0020 N EN Technical documentation 14 8 USE OF BSM II WITH GENSYS 2 0 AY When you have a lot of analogue values to monitor BSM II can be connected to GENSYS s 2 0 to log measurements and process data efficiently This chapter will explain this type of configuration SP IY 8 1 SCHEMATIC GENSYS 2 0 ere HEILT Hi HH ae BSMII CAN2 li COM2 a Ola DC U 5 CANH 7 120 Q active Ui O i CAN L R 120 if end of bus Hy oo iS 2 Q EERTE PibasattPiviias FIGURE 61 WIRING GENSYS 2 0 TO BSM II Notes See 22 3 in order to choose the cable that fit your application If BSM Il is at the end of the CAN bus add one 120Q2 resistor in parallel with terminals 5 and 7 IG 8 2 CONFIGURATION The communication between GENSYS 2 0 and BSM II uses a CANopen protocol BSM II is a slave unit and GENSYS 2 0 a master unit GENSYS 2 0 can be connected to several devices via its COM2 BSM II Max 2 Wago coupler Max 32 Only one of the two BSM II must be set to log data from GENSYS 2 0 limited by the number of messages sent from GENSYS
6. Zd al wiy cs wey bd Re A005 004 i i 2 E OE EE Speed inputs Low temp warring Low water level Low fue warning Charger tault Air damper sv Exter electrical fault wy ion icat GENSYS 2 0 appl issioning a Installing and commi Chapter 68 10 3 INSTALLATION INSTRUCTIONS The GENSYS 2 0 module has been designed for front panel mounting Indoor or outdoor installation is possible as long as the following requirements are met The chosen cabinet must meet the standard safety rules of the workplace The chosen cabinet must be closed during normal use to prevent the user from coming into contact with power cables Only the front panel must be accessible during normal use In accordance with the Bureau VERITAS marine agreement the module must not be installed in areas which are exposed to the weather 10 3 1 MOUNTING To secure the GENSYS 2 0 onto the panel use the special kit provided with the module The kit contains 4 screws 2 brackets and 1 mounting tool FIGURE 36 MOUNTING KIT Remove the connectors Pass the module through the panel cut out Ensure that the gasket is properly positioned on the panel and that it is flat On the rear side of the module insert the first bracket into the two holes on the upper edge of the module and push it to the left Chapter Installing and commissioni
7. 50 0 3 3 1 1500 Nominal speed for MDEC through CAN bus 300 352 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 183 Variable Label Value Description number V1853 Branch T water The Analogue water temperature that comes from the soll MTU CAN bus will be used V1854 The Speed measure that comes from the MTU CAN bus will be used V1857 MTUPV110003 CT Each device on the MTU CAN bus has a node number GENSYS 2 0 uses have the number 6 V1858 MTUPV110010 CT V1859 MTUPV110014 CT Protection control for over speed from MDEC E0332 3 Protection control for combined alarm yellow from ut MDEC E0339 Protection control for combined alarm red from MDEC V1860 MTUPV110029 CT Protection control for low oil pressure from MDEC MT Ter V1861 MTUPV110030 CT Protection control for very low oil pressure from MDEC ree essen V1862 MTUPV110047 CT Protection control for low fuel pressure from MDEC rere O osan V1863 MTUPV110048 CT Protection control for very low fuel pressure from MDEC MTU O ass ol E0363 7 V1865 MTUPV110099 CT Protection control for low coolant level charge air from V1866 MTUPV110129 CT Protection control for high coolant temperature from V1867 MTUPV110130 CT Protection control for very high coolant temperature V1871 pn te Me control for low engine speed from MDEC E0426 a E0343 V1864 Protection control for low coolant level from MDEC P
8. FIGURE 64 STANDARD MODE EXAMPLE WITH A 4X100KW POWER PLANT I i _ a e ef po 0000 msE n HI Fr SSS r FIGURE 65 OPTIMISED MODE EXAMPLE WITH A 4X100KW POWER PLANT A53 Z0 9 0020 N EN Technical documentation GE1 GE2 GE3 mm GE4 wre GE1 GE2 GE3 GE4 Chapter Additional functions 132 The generating set that will start or stop can be selected in 3 different ways e By generator number see chapter 14 13 3 e By hours run see chapter 0 e By number of the E1617 parameter see chapter 14 13 5 Selection mode is defined by parameter E1258 Note If the management of the load dependant start stop is inhibited E1258 0 the different GENSYS 2 0 units installed on the power plant do not interact to start or stop generating set according to the load demand 14 13 SSTART STOP BY GENERATOR NUMBER If this mode E1258 1 has been selected on all units of the power plant the automatic start stop sequence will be done by the genset number which is defined in the power plant overview If a digital or virtual digital input of one GENSYS 2 0 is set as priority generator this GENSYS 2 0 will start first The next to start will be decided by
9. Thus the span to achieve the required span 2 5Hz is 2 5 Volts therefore the settings are e Gain E1076 25 2 5Vdc e Offset E1077 0 OV It s important to do the first starting without connect the GENSYS 2 0 speed output in order to be sure that the engine running at 50Hz If it s not the case the speed governor control must be set correctly For the entire settings of the GENSYS 2 0 gt Speed governor see 11 1 1 When you power up the GENSYS 2 0 the display does not work Check the jumper situated under the plastic cap near the logo on back cover is removed or in OFF position If not remove power supply to remove this jumper or set it to OFF position If there is no change the module is defective and needs to be returned to CRE Technology If fault occurs while testing speed or voltage Check the connection of OV signals In J1939 the communication doesn t works Check that the ECU is powered Check that the configuration correspond to the engine ECU Check that the J1939 or MDEC address is correct Contact the manufacturer if it s not a standard address Check that the wiring is correct GENSYS 2 0 COM2 to ECU by J1939 and 1200 resistors in end of line are set Switch off power supply GENSYS 2 0 and ECU and switch on in order to reset the communication Check that the configuration of the ECU and the ECU unit are consistent with the J1939 norm Note Some ECU doesn t g
10. 2 Z090210 2 vxxx txt corresponds to the English version 2 Z090210 3 vxxx txt corresponds to the French version Note vxxx is the corresponding software version of your GENSYS 2 0 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 182 37 MDEC gt GENSYS 2 0 wiring X003 connector FIGURE 85 MDEC GENSYS 2 0 CONNEXION Label Digital output to stop req emergency stop Digital output to start request CAN High CAN Low CAN ground GENSYS 2 0 MDEC X1 X003 terminal connector connector 4 uest and 25 26 to ground 44 to ground 5 0 h COM 2 pin 7 COM 2 pin 2 COM 2 pin 5 Analogue speed command em 18 Analogue speed reference GI b 31 5Vref TABLE 69 MDEC CONNEXION Useful GENSYS 2 0 parameters are listed below to ensure proper communication with the MDEC module Variable Label number V1076 ESG amplitude V1077 ESG offset V1156 Local language V1311 PC language V1710 User param 001 V1711 User param 002 V1712 User param 003 V1852 Branch P oil Value Description Speed output amplitude to have a trip frequency of 3Hz 0 00 Offset to obtain nominal frequency gt Custom language selected for MDEC labels on the Trade 3 Custom language selected for MDEC labels on your PC 30 Delay 100ms before triggering an MTU CAN bus error 30 seconds here The Analogue oil pressure that comes from the MTU CAN bus will be used
11. Add support of speed governor GAC ESD5330 May 2013 Add support of voltage governor SINCRO Add chapter 2 1 mechanical characteristics of GENSYS 2 0 CORE Additional information on Heavy Consumer function Additional information on Power Reserve function A53 ZO 9 0020 N EN Technical documentation Chapter Overview You can download the most up to date version of this documentation and different other documentations relating to GENSYS 2 0 on our Web site http www cretechnology com Documentations available on CRE technology Web site A53 ZO 9 0020 x EN is the GENSYS 2 0 technical documentation this manual This documentation is generally used for product integration A53 ZO 9 0031 x EN is the translation help tool to download a CUSTOM language file A53 ZO 9 0020 x EN is the Complete variable list with labels units and limits in English in PDF format This documentation is generally used as reference during the integration phase A53 Z0 9 0030 x is the Complete variable list with labels units and limits in all languages in EXCEL WORKBOOK format This documentation is generally used as reference during the installation phase It is generally called EXCEL FILE NSG SG SG SG NOTE Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Apply all plant and safety instructions and precautions F
12. An oil pressure fault has been detected i Boe een Digital input set as Oil pressure fault A water temperature fault has been detected oe digital input set as Water temperature fault E2804 Spare Input J4 E2805 Spare Input J5 E2806 Spare Input J6 E2807 Spare Input J7 E2809 If the digital input is used as a protection an Alarm Fault will be activated A53 Z0 9 0020 N EN Technical documentation Alarm Fault control E1422 E1425 E1162 E1165 E1168 E1171 E1174 E1098 Hard shutdown Hard shutdown E1996 E1997 E1267 E1268 E1269 E1270 E1271 E1272 E1273 E1274 E1275 E1276 E1328 E1329 E1330 E1331 E1332 E1333 E1334 E1335 E1336 E1337 E1368 E1369 E1370 E1371 E1372 E1373 E1374 E1375 E1376 E1377 E1680 E1681 Chapter Protections 111 Potential Alarm Fault control Alarm Fault Variable Description A fault sensor lost is trigged if the speed is null and the engine started A fault is trigged j the breaker controls Mains or generator don t work correctly An alarm is trigged if the eRe controls Mains or generator don t work correctly correctly A fault is trigged if the requirements to start c the engine are not observed Water temperature and oil prelubrification 2 A fault is trigged if the motor didn t succeed to start T 2 5 l Threshold protection minimum or maximum Threshold protection minimum or maximum Alarm 112 A53 Z0 9 0
13. Equations are required for analog sensor management in modules with firmware older than v4 00 The 3 filling features all have exactly the same behavior Fuel filling will be described below For the other functions fuel is to be replaced by coolant or oil and the variable number by the values shown in the figure above Function ALLS Fuel Cooling Oil Low level input E2230 E2243 E2246 High level input E2231 E2244 E2247 Filling output E2229 E2242 E2245 TABLE 26 FILLING PARAMETERS IN AUTOMATIC MODE WITH EQUATIONS E2230 Fuel low level E2231 Fuel high level E2229 Fuel filling FIGURE 53 FUEL FILLING DIAGRAM A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 93 2 Example If the tank is fitted with a fuel level sender that can be connected to an analogue input F1 F2 or F3 F4 it is possible to calculate the fuel low high limits using equations The following example shows the case of filling a tank It requires filling if it is less than 20 full and filling should stop when it reaches 80 full Output 1 C1 Analogue input 1 F1 F2 Fre FIGURE 54 FILLING EXAMPLE E2230 is the low fuel level E2231 is the high fuel level E0031 is engine measure 1 potentiometer input F1 F2 E2020 is the digital Spare output 1 which triggers the filling of the tank C1 terminal PROG 1 BLOC E2230 E0031 LT 40 E2231 E0031 GT 80 E2020 E2230 OR E2
14. SG 10 5 3 START THE GENERATOR In Manu mode press Start button KG Check the starter and fuel pump activation If you want to simulate the sequences of starter and fuel switching disconnect the A1 and A2 terminals then navigate to the menu Display Inputs outputs state Relay outputs the states of A1 and A2 will be displayed in real time When the engine has been started check the engine speed and the generator voltage They must be stable and to the desire value ex 1500rpm 50Hz 400VAC these information are available in the menu Display Generator electrical meter Global view Generator oe Press Stop button to stop generator 10 5 4 CHECK THE CONTROL OF THE DEAD BUS BREAKER Start the generator in Manu mode by pressing Start button Press the generator breaker 0 I key The breaker should close control OK and the GENSYS 2 0 front face led should light up feedback position OK Press the generator breaker 0 1 Key The breaker should open and the led should go out Chapter Installing and commissioning a GENSYS 2 0 application 72 A53 Z0 9 0020 N EN Technical documentation 10 5 5 CHECK OR IMPROVE SYNCHRONIZATION Check that breaker control is disabled Unplug connector E Check voltage on bus bar Start the generator in Manu mode by pressing Start button Press the generator breaker 0 I key Check that you ar
15. User interface for more details concerning the functions of front panel LED and keys Navigation bar Navigation mode Scroll select menus and parameters Enter a menu switch to Input mode Used with other keys only 1 Shortcut to special function Increase speed in manual mode Increase voltage when associated with Shift key in manual mode Shortcut to special function Decrease speed in manual mode Decrease voltage when associated with Shift key in manual mode Return to parent menu TABLE 3 DISPLAY PANEL KEYS A53 ZO 9 0020 N EN Technical documentation Input mode during parameter modification Change parameter value Validate parameter and return to Navigation mode Not used Not used Not used Discard parameter changes and return to Navigation mode Chapter Description 23 5 12 SERVICE PANEL Function This key will stop the alarm horn Direct access to the Fault menu An associated red LED indicates the Fault status of the generator Pressing this key will switch to the associated menu showing active faults Pressing a second time on the same key will switch back to the menu displayed beforehand Fault archive can be deleted in the System Date Time meter Data logging reset menu Direct access to the Alarm menu An associated orange LED indicates the Alarm status of the generator Pressing this key will switch to the associated menu sh
16. seccccsseecccseccccauseccauusessaueseesasessscueessaausessauseessaueeesauaecssausesssueessauasessges 214 Table 84 Generator 42 Configuration rea 215 Table 85 Generator 2 2 Configuration serieren naia e A E A AEE eo OR EE E AEE ea E 215 Table 86 Generator electrical fault Configuration cccssesccccnsseseeccnsnseeccusuessesessuuseecessuunsessssaunsesessauasessssaunsesssaaeaeesenas 216 es NNN NNN hr 216 Table 88 gt Mons BUS CON GUANO scsinusncimostteczasannsnstioscddaxonenstezencsuaskensueeuviinesddexonendentancsuasneaenedudtoesddaroneadtetancsvasneweneandtoeas 217 Table 89 Mains electrical fault configuration ssccccccsssessccccssseccecausesececsuseeeessauseeessaauseeeessaunseeessauneeessaausesessaanseeeeas 217 Table 90 External internal start sequence configuration rrrrrrrrrrrrrnnrrrnrrnrrrnrnnrrnnrrrnrsssrsrsssssssssssssssssssssssssssssssssssssssssee 218 Table 91 Crank configuration parameters scccccseesesvecuonsessecuensessecuenvessccucesessccucevsescencessescencesesscencesssssencesssscencesesseess 218 Table 92 Checking before starting CONFIQUIATION cccccssesecccnsnesseccnsnessecscsueseeeessauseeesssaussesessaunsesesaaunseesssauasecessaueeeenas 218 Table 93 Speed control settings configuration rrrrnnrrrrrrnnnnnrrrrnnnnnrrrrnnnnnrrrrnnnenrrrrnnnenerrrnnnenernnsnnessrrnnnnessnnnnnessrnnnnnenesee 219 Table 94 Speed governor control NNN en 219 Table 95 J1939 MDEC configuration rrrrr
17. t want to change its network settings CRE Technology can provide a USB Ethernet converter to setup a second network configuration on your computer dedicated to GENSYS 2 0 communication Reference of this module is A53W2 A53 Z0 9 0020 N EN Technical documentation Chapter User interface 42 6 3 5 CHANGING GENSYS 2 0 IP ADDRESS GENSYS 2 0 IP address can be changed in configuration page System Communication ports config COM4 ETHERNET GENSYS 2 0 also handles DHCP function in this case GENSYS 2 0 must be connected on a network that provides a DHCP server During the power on sequence GENSYS 2 0 will be assigned its IP address by the DHCP server If DHCP process fails the fixed IP address will be used factory set to 192 168 11 1 Note Once the new IP address is entered or DHCP use is changed you will need to restart the module for the new settings to take effect i Chargement ea COM4 ETHERNET Re start module to walidate the update Use DHCP Disable IP Gu address 10 o o Jo Communication ports TCF 408180 UDP 4082 7024 Modbus TCP 4083 502 Esc Faults Alarms Information Save modified parameters FIGURE 14 ETHERNET CONFIGURATION PAGE ADVICE Please contact your network administrator to configure your router and module s according to your need A53 Z0 9 0020 N EN Technical documentation Chapter User interface 43 7 OPERATING MODE There are 4 main op
18. 1 1 2 PWM 500 HZ CATERPILLAR PERKINS K4 output is a 500Hz PWM output signal between 0 and SV It is protected against short circuits between the output and the battery negative voltage To activate this PWM output in order to control speed of Caterpillar or Perkins engines please check GENSYS 2 0 parameters as shown below A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 78 Variable Label Value Description number E1639 500 Hz ACT 1 Activates the speed control with 500Hz PWM In this mode the analogue speed output G9 G11 is unavailable E1077 ESG offset Is the PWM duty cycle set for nominal frequency E1076 ESG 30 Is the range of the PWM duty cycle to control engine amplitude speed For example if you have set 20 0 the PWM will vary 10 around the nominal duty cycle value TABLE 19 PWM PARAMETERS PWM Offset 70 100 Amplitude 30 El eee lt gt EEE EE E HS ml NE Jr ere eas 5 Min correction 0 Max correction Deviation E2058 FIGURE 43 PWM DYNAMIC On firmware versions before v4 55 offset and amplitude values were inversed compared to CATERPILLAR usage l e offset E1077 had to be set to 30 in order to get a 70 PWM on the physical output Also amplitude E1076 had to be set to a negative value for example 30 in order to get a proper control higher soeed when GENSYS 2 0 requested a positive correction Starting fr
19. 2 analogue variables variables module n E0584 60593 E0594 E0595 4 E0616 60625 E0626 E0627 6 E0648 60657 E0658 E0659 8 a TABLE 56 BROADCAST DATA RECEIVED FROM INTER MODULE CAN BUS VU gt O Q OD Q O at gt vu z L es ft z 92 a ODO O E O u E O Chapter Communication Note Even if CAN bus inhibition is activated between GENSYS 2 0 units see chapter below broadcast data is always sent to the CAN bus and received on the other units Analogue and digital data broadcast example In this example two GENSYS 2 0 are connected together using CAN bus COM1 Both units GENSYS 2 0 1 and GENSYS 2 0 2 send two broadcast variables to each other on the CAN bus one variable being digital input J6 E2806 and the other one being analogue value E0033 engine speed 165 A53 Z0 9 0020 N EN Technical documentation E0033 E2806 FIGURE 8 ANALOGUE AND DIGITAL DATA BROADCAST EXAMPLE To send desired data on CAN bus the following equations should be used on both GENSYS 2 0 units BLOC Send input J6 on CAN bus using first digital broadcast data X2752 2806 Send engine speed on CAN bus using first analogue broadcast data X2762 33 BEND Following table lists variables used in GENSYS 2 0 to store data coming from the other unit Storage variables used GENSYS 2 0 1 digital input J6 mu Stored in E0536 of GENSYS 2
20. 2344 Output C4 Configuration Outputs Digital outputs TABLE ZO PARAMETERS SPEED AND VOLTAGE CONTROL WITH CONTACTS PULSES 12 2 SPEED CALIBRATION PROCEDURE Here follows the procedure for calibrating the Hz and Hz outputs on the GENSYS 2 0 necessary in order to have good frequency droop compensation and load sharing See Figure 46 2 Show the following parameter on the information screen E2058 Place the external speed potentiometer in the centre mid position Set the following parameters as follows E1598 on 50 which is about 1 percent load sharing difference dead band on E2058 A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 80 E1600 on 2 which is 200 msec Pulse time E1874 on 2 0 sec which is pulse pause time for frequency voltage compensation E1873 on 0 1 sec which is pulse length for frequency voltage compensation E1309 on O which is Integral gain I phase E1113 on O which is Integral gain I Frequency Note For best results during synchronization it s important to set the synchronization GPID to high values 80 to 20 1 Regulation setting synchronization load ramp If the generator makes too much or not enough correction during an active phase synchronization load sharing the pulse time is bad adjusted e Decrease E1600 to reduce the pulse control on the governor e Increase E1600 to have more correction on the
21. Technical documentation Description Oil pressure resistive sensor input Water temperature resistive sensor input Free resistive input 1 Free resistive input 2 Logic input J4 to J15 Transistor outputs C1 to C5 Relay output A1 Relay output A2 Virtual input 1 to 20 Virtual input 21 to 20 Maintenance cycles in running hours Chapter Text file amp PLC 149 Identifier Factory label Description L1447 to L1451 Cycle 1 d Cycle 5 d Maintenance cycles in days L2657 User meter 1 Free user counter n 1 L2659 User meter 2 Free user counter n 2 TABLE 46 LABEL DEFINITION BLOC Logo page labels GENSYS 2 0 CRE product Genset Paralleling www cretechnology com TABLE 47 CUSTOM LOGO LABELS Each line of this block contains 2 elements The variable number of the text preceded by the letter L for label and T for page logo Ex L1130 The text itself Labels are 14 characters long while Texts are 28 characters long maximum Ex Sample Label Supported characters include a z A Z 0 9 and the following graphical characters lt space gt S lt gt 4_ All other characters are considered as insecure and their use is prohibited Their use can result in a bad display EX LABELS JENS Sample label Note The label is language sensitive i e a text file uploaded with PC language set to French will modify only the French labels The English or Italian labels will rem
22. level 2 equations and to some advance functions 3 main menus are available Display will give information about the generating set bus bar or mains and will display real time information and parameters status Configuration is only accessible if you have entered a level 1 or 2 password You will be able to program GENSYS 2 0 according to the needs of your plant System is only accessible if you have entered a level 1 or 2 password The system menu will let you change parameters that are not related to the plant but rather to the GENSYS 2 0 system Date Hour languages communication port interface 19 2 DISPLAY MENU This menu gives access to the following information e Power plant overview level 1 amp 2 e Generator electrical meter e Mains Bus electrical meter e Synchronization e Engine meters e Inputs outputs state e Active timers level 1 amp 2 e Maintenance cycle monitoring level 1 amp 2 e About only level 0 e Data logging only on PC A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 203 19 2 1 POWER PLANT OVERVIEW This menu displays the power plant parameters parameters shared by up to 32 different GENSYS 2 0 and or MASTER 2 0 units 1 Power plant status This screen displays the machine status E2071 of each generating set 2 GE 01 to 16 kW This screen displays the percentage of nominal active power supplied by each generating set from 1 to 16 in real
23. text describing the engine state coded on 28 characters e Units text associated to units coded on exactly 5 characters e Modifiable labels text associated to modifiable labels e g Inputs outputs coded on exactly 14 characters e Logo screen saver texts text associated to main screen saver coded on 28 characters To update the Custom language you have to use the A53 ZO 9 0031 x EN Translation Help Tool xls file that allows creating 2 translation files to download into the unit via the web site or by SD card e Open A53 Z0 9 0031 x EN Translation Help Tool xis file e Activate the macros e Click on Step 1 Click here to prepare CUSTOM sheet e Select the software version e Click on OK button A Custom tab appears e Translate texts label into the desired language e Click on Step 3 Click here to check TXT validity The script will check that translation are correct label too long too small wrong characters If an error is detected the error s will be underlined in red in the Custom tab If there is no error 2 files containing the translations sill be save on PC Download these files into the unit via SD card or web site see 17 7 3 or 19 4 7 To display the updates the unit must be configured in Custom language in System Languages menu A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 159 17 COMMUNICATION 17 1 CAN BUS GOOD PRACTICES This chapter describes rules t
24. 20 70 C LCD display may be slow under 0 C Normal speed is reached when the temperature rises back above 0 C Storage 30 70 C Humidity 5 to 95 Altitude 2000m maximum according to EN 61010 1 standard Tropic proof circuits for normal operation in humid conditions Front panel IP65 protection Back panel IP20 protection Note The module can be used in humid conditions however back panel must not be subject to rain or water dripping A53 ZO 9 0020 N EN Technical documentation Chapter Overview 15 LS CHARACTERISTICS Size 248x197x57mm 9 76x7 76x2 24in Weight 1 9kg 4 2Ibs Panel cut out 177 mm 6 97 in 228 mm 8 98 in FIGURE 1 PANEL CUT OUT Note Cut out must be cleaned and de burred before mounting A53 Z0 9 0020 N EN Technical documentation Chapter Overview 16 2 GENSYS 2 0 CORE Z CHARACTERISTICS Size 250x200x57mm 9 84x7 87x2 24in Weight 1 9kg 4 2Ibs Mounting dimensions 250mm 9 84in 200mm 8 7in gt ED eee ei ee i fmm fram 1 O27in O 27in 1 ee te FIGURE 2 GENSYS 2 0 CORE MOUTING DIMENSIONS Note The GENSYS 2 0 CORE can be install on rail DIN e 2 DESCRIPTION The GENSYS 2 0 CORE can control a single or a multiple generating sets power plant You can combine this module with one RDM 2 0 remote display e GENSYS 2 0 CORE can be connected to the RDM 2 0 e GENSYS 2 0
25. 3 2727 Trip out 4 2728 Trip out 5 2213 Smoke limiter 2214 Warm up 2206 Horn Chapter I O lines Can be used to close mains breaker Can be used to open mains breaker Can be used for an external fuel pump in conjunction with Fuel low level and Fuel high level or Manu fuel fill functions attributed to spare digital inputs 2220 Mains breaker Close 2222 2215 Air fans To be wired to fan relay Generator breaker Can be used to close genset breaker 2219 Close Generator breaker Can be used to open genset breaker 2221 Oren Mains breaker Open 2229 Fuel filling Can be used for a compressor in conjunction with Coolant high Coolant filling level and Coolant low level or Manual air fill functions attributed to spare digital inputs 2242 102 A53 Z0 9 0020 N EN Technical documentation Value Function Description Can be used for oil level filling in conjunction with Oil high Oil filling level and Oil low level or Manu oil fill functions attributed to spare digital inputs The behavior will change according to the mode In Manual 2341 f mode if you program the f function the output will be activated when you press the GENSYS 2 0 key or if there is a f U 2245 Manual f request E2233 Likewise for the other functions 2342 i f activates with key or Manual f request E2234 f activates with SHIFT keys or Manual U request E2
26. A53 ZO 9 0020 N EN Technical documentation Chapter Communication 160 Example of CAN connection between 3 modules COM1 FIGURE 78 EXAMPLE OF CAN CONNECTION BETWEEN 3 MODULES CRE Technology provides a complete range of products aimed at installing your CAN bus complete cables wires connectors Please contact your local CRE Technology distributor to help you choose adequate equipment to fit your needs WARNING Never plug or unplug the CAN bus connector when the unit is switch on It could lead to internal damages on CAN transmitter receiver 17 12 MAXIMAL LENGTH OF A CAN BUS The maximal length of a CAN bus mostly depends on the communication speed but also on the quality of wires and connectors used As said above 120 Q termination resistors should also be used appropriately Table below indicates the maximal length of a CAN bus depending on the communication speed Communication Maximal length speed kbits s metres 10 5000 20 2500 50 1000 Chapter Communication TABLE 52 MAXIMAL LENGTH COMMUNICATION SPEED Next table lists the standard communication speed of each CAN protocol that can be used by your CRE Technology module CAN bus Protocol Speed Note kbits s COM1 CRE Technology 125 Fixed protocol COM2 CANopen 125 E1596 can be changed from 10 to 1000 kbps By CRE Config software or modification by variable number MTU MDEC Fixed J1939 CANopen Fixed TABLE 53 SPEED COMMUNIC
27. BREAK CO MODE ON MAINS FAILURE Fastest mains failure Switch over delay E1459 Genset ready Mains back delay E1085 Synchronization Unload ramp Ramp configurations are available in the Configuration Generator menu The paralleling time depends on the load the ramp time and the high and low thresholds Chapter Predefined configuration 61 A53 Z0 9 0020 N EN Technical documentation 2 Permanent mode WHEN THE REMOTE START IS ON GENSYS 2 0 STARTS THE GENERATOR SYNCHRONIZES AND PARALLELS WITH THE MAINS THEN RAMPS UP LOAD UNTIL IT REACHES ITS SET POINT SEE FIGURE 29 amp Figure 30 In base load mode E1153 2 the generator has a constant load and the mains take the utility load variations If the utility load is less than the generator set point mains are in reverse power In the peak shaving mode E1153 1 the mains have a constant load and the generator takes the utility load variations T1 T2 T3 T4 T5 T6 E0022 Mains voltage E2201 Mains failure E2000 Mains breaker E0003 Genset voltage T3 E2001 Genset breaker Black FIGURE 29 TYPICAL SEQUENCE IN PERMANENT MODE ON MAINS FAILURE Fastest mains failure Switch over delay E1459 Genset ready Mains back delay E1085 Synchronization Unload ramp Chapter Predefined configuration Note In this case the external start request E2201 is equal to O 62 A53
28. QJ F a Power Tank 2 5 12 K2 Power supply 2 5 12 A53 Z0 9 0020 N EN Technical documentation Comment Automatic voltage regulator AVR control Compatible with most regulators Details in 11 3 Digital input with 10kQ pull up dedicated to Mains breaker feedback Accepts NO or NC contact to OV Not isolated Digital input with 10kQ pull up dedicated to generator breaker feedback Accepts NO or NC contact to OV Not isolated Digital input with 10kQ pull up dedicated to remote start stop request in Auto mode Accepts NO or NC contact to OV Not isolated Digital input with 10kQ pull up Default factory set as input for oil pressure fault Accepts NO or NC contact to OV Not isolated Can be programmed as a spare input Details in 12 1 Digital input with 10kQ pull up Default factory set as input for water temperature fault Accepts NO or NC contact to OV Not isolated Can be programmed as a spare input Details in 12 1 Digital input with 10kQ pull up 10 inputs can be configured with a specific function or programmed with PLC equations Accepts NO or NC contact to OV Not isolated See details in 12 1 Only used for 12V power supply backup during crank time An external capacitor can be connected between terminal K1 and K3 for better tolerance to power drops A 47 000uF Capacitor can help accept a 200ms power drop depending on inputs outputs states 9 to 40V 10W consumption Pr
29. Write mode AVERTISSEMENT Be careful when modifying a parameter while the engine is running as unexpected behaviour while functioning may damage your generator It is always advised to change parameters when generator is stopped As said above parameters Elnnn are set to READ ONLY Write access can be done on a per parameter basis using a configuration text file sent by PC to the GENSYS 2 0 Please refer to 16 3 2 for more details on this Read Write attribute MODBUS functions handled by GENSYS 2 0 are listed in the table below Function Description 01 02 Reading of logical values coil status discrete input status 03 04 Read holding input registers 16 bits Write logical value single coil 05 06 Preset single register 16 bits variable 15 OxOF Write multiple logical values multiple coils 16 0x10 Preset multiple registers TABLE 71 MODBUS FUNCTIONS HANDLED Functions 01 02 05 and OF require at least firmware v4 03 All GENSYS 2 0 variables are 16 bits registers Yet it might be useful to consider them as logical a values if they are only set to O or 1 in order 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 Chapter Communication Starting from firmware v4 03 advanced access rights are available e Activate Inhibit Read Write access individually on Modbus RTU or Modbus
30. accessible by equations Tx Custom frames WARNING This feature is designed for experienced user A wrong configuration could damage your generator If needed a custom frame can be sent by the GENSYS 2 0 to the J1939 device To configure your Tx custom frame see the frame n 2 configuration of a Custom engine see below the chapter Custom engine Note There are no web pages to configure these TX custom frames Please use custom PLC equations to access custom TX variables The variables are only accessible by equations WARNING For QSX15 G8 ECU from CUMMINS it s not possible to use the TX custom frame A53 Z0 9 0020 N EN Technical documentation Chapter Communication 180 7 Custom engine WARNING This feature is designed for experienced user A wrong configuration could damage your generator When selecting the Custom engine you can configure 2 frames to send by J1939 Use custom PLC equations to access custom TX variables that are described below frame number Variable Description E1856 GENSYS 2 0 address the MSB 0 means that the frame is not send E2667 to E2674 Bytes to send E2667 being the n 1 byte E1856 GENSYS 2 0 address E2817 to E2819 PGN on 3 bytes E2817 being the LSB and E2819 being He nee 138 and EN Ree E2820 Bytes number to send from 0 to 8 bytes des E2821 to E2828 TABLE 68 JI939 CUSTOM ENGINE CONFIGURATION 1 Fr
31. activated a gt g o amp Fault 6 amp larms Information Gensys 2 0 CRE Product Genset Paralleling Wu cretechnology y com 15 36 13 14705708 7 FIGURE 7 DEFAULT SCREEN SAVER 34 A53 Z0 9 0020 N EN Technical documentation 6 SECURITY LEVEL AND PASSWORD GENSYS 2 0 features password protected access levels to define which menu and parameters can be accessed Table below details these levels and what can be accessed Level Default password Authorization Accessible menu G59 options This is a special function access see 14 10 for more details No password Press This level is not password ENTER key protected DISPLAY menu only equations and parameters PLC programming level 2 All menus advanced Reserved Used to change PLC level 2 functions equations and parameters User level parameters settings amp commissioning 1 1 digit ONE All menus Used to change PLC level 1 TABLE 8 AUTHORIZATION LEVELS AND PASSWORDS Active and lower level passwords can be changed in the system menu see 19 4 2 When the password page is shown on the LCD display the user must first press on the ENTER key to switch to password input mode as for other parameters Password ABI DEFGHIUKLMNOPQRSTUVWXYZ abcdefghijklmnopqrstuvwxyz 0123456789 FIGURE 8 PASSWORD INPUT MODE DISPLAY Three lines of characters upper and lower case letters O t
32. additional functions related to these variables you will have to program your own PLC equations It is also possible to monitor and manage MDEC variables remotely through MODBUS communication on GENSYS 2 0 COM5 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 185 ye Alarms The following example will show you how to handle predefined alarms listed is an example of the predefined alarm seen above E1857 is dedicated to over speed protection from MDEC E0332 The equation is the following TEST E0332 EQ 1 AND E1857 NE 0 EQ 1 THEN E2199 E1857 1 TEND E0332 is the over speed alarm from MDEC E1857 is the control If you set E1857 as security E1857 5 and E0332 is set to 1 then E2204 hard shut down will also be set to 1 and trigger the hard shutdown process If you want to use an MDEC alarm that is not handled directly by GENSYS 2 0 you can use a virtual input as described in the following example If you want to handle an MDEC alarm for SS Power Reduction Active E0338 you can use the virtual input 2 E2284 With the CRE config software set the function E1329 of the virtual input 2 to External alarm and load the following equation in a text file E2284 E0338 8 Fault code numbers Combined yellow red alarms are global warnings They can be triggered by one of several faults provided on the CAN bus see list below Apart from these predefined errors additional
33. after decimal point e 1 e 0 1 e 0 01 e 0 001 12 3 2 WATER TEMPERATURE CONFIGURATION You can now choose units C or F and degree of accuracy number of digits after decimal point e 1 e 0 1 e 0 01 e 0 001 l2 3 3 CONFIGURATION OF ENGINE MEASUREMENTS 1 AND 2 Spare Analogue measurements 1 and 2 they can be named and the unit to be displayed chosen among the following 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 You can then choose the degree of accuracy number of digits after decimal point e 1 e 0 1 e 0 01 e 0 001 12 3 4 CALIBRATION OF ANALOGUE INPUTS 1 Oil and water 0 400 Ohm sensors Oil Pressure and Water Temp this menu relates to the dedicated analogue inputs oil pressure and coolant temperature Please enter the pressure or temperature read by your sensors according to the resistance shown in the table Oil Temperature calibration points are E1188 to E1198 which correspond to 0 to 400 Ohm Water Temp calibration points are E1199 to E1209 which correspond to 0 to 400 Ohm A53 Z0 9 0020 N EN Technical documentation Chapter I O lines 105 Please enter calibration points using this table Ohm VDO5b VDO10b VDO25b AC10b Veglia8b Veglia12b Dat 10b O 345 487 2120 260 8442 12663 40 834 1585 3777 4316 6922 10387 892 80 2014 3945 9674 8892 5402 8111 6102 160 24
34. alarm sources are available and can be detected using MDEC fault code numbers The MDEC fault code is read by GENSYS 2 0 and stored in MDEC GENSYS 2 0 variable E0372 If several failures happen together the fault code variable will be refreshed every second This will help you find which alarm is activated in case of a combined alarm A53 Z0 9 0020 N EN Technical documentation Chapter Communication 186 17 4 COM 3 USB This communication port is no longer used in firmware as from version 2 0 PC connection is now provided via the RJ45 Ethernet communication port 17 5 COM ETHERNET The Ethernet port features the following communication possibilities Visualization and configuration of GENSYS 2 0 via its internal Web site or using CRE Config software starting from GENSYS 2 0 firmware v3 00 Modbus TCP control of GENSYS 2 0 using SCADA equipment 17 5 MODBUS TCP To communicate through Modbus TCP you need to set up the following data on GENSYS 2 0 IP address of the GENSYS 2 0 which can be set up in menu System Communication ports config COM4 ETHERNET Modbus TCP port E4083 which can be set up in the menu System Communication ports config COM4 ETHERNET On firmware older than v4 03 also configure Modbus slave identifier E1634 which can be set up in menu System Communication ports config COM5 RS485 MODBUS RTU Note The standard Modbus TCP port is 502 Since firm
35. and takes the entire load upon mains loss even if the remote start J3 is off In all cases you have to set a mains protection in order to determine the behaviour of your generator when mains power disappears 9 6 2 MAINS PARALLELING MODE Choice of mains paralleling mode is configured through parameter E1148 1 No Break CO No break change over When remote start is on the generator starts synchronizes and parallels with the mains then takes the load ramps up Once the mains are unloaded GENSYS 2 0 opens the mains breaker See Figure 27 When remote start is off the mains takes the load in the same way as the generator did previously If the generator started for a mains failure when mains power returns the GENSYS 2 0 synchronizes the load transfer ramps down opens the breaker and then stops the generator See E0022 Mains voltage E2201 Start request on J3 E2000 Mains breaker E0003 Genset voltage T1 E2001 Genset breaker FIGURE 27 TYPICAL SEQUENCE IN NO BREAK CO MODE ON START REQUEST T1 Genset ready T2 Synchronisation T3 Load ramp T4 Synchronzation T5 Unload ramp A53 Z0 9 0020 N EN Technical documentation pter Predefined configuration Ch 60 T1 T2 T3 T4 T5 T6 E0022 Mains voltage E2201 Mains failure E2000 Mains breaker E0003 Genset voltage T3 E2001 Genset breaker Gp Black FIGURE 28 TYPICAL SEQUENCE IN NO
36. breaker control PF control Deutz gas engine Signal Remark Direction TEM GENSYS 2 0 description Compact CANopen module Start request used only if the kW set GENSYS 2 0 gt TEM X141 4 C5 point is in the TEM X142 4 kW demand Used to start stop and GENSYS CANopen 0 20mA to fix the kW set point 2 0 CANopen module output 2 gt TEM Genset ready TEM gt GENSYS 2 0 X31 5 J15 X31 6 FIGURE 62 WIRING GENSYS 2 0 TEM Chapter Additional functions TEM Alarm Relay TEM gt GENSYS 2 0 X31 1 J7 X31 2 X31 4 Hz Digital signal GENSYS 2 0 gt TEM X141 6 C1 X142 6 Digital signal GENSYS 2 0 gt TEM X141 7 X142 7 Pickup A53 Z0 9 0020 N EN Technical documentation 128 Signal Remark Direction TEM GENSYS 2 0 description Compact CANopen module ia eee eee ee signal 0 20mA module output 1 TABLE 39 WIRING GENSYS 2 0 amp TEM Note This wiring diagram is only an example you can use a different wiring setup if necessary To start an application contact your local distributor or CRE Technology support 14 10 G59 NORM ACCESS LEVEL Access to this specific feature is done using a special procedure 1 First connect with password level 1 Go in menu Configuration Modification by variable n Set parameter E1610 on 2 2 Go back to the login page press 3 times on ESC Enter password CustMenu Now you can access to the special features concerning G
37. breaker n 1 upon start if the nominal power lt E4003 5003 Unload brker Order output to close generator breaker n 1 upon start if the nominal power lt E4004 5004 Unload bikers Order output to close generator breaker n 1 upon start if the nominal power lt E4005 The unit is actually in voltage synchronization mode to parallel with the Mains or busbar 3320 Alternator voltage Will activate when the generator is started and generator presence voltage is OK 2883 GE on load ne when generator voltage is OK and GE breaker is TABLE 3 DIGITAL OUTPUTS FUNCTION 2927 Syncing U U Description Output will be active when the measurement of analogue input 3 1st spare measure is over or under the set value it will not de activate until measurement is under or over set value hysteresis value To choose the direction of the protection see Configuration gt engine battery settings SS measure 1 min or max thresh To be programmed and used with the following parameters Meas 1 thresh E1428 Meas 1 hyst E1429 Output will be active when the measurement of analogue input 4 2nd spare measure is over or under the set value it will not de activate until measurement is under or over set value hysteresis value To choose the direction of the protection see Configuration gt engine battery settings SS measure 2 min or max thresh To be programmed and used with the following parameters Meas 2 thresh E1
38. changed by the user the new value is stored in a RAM memory The new value will be effective as soon as it is entered but it will be lost if power supply is lost Here is how to permanently save parameters Press Shift and I front keys at the same time 4 a Starting from firmware v3 00 two additional methods are available to permanently save Vo a parameters in memory Go to menu System Shift I or use Shift I link at the bottom of any page displayed in your PC and select Shift I link Shift I Cliquer sur Shift I pour stocker les parametres en flash hift I Esc Defauts larmes Information Shift I A53 Z0 9 0020 N EN Technical documentation Chapter User interface 37 2 Using Modbus you can process as follows o Write 0 zero into parameter E4066 o Write 1 one into parameter E4066 to initiate backup o Wait 3 seconds and read parameter E4066 A value of 2 two means that parameters where successfully saved into FLASH memory Note Parameter E4066 must first be set as write enabled to be modifiable via Modbus See Modbus chapter for more details NOTE Back up procedure may take a few seconds It is thus essential to save parameters while engine is stopped NEVER SHUT DOWN YOUR MODULE DURING STORAGE SEQUENCE ORANGE LED ILLUMINATED 6 3 REMOTE CONTROL USING A PC ETHERNET CONNECTION 6 3 COMPATIBILITY WITH CRE CONFIG SOFTWARE software This software features a
39. close generator breaker n 1 upon startup if the nominal power lt E4003 5003 Unload brk4 in Order output to close generator breaker n 1 upon startup if the nominal power lt E4004 5004 Unload brk5 in Order output to close generator breaker n 1 upon startup if the nominal power lt E4005 99 A53 Z0 9 0020 N EN Technical documentation Value Function Description 2515 External GE OK Used to indicate that the generator is ready when using an external start module see 14 5 External request to stop a genset Will be done if stopping 2928 Unload chk kW this engine will not overload the power plant according to load dependent start stop setup 2850 Manual marnback Order to synchronize the generator with the mains after a mains electrical fault see 14 2 TABLE 30 INPUT FUNCTIONS 1 Available only in level 2 12 16 DEDICATED INPUTS In the menu list each input is named after its pin number on the wiring of GENSYS 2 0 Polarity can be normally open or normally closed Program this according to the wiring you will have on site As areminder J1is the Mains breaker state J2 is the Genset breaker state J3 is the remote start input l2 2 DIGITAL OUTPUTS Outputs 1 to 5 are wired on the C connector These outputs are electronically protected but not isolated Outputs 1 to 5 E1260 E1261 E1262 E1262 E1264 function and polarity can be defined Relay outputs A1 Crank and A2 Fuel can also be set
40. commi Chapter 67 10 2 COMPLETE WIRING DIAGRAM 02 Tn FE m Iie 3 HER 37 0 O Ego oO a Sg 2 AO a Yo 9 pe 2 2 g 4 om gt s g 3 3 3 vn i po S C gt H CRANK FUEL D SPARE Spare ouput examples speec to speed governor Engine preglow SPARE Visual Audio alarm Generator breaker trip Lubrification pump T Reverse power eo SPARE e SPARE t SPARE i mi ar K AN i EVY FY Z JE ma 3 AA Iz OW VAN E a Is i al z FG IF NA F _ 3 z 13 a s Bi ik I p ya 18 1 Ap RE JE ee x Mains power by external tracucer ot Sa 1 20mA or j 10V Parallel lines to GCR or WOODWARD analog icad sharing COM 5 isolated RS485 MODBUS RTU COM 1 IsolatedcCAN1 INTER GENSYS MASTER 2 0 COM 2 Isolated CAN 2 J1939 COM 3 Isclatec USB to PC uonyeoidde surew 0 asuh Oo S p 2 8 9 a 3 COM 4 Isolated ETHERNET FIGURE 35 COMPLETE WIRING DIAGRAM A53 Z0 9 0020 N EN Technical documentation D Power Tank 23 Power supply Power supply Emergency Lo stop Crank output 6 Fuel Bj relay out output 7 Ully Fi Shield co Oil pressure meas 2 Oil pressure meas 2 Water temp meas Water temp meas Engine meas 1 a Engine meas
41. conjunction with digital transistor output Will only work in manual mode If an external reset is wired to the input choose fault reset request This will have the same effect as pressing the reset key on the GENSYS 2 0 front panel on Fault and Alarm displays 2227 Manual start request To be selected if a remote start command is to be installed A53 Z0 9 0020 N EN Technical documentation Manual water preheat request Fault reset request Chapter I O lines 97 Value Function Description To be selected if a remote stop command is to be installed different from emergency stop To be selected if a remote frequency increasing command 2233 Manual f request 4 i B is to be installed To be selected if a remote frequency decreasing command 2234 Manual f request s 4 B is to be installed To be selected if a remote voltage increasing command is 2235 Manual U request B B to be installed To be selected if a remote voltage decreasing command is 2236 Manual U request l B B to be installed To be selected for a max level sensor or a calculation can 2231 Fuel high level l l be used in conjunction with digital transistor output To be selected for a min level sensor or a calculation can 2230 Fuel low level l be used in conjunction with digital transistor output To be selected for a max level sensor or a calculation can 2244 Coolant high level l ap be used in conjunction with digital transistor outp
42. consider the power plant differently with two separate bus bars This is where we will use CAN bus inhibition Note In this example feedback from the tie breaker can be connected to a GENSYS 2 0 digital input and used in PLC custom equations to set or reset appropriate inhibition variables A53 Z0 9 0020 N EN Technical documentation Chapter Communication 168 17 3 COM2 CAN PROTOCOLS CANOPEN 41939 MTU MDEC GENSYS 2 0 LT doesn t support CANopen communication on COM2 The COM2 port is a CAN bus communication port allowing to communicate with e Industrial extension modules CANopen 17 3 1 e electronic ECU using J1939 17 3 2 e ECU MDEC from MTU 817 3 3 Note CANopen is configured by default It can be used in parallel with J1939 but not with the MTU MDEC Chapter Communication 169 A53 Z0 9 0020 N EN Technical documentation 17 3 COMe CANOPEN COMMUNICATION A GEN Q Industrial CANopen extension modules can be used to increase the number of Zo digital analogue inputs and outputs of GENSYS 2 0 4 pr Modular EEE remote I O gt Ce ke 4 vi gt gt Sedler Pat FIGURE 83 MODULAR REMOTE CANOPEN I O EXTENSION MODULE The refresh rate of these CANopen inputs and outputs is 100ms Wiring of the CAN bus on COM2 should be as described in chapter 17 1 CAN bus good practices Also refer to the CANopen extension module s user manual for correct wirin
43. consumed trip drive fuel trip PTO moving fuel trip PTO non moving fuel trip idle fuel since the last trip reset Electrical potential measured at the input of the electronic control unit supplied through a switching device Change in engine oil pressure measured across the filter due to the filter and any accumulation of solid or semisolid material on or in the filter Accumulated time of operation of engine Temperature of the turbocharger lubricant Temperature of the engine lubricant Temperature of fuel entering injectors The ratio of actual engine percent torque indicated to maximum indicated torque available at the current engine speed clipped to zero torque during engine braking The ratio of actual accelerator pedal position to maximum pedal position Although it is used as an input to determine powertrain demand it also provides anticipatory information to transmission and ASR algorithms about driver actions Chapter Communication 176 Measure PGN Ea SPN Description ACTUAL_TORQUE OxFOO4 The calculated output torque of the E2852 engine The data is transmitted in indicated torque as a percent of reference engine torque DD_TORQUE OxFOO4 The requested torque output of the E2851 engine by the driver It is based on input from the following requestors external to the powertrain operator via the accelerator pedal cruise control and or road speed limit governor E2839 protecti
44. decrease the synchronization time See 14 12 for more details on PID Parameter Comment var num Frequency Global gain of the frequency synchro E1111 Integral of the frequency synchro E1113 Phase Angle Global gain of the phase synchro E1307 Integral of the phase synchro E1309 TABLE 106 PHASE SYNCHRO PID CONFIGURATION The internal GENSYS 2 0 synchroscope is displayed and lets you monitor in real time the changes you make on these parameters Chapter Menu overview 228 A53 Z0 9 0020 N EN Technical documentation 19 3 CONTROL LOOP 1 kW control kW sharing loop This menu allows setting the kW sharing PID when the generator shares the load with other generators See 14 12 for more details on PID Parameter Comment WED G Global gain of kW sharing E1102 TABLE 107 KW SHARING LOOP PID CONFIGURATION While you adjust the PID settings the following parameters are displayed e Generator active and reactive power P et Q e Engine speed e Generator voltage phase 1 e Frequency e Sum of the speed output en Ramp Constant kW This menu allows setting the power management PID when one generator is paralleled with mains See 14 12 for more details on PID Parameter Comment var num G Gloabl gain of ramp constant kW E1099 Integral of ramp constant kW E1101 TABLE 108 RAMP CONSTANT KW PID CONFIGURATION While you adjust the PID settings the following
45. droop mode load sharing is controlled by droop but can also be managed with the and keys To stop engine push the STOP key S On MARINE units 100 manual mode is the standard manual mode Simply press on Ka E gt front panel to activate this mode A53 Z0 9 0020 N EN Technical documentation Chapter Operating mode 48 8 START SEQUENCE During the start sequence protections are inhibited This concerns all engine protections When the engine reaches genset ready the protections are activated A timer can be added to inhibit protections during the safety on delay E1514 The timer will start when the genset is ready E1080 Nominal Speed E1079 Idle Speed 2nd attempt 1st attempt E1325 Crank drop out Start y l T1 T2 T3 T4 T5 T6 T7 T8 3 T9 T10 T11 T12 T13 l T14 1 i i i i i l l i i i i I l i i i i i I l i i l l i i i 1 l i l E2018 Crank Relay I I I I l I I I I I I I I I I I I I I I I I I I E2019 Fuel Relay E2214 Warm up Start seque ce E2192 validation protection FIGURE 17 TYPICAL START SEQUENCE FOR FUEL ENGINES T1 Prelubrification delay E1145 T2 Spark plug preheat delay E1157 T3 Maximum starting time E1135 T4 Delay bewteen 2 start attempts E1136 T5 Spark plug preheat delay E1157 T6 Maximum starting time E1135 T7 Warm up delay E1139 T8 Sp
46. fault in conjunction with open mains on fault in permanent mode or no break change over mode Always use No start on fault when generator breaker or both breakers to open is selected Chapter Additional functions 118 A53 ZO 9 0020 N EN Technical documentation IY 4 GENERATOR ELECTRICAL FAULT In case of a generator electrical fault the generator breaker is opened and the alternator is de excited if wired during a certain time E1265 If the fault is still present after this time has elapsed a hard shutdown occurs Otherwise GENSYS 2 0 will try to re synchronize Associated parameters are listed in the table below Parameter Default value Description 1843 30 0s Time to wait after a generator electrical fault disappears before trying to synchronize 1844 Attempts to re synchronize when a generator electrical fault appears and disappears TABLE 37 GENERATOR ELECTRICAL FAULT 1 Available in Configuration Generator 2 2 GE electrical fault menu l IOo o I I I I G ti t DE passet I SYNCH FAULT STOP status asnasan I Generating set circuit breaker Generating set electrical fault E2200 i I I I l Chapter Additional functions E1843 FIGURE 58 PERMANENT MAINS PARALLELING AND GENERATOR ELECTRICAL FAULT 119 A53 ZO 9 0020 N EN Technical documentation 14 5 GENSYS 2 0 WITH EXTERNAL AUTOMATIC START MODULE 14 5 OVERVIE
47. governor If the generator oscillates around the setpoint during an active phase or if it s hard to reach the setpoint it means that the dead band E1598 is bad adjusted e Decrease dead band E1598 to improve the accuracy around the setpoint e Increase dead band E1598 if the generator oscillates in frequency or in load If the generator takes too much time to reach the nominal speed during the regulation it means that period E1874 is too long If you don t get the desired compensation check the following points e ls the potentiometer still running when GENSYS 2 0 sand an output signal e Otherwise the potentiometer doesn t control a wide enough speed range Note If a pulse generates an over compensation the motor potentiometer still running even if there is no pulse A shunt resistor on the motor input can correct this problem 2 Frequency center settings If the generator changes his speed but compensated too much or not enough to reach the nominal speed the pulse E1873 is bad adjusted e Decrease E1873 to reduce the center frequency control e Increase E1600 to increase the center frequency control Note If an automatic center frequency control exist e g isochronous mode the parameter E1873 can be set to 0 A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 81 1 2 3 VOLTAGE CALIBRATION RROCEDURE Here follows the procedure for calibrating the U and U
48. hostname factory settings Example of 4 GENSYS 2 0 connected to an intranet 192 168 123 101 genset1 place optional comments here 192 168 123 102 genset2 800kVA engine 192 168 123 103 genset3 450kVA engine 192 168 123 104 genset4 320kVA engine When trying to change the host file with Windows Vista you may come across a warning message like those shown below Warning message 1 Access to C Windows System32 drivers etc hosts was denied Warning message 2 Cannot create the C Windows System32 drivers etc hosts file Check that the file s name and location are correct This problem may occur even if you are the system administrator To solve this problem follow these steps 1 Click on Windows start button Oo then select All Programs Accessories right click on Notepad and select Run as administrator e If you are prompted for an administrator password or for a confirmation type in the password or click Allow button 2 Open the Hosts file make the necessary changes and then click Save on the Edit menu Notes on Ethernet connection If you change the IP address of a GENSYS 2 0 you should also adapt Windows hosts file to be able to use the hostname http gensys or any other hostname of your choice in your Web browser Otherwise you will have to directly type the IP address of the GENSYS 2 0 you want to connect to in your Web browser If your computer is connected to your company intranet and you cannot or don
49. increasing genset number which is defined in the power plant overview settings menu Example If the genset 3 has priority then e On increasing load demand the next genset to start will be the genset 4 follow by genset 1 e On decreasing load demand the next genset to stop will be the genset 1 follow by the genset 4 ARBITRATION ORDER Genset 3 is in forced RUN gt Genset 4 will start first and stop last upon load change FIGURE 66 AUTOMATIC LOAD UNLOAD Chapter Additional functions Notes If there are no generators in Forced running mode the priority generator with remote start always starts and closes its breaker on the bus bar even if there is no load nt When all generators are stopped and have remote start activated upon start up the Forced running generators stay on the bus bar while the others coordinate stopping one by one 133 A53 Z0 9 0020 N EN Technical documentation 14 13 4START STOP BY HOURS RUN In this mode E1258 2 the genset to start stop will automatically be selected according to the GENSYS 2 0 hour meter e On increasing load demand the next genset to be started is the one with fewest hours run e On decreasing load demand the next genset to be stopped is the one with highest hours run 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 start Coordinat
50. lt lt lt lt Opt4Param13 Opt4Param14 Opt4Param15 Opt4Param16 Fuel relay fct CANopenErDelay CT Fail synch Phase offset A53 ZO 9 0020 N EN Technical documentation 00000 00000 00000 00000 00000 00000 00000 32768 65535 65535 65535 65535 65535 65535 65535 32767 Chapter Text file amp PLC 158 16 6 RESETTING TO FACTORY PARAMETERS This function only available in level 2 gives you the ability to reset your module into its factory configuration thus erasing all changes made since the first use of the module erasing all parameter changes and custom PLC This can be done either from front panel or embedded Web site in menu System Reset factory settings Then simply select reset Note For safety reasons parameters E1929 Phase Offset Option 8 will also be reset Remember to set it manually if needed for example when using Dyn11 transformer If the custom language has been changed it will not be reset to factory custom language The passwords are not resetting 16 7 DOWNLOAD A CUSTOM LANGUAGE FILE This function allows to change the Custom language by another language The unit contains 7 text types with different characteristics e Labels text describing a variable on exactly 14 characters e Web page texts text not associated to a variable coded on 28 characters e Power Status text describing the module state coded on 28 characters e Engine Status
51. main paralleling ssecccccsseeseccccneeececcceeseccccauseecsscaunsecsssaussecsssaunsessssaueseeseas 45 Figure 16 Assisted manual mode with main PArallelinG cccccsseccccseseccnsuseccseueccssssccsausecssausecssusecssaunsessausesssuasessaanseeas 46 Figure 17 Typical start sequence for fuel Engines cccccsseesecccnseseccccauesecescauseceseaunseeesaausecssaauusecsssauasecsssaunseessaaeseeeeas 49 Figure 18 Power plant in change over mode without PALALlCliNnG cccsseecccseeecccseeecccseseccsausecsauuecssauseccsausecssaeeesssunseees 51 Figure 19 Typical sequence in change over mode on mains failure rrrrrrrrrrrnnnrrrrrrnnnnnrrrrnnnnrrrrrnnanrrrrrnnenrrrrrnnenrrrnnnnenseee 52 Figure 20 Typical sequence in change over mode on start FEQUEST ccccssssessseccccccnneseseeccccssaauseseccessssauaeseesessssaaaanseeess 53 Figure 21 Power plant in change over without PArallelinG scsccccccseeseccccnnssececcaeesecsscauseeecscaunsecsssuunsecessausecsssaanseeeeas 54 Figure 22 Power plant with several GENCLAtOSS sssesccccnssesecccnsesecescausecessauseeesssuuseessasuusecessaunsecsssaunsecessauseesssaanseeeeas 55 Figure 23 Generator paralleling with parallel lines ccccccssescccsseecccsesecccsuseccsausecsseseccsausecesaseessuneessausecssaasessauaesessansesas 56 Figure 24 Static paralleling with 4 generators coupled together in emergency SITUATION cssecccsseesecsseseccsesecsaeseees 57 Fig
52. mode X TABLE 15 PARALLELING WITH MAINS CONFIGURATION EE 1 On the CAN bus point of view MASTER 2 0 is equivalent to a GENSYS unit so it must be identified by a number For example the use of one MASTER 2 0 gives a maximum of 31 generators 2 Mains paralleling mode is fixed to No changeover when a single GENSYS 2 0 is used together with one or more MASTER 2 0 A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 64 To allow Power Factor regulation the Mains breaker in J1 input to GENSYS 2 0 must be connected Power Factor regulation is not an option 9 7 INTERFACING GENSYS 2 0 WITH GCIR a x smm NBAT 2 To other GJ censys n FIGURE 32 GCR GENSYS 2 0 WIRING DIAGRAM GCR 39 40 GENSYS 2 0 G4 G6 parallel lines 0 3V to control active power GCR 42 43 GENSYS 2 0 G1 G3 mains synchronization bus 3V GENSYS 2 0 K3 Vgart from speed governor number 1464 Mains kW Meas mA G1 G3 Variable Variable label ET ge ERE 1461 10V 1020 20mA setting 20000kW 1021 OkW setting TABLE 16 GENSYS 2 0 GCR CONFIGURATION A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 65 5 8 POWER PLANT PARALLELED WITH SEVERAL MAINS USING A MASTER 2 0 OR GCR PER MAINS Synchroniz ation bus Analog l
53. no voltage reference available OV must be wired with 4 mm cable as follows battery gt speed governor gt GENSYS 2 0 See table below for presets For specific settings contact your dealer Remark Voltage converter to isolate the signal on the line DC DC advise 10 Barber 06 5Volts Colman Frequency bias input 0 See Figure 42 Connection with EFC Cummins 1 05 ILS signal sv 27 ILS signal Digital supply 25 ILS signal Manufacturer Model ESG ESG Terminal Terminal Amplitude offset G9 out G11 ref 1076 1077 10 0 KG6 25 00 46 50 E3 System E6 ee 24 26 CUMMINS ECM pour QSK23 QSK40 1 00 00 00 QSK45 ae QSK 1 00 nl All models X S BARBER COLMAN with analog input DPG 2201 10 1 6 1 6 A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated 1 0 lines 76 Manufacturer Model Terminal Terminal Remark Amplitude offset G9 out G11 ref 1076 1077 25 00 0 WOODWARD 2301A D 25 00 Shunt 14 16 ILS speed 90 00 25 00 2301A 99 00 1 00 Speed only Pro act 25 00 00 00 Aux Aux Pro act Il EPG System 25 00 30 00 P N 8290 189 8290 184 MDEC 50 00 00 00 VOLVO EDC 4 15 00 24 l conn 25 c conn 25 50 25 00 25 00 DEUTZ 8 00 to 13 50 EE DE All ESD except 20 63 8 ESD5330 Without o
54. out system is triggered This means that a timer variable is run and will activate a non essential consumer trip output each time this variable reaches the delay fixed by parameter E1894 TM trip out Up to 5 non essential consumer trip outputs can be activated this way These outputs will remain active until both of these conditions are met e Generating set load and or frequency are within the thresholds limits e Trip alarm is reset for example using the front panel amp Hr 192 36 128 50 s090 htm Cc AN o C1 label Output C1 utput 1 7 Trip out I v Output 1 mode 1436 ND h D g C2 label Output C2 S Output 2 3 Trip out 2 v ke Output 2 mode 1437 ND h a O lt lt gt gt Esc Faults Alarms Information save modified parameters FIGURE 73 NON ESSENTIAL CONSUMER TRIP OUTPUT SETTING 143 A53 Z0 9 0020 N EN Technical documentation Diagrams below show the behavior of the trip alarm and trip outputs depending on the load or the frequency of the generating set Timer_2 Load kW E1910 kW 2 E1907 kW 1 E1906 Ka bd htl a a bk I am be Re ed n h fn br oe i i bm i ok be be a bom h med Timer 1 E1909 Trip Alarm E2729
55. outputs on the GENSYS 2 0 The same procedure than the speed calibration procedure see 11 2 2 has to be followed to calibrate the voltage control See Figure 46 E1599 No action range for U U in default value 50 E1601 Impulsion delay for U U default value 2 200ms E1874 Set to 2 sec which is the pulse pause time for frequency voltage compensation This parameter was adjusted for speed control so do not modify E1873 Set to 0 1 sec which is the pulse length for frequency voltage compensation This parameter was adjusted for speed control so do not modify E2058 Maxi Hz 7000 E1598 Maxi Hz 7000 GENSYS 2 0 wants the genset to go faster Load sharing Synchro pulses only ants the serrset to go slower E160 Boe E2342 pulse Hz TN E2341 pulse Hz lt gt T 700 E2058 seconds Frequency centre pulses only Frequency A DEADBAND 0 1Hz GENSYS 2 0 wants the genset to go slower 1873 GENSYS 2 0 wants the genset E2342 pulse Hz to go faster E1873 lt gt E2341 pulse Hz lt gt E1874 Summation of both signals E2342 pulse Hz E2341 pulse Hz FIGURE 46 SPEED AND VOLTAGE CONTROL PULSES A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 32 1 3 ANALOGUE AVR AUTO VOLTAGE REGULATOR CONTROL AVR output can be an analogue output or a digital pulse output Analogue output is detailed here digita
56. set or Both Delay before start sequence begins on Mains electrical fault appearance 1842 No load delay Indicates the time to let the engine run without load when generating set circuit breaker is opened If set to O engine will never stop TABLE 36 MAINS ELECTRICAL FAULT 1 available in Configuration Mains Bus Mains electrical fault menu 2 modification by variable number Chronogram below shows the behavior when using change over mode Start on Mains electrical fault E1841 is set to Yes l l l Generating set circuit breaker Mains circuit breaker E2000 Digital input set as Mains electrical fault E2201 Chapter Additional functions Bus voltage present l l D Change over timer l gt Mains back timer Timer before start Start sequence l l FIGURE 56 CHANGE OVER WITH ONE DIGITAL INPUT SETUP AS MAINS ELECTRICAL FAULT 117 A53 Z0 9 0020 N EN Technical documentation Chronogram below shows the behavior when using Mains permanent paralleling mode When Start on Mains electrical fault is set to Yes l Generating set l l circuit breaker l l Mains circuit breaker E2000 Digital input set as Mains electrical fault E2201 I I I I l I Bus voltage present I l I Mains back timer i Synchronization FIGURE 57 PERMANENT MAINS PARALLELING WITH ONE DIGITAL INPUT SETUP AS MAINS ELECTRICAL FAULT NOTE Never use No start on
57. standard W1476 XO 20 V2739 Master If 1 this GENSYS 2 0 is the master X X gen Nb TABLE 35 INTEGRAL INHIBITION Warning When the CAN bus is not used you have to disable load sharing see table above In the case of a CAN bus failure where E1259 is not set at 6 load sharing in droop disabled you also have to disable load sharing IG 2 OPERATOR CONTROLLED RETURN TO MAINS Normal operation In the case of mains failure the engine starts and takes the load When the mains voltage returns the engine resynchronizes with the mains and automatically gives back the load The Operator controlled return to mains special function set with the parameter E1620 1 allows the operator to control the moment the engine will return the load to the mains To do this a digital input of the GENSYS 2 0 must be set as Manual main back E2850 The unit will wait the synchronization order provide by the digital input before re synchronizing the engine to the mains A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 116 14 3 MAINS ELECTRICAL FAULT Mains electrical fault management dedicated parameters and default values Parameter Default value Description 1841 Yes Indicates if the generating set should be started on Mains electrical fault appearance 1846 Mains Indicates which circuit breaker should be opened on Mains electrical fault appearance Choose between Mains Generating
58. this parameter can be done only when the generator is stopped Moreover a confirmation page will be displayed when modified the phase offset Note After choosing your phase offset you can lock this value by disabling the option 8 A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 135 14 15 VOLTAGE SYSTEM 120 THREE PHASES 180 TWO PHASES SINGLE PHASE Parameter E4039 allows you to select the system to be used in the Configuration Power plant menu System used E4039 Three phase 120 O default value Two phase 180 Single phase TABLE 4 VOLTAGE SYSTEM SYSTEME CONNEXIONS 3 phases 120 Generator N Generator Li i ika Generator L2 TE Generator L3 z 6 0t 3 phases Neutre 0 Bus Mains Li Bus Mains L i Bus Mains L3 2 phases 180 ate ty Generator Li i ika Generator L2 TE Generator L3 z m Ja W Oo T Bus Mains L1 2 phases Bus Mains L2 i Bus Mains L3 180 Neutre SUITE JA SUG Chapter Additional functions 1 phase Neutre Bus Mains L1 Bus Mains L2 Bus Mains L3 sure JA SUg yasuayH FIGURE 69 VOLTAGE SYSTEM 136 A53 Z0 9 0020 N EN Technical documentation 14 16 MAINTENANCE CYCLE Here you can setup custom cycles called maintenance cycles User can set them up to schedule maintenance operation after the desired amount of running hours or days 5 cycles are based on r
59. time the E0042 E0057 3 GE 17 to 32 kW This screen displays the percentage of nominal active power supplied by each generating set from 17 to 32 in real time the E6000 E6030 E6060 E6450 4 GE 01 to 16 KVAR This screen displays the percentage of nominal reactive power supplied by each generating set from 1 to 16 in real time E0132 to E0147 5 GE 17 to 32 kVAR This screen displays the percentage of nominal reactive power supplied by each generating set from 17 to 32 in real time E6001 E6031 E6061 E6451 6 GE 01 to 16 nominal kW This screen displays the nominal active power of each generating set from 1 to 16 E0073 to E0088 7 GE 17 to 32 nominal kWI This screen displays the nominal active power of each generating set from 17 to 32 E6003 E6033 E6063 E6453 8 GE 01 to 16 nominal kVAR This screen displays the nominal reactive power of each generating set from 1 to 16 E0089 a E0104 9 GE 17 to 32 nominal kVAR This screen displays the nominal reactive power of each generating set from 17 to 32 E6004 E6034 E6064 E6454 Note These display pages fit according to the number of unit selected A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 204 19 2 2 GENERATOR ELECTRICAL METER 1 Global view generator This screen displays all generator electrical meter in real time e Phase to phase voltage for each phase E0003 E0004 E0005 e Phase to neutral
60. up for other functions On industrial range initial settings are Crank and Fuel Polarity cannot be changed for these relay outputs A1 Crank output function can be set with E1989 A2 Fuel output function is set with E1916 On firmware versions before v4 55 relay output setup as not used were still working as CRANK and FUEL function Starting from v4 55 unused configuration really means that output relay will never be activated Yet in order to keep a consistent behavior on existing sites that are upgraded with newer firmware parameters E1916 and E1989 will be automatically adapted if you send a TXT file from an old firmware i e from v1 00 to v4 04 into a newer unit with firmware v4 55 or later This means that an old text file containing V1916 0 or V1989 0 in the PARAMETERS section will result in newer units in V1916 2019 FUEL and V1989 2018 CRANK You will be informed of such event by the compilation result WARNING 002 V1989 adjusted to match new firmware usage WARNING 003 V1916 adjusted to match new firmware usage A53 Z0 9 0020 N EN Technical documentation Chapter I O lines 100 l2 2 1 OUTPUT CONFIGURABLE FUNCTIONS Value Function Description To be selected if output is not wired LS GY To be selected if output is used by Used by equations equations oO Water preheat Can be used for coolant pre heat system Pre lubrication Can be used for pre lu
61. user friendly interface to monitor measurements and set up GENSYS 2 0 parameters You can download CRE Config software from CRE technology Web site http www cretechnology com Please refer to CRE Config software documentation for more details d Starting from firmware v3 00 GENSYS 2 0 can be monitored and controlled using CRE Config v liiian Dash Inteerretion Dipty I Irfinar Dephay 2 Intvemartor Diepdyy 3 m ne Maa GTRSYE IT PET ae Fana Figure 12 CRE Config software A53 Z0 9 0020 N EN Technical documentation Chapter User interface 38 6 3 2GENSYS 2 0 INTERNAL WEB SERVER Connect GENSYS 2 0 to your computer using an Ethernet cross over cable Start your Web browser Ex Firefox or Internet Explorer Type in the GENSYS 2 0 URL or IP address factory settings http gensys or http 192 168 11 1 according to your GENSYS 2 0 and Windows hosts file settings http 192 168 11 1 Windows Internet Explorer E BIK y X Live Searct Pie Fichier Edition Affichage Favoris utils Liens Netvibes General Personnaliser les liens 9 Sites CRE product gensys w k 18 http 192 168 11 1 fh gt ED dv E Page G outis Or Password Faults Alarms Information gt GENSYS 2 0 password page appears Enter your password to browse GENSYS 2 0 Web site Note Parameter E4042 serves as a Web connection timeout delay Once this ti
62. variable E2762 1 analogue variable E2763 2 analogue variable TABLE 55 BROADCAST DATA SENT ON INTER MODULE CAN BUS Custom equations are required to control data that will be sent to other modules Variables E2752 to E2763 are pointers to the data that will be sent on CAN bus This means that they should be assigned the variable number of the data you want to be broadcast to other modules Example In this example a main fuel tank is available to feed 4 generating set A fuel level sensor is connected to the first spare analogue input of module number 2 Engine Meas 1 on terminal F1 F2 So fuel level is measured and stored in variable E0031 of module number 2 You may broadcast this fuel level to the 3 other CRE Technology modules by adding the following custom equation into module number 2 X2762 31 This will send the value of variable E0031 to other modules This way fuel level will be sent using 1 broadcast analogue variable All modules will receive this fuel level into variable E0562 see below for broadcast data receiving variables It is important to understand that using this equation other modules will not receive value 31 but the content of variable E0031 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 164 Data received from other modules are stored in the variables listed below Custom data received from other modules 1 10 digital l Received from dk 1
63. you how to customize equations to send your own variables to the BSM II See also the application note A43Z090101A to customize the BSM II archiving Download the text file level 1 equation Z090211a 1 txt to the GENSYS 2 0 as described in 17 7 3 or 19 4 7 Download the text file level 1 equation A43Z090100a_1 txt to the BSM II 1 Change the Node ID of BSM II See BSM II user s manual to choose the node ID in the BSM Il Then change this node ID Output address in the settings of the GENSYS 2 0 default ID equal 1 via the CRE Config software 2 Delete message If you do not need to send all variables set in default equations you can delete output messages To do this set Output data type to Unused and Output address to 0 via CRE Config software A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 126 3 Add message Each message sends a maximum of 4 Analogue values to BSM II By using the CRE Config software e Set Output address to the correct Node ID of the BSM Il e Set Output Data Type to Analog e Set Number of Outputs Max 4 e Add equation described below 4 Customize the variables sent to BSM II All variables are transferred as analogue outputs from GENSYS 2 0 to BSM Il Analogue output GENSYS 2 0 Variable AO1 gt AO8 E2432 gt E2439 AOS gt AO16 E2682 gt E2689 A017 gt A032 E2708 gt E2723 All variables are transferred as analogu
64. 0 280 7911 20000 30000 20000 0 10 gt 320 9090 20000 30000 200000 10 gt 360 10270 20000 30000 20000 0 10 gt 400 11449 20000 30000 20000 0 10 gt TABLE 32 OIL PRESSURE CALIBRATION POINTS 1000 1000 70 96 52 62 89 43 56 51 ao 32 38 Je a7 3 TABLE 33 WATER TEMP CALIBRATION POINTS O gt D 2 Engine measurements 1 and 2 2 am Spare 1 engine measure calibration points are E1210 to E1220 O Spare 1 engine measure impedance points are E1188 to E1198 Spare 2 engine measure calibration points are E1232 to E1242 Spare 2 engine measure impedance points are E1199 to E1209 For each of the two spare sensors this table shows the given value left side for each of ten sampled resistive values in ohm right side Intermediate values are obtained with linear approximation E g min 3000 max 6000 gives the values corresponding to 3000 3300 3600 3900 4200 4500 4800 5700 6000 Ohms These can be used in equations or displayed A53 Z0 9 0020 N EN Technical documentation 12 3 5 USE SPARE ANALOGUE INPUT AS DIGITAL INPUT If necessary it is possible to use an analogue input as a digital input 1 Purpose Use spare analogue input spare 1 and 2 connections F1 F2 and F3 F4 as digital input 2 Configuration Spare analogue input calibration table should be set as shown below to mimic digital input GENSYS 2 0 3 Parameters Calibration table for a normally closed in
65. 0 2 GENSYS 2 0 1 engine speed mu Stored in E0546 of GENSYS 2 0 2 GENSYS 2 0 2 digital input J6 wap Stored in E0552 of GENSYS 2 0 1 GENSYS 2 0 2 engine speed mu Stored in E0562 of GENSYS 2 0 1 Chapter Communication TABLE 57 ANALOGUE AND DIGITAL DATA BROADCAST EXAMPLE 166 A53 Z0 9 0020 N EN Technical documentation 7 2 3 CAN BUS INHIBITION COM1 CAN bus is mainly used by GENSYS 2 0 modules to send power management data to each others CAN bus inhibition is used to prevent one GENSYS 2 0 from taking into account data coming from one or more specific GENSYS 2 0 units This is especially useful when tie breakers are used to change the configuration of the power plant for example from a 6 generator power plant to two power plants with 3 generators each Variables below are used to decide with which modules the GENSYS 2 0 should communicate power management data Variable Description when variable is set to 1 E2695 E2696 E2697 E2698 E2699 E2700 E2701 E2702 E2703 E2704 E2705 E2706 E2885 E2886 E2887 E2888 E2889 E2890 E2891 E2892 E2893 E2894 E2895 E2896 E2897 E2898 TABLE 58 CAN BUS INHIBITION VARIABLES All firmwares Chapter Communication Firmware v4 00 and above only If one of these variables is set to one power management data from the corresponding GENSYS 2 0 will not be taken into account 167 A53 Z0 9 0020 N EN Technical documentation Note Broadc
66. 0 N EN Technical documentation Chapter Menu overview 235 19 4 4 LANGUAGES Parameter Possible value Comment var num English 0 PC language Francais 1 Allows you to choose the language of the menus d E1311 Espanol 2 isplayed on your computer English 0 Local language Francais 1 Allows you to choose the language of the menus d Custom 3 isplayed on your GENSYS 2 0 front panel E1156 Espanol 2 Custom 3 TABLE 18 LANGUAGE SELECTION Note By default the Custom language is the Italian language It s possible to download a language file in order to modify the Custom language See 16 7 for more details 19 4 5 COMMUNICATION PORTS CONFIG 1 COM1 CAN1 INTERGENSYS This isolated communication port is dedicated to inter unit data communication using a proprietary protocol This bus allows synchronization load sharing active and reactive dead bus management automatic load unload Broadcast data Action to be performed upon CAN bus fault E1259 occurrence can be set using password level 2 See 17 2 1 for more details 2 COM2 CANopen J1939 This bus is used for communication with CANopen remote I O modules Beckhoff Wago or electronic engines communication J1939 or MTU MDEC 3 COM3 USB TCP IP PROTOCOL Reserved to CRE Technology 4 COM4 ETHERNET This menu allows configuring the Ethernet connection to communicate with a PC Please contact your network adm
67. 020 AND E2231 BEND Note Don t forget to configure output 1 in Used by equations A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 94 1 9 ANALOGUE LOAD SHARING LINE It is possible to use traditional analogue load sharing lines often called Parallel lines with the GENSYS 2 0 product The example shown is in association with a BARBER COLMAN product BARBER COLMAN DYN2 80108 80109 Parallel lines G6 Parallel lines Parallel lines lines Parallel lines Parallel lines FIGURE 55 WIRING PARALLEL LINES Change the following parameters in menu Configuration Power plant to activate the parallel lines e Load sharing E1158 Analog 0 e Deadbus manage E1515 NO 1 1 10 WATCHDOG OUTPUT A watchdog option is available using the C5 output This option must be specified upon ordering your unit so that CRE Technology can activate it For more information concerning this function please contact CRE Technology A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 95 le 17 0 LINES le DIGITAL INPUT They are divided into dedicated and configurable inputs For Digital inputs J4 to J15 the following parameters can be set Label can be modified with parameters file Validity can be modified using configuration menu or equations Direction can be modified using configuration menu or equations Delay can be modif
68. 020 N EN Technical documentation Potential Variable Description Alarm Fault control Alarm Fault detected o E0339 Low Oil P Low oil pressure detected by J1939 MTU E1858 E0343 High Cool T a water temperature detected by J1939 E1859 E0355 Very Low Oil P Very low oil pressure detected by J1939 MTU E1860 Very high water temperature detected by E0356 Very Hi Cool T 11939 MTU E1861 E0358 Hi Overspeed High overspeed detected by J1939 MTU E1862 E1867 E1868 Protection used by MTU MDEC see 17 3 3 E1869 E0422 Trame RX 2 2 E1870 E0426 Trame RX 2 6 E1871 2729 Tipala Overload alarm used for non essential Aan consumer see 15 2 MASTER 2 0 only Indicates that the power plant is not available Punai Une GENSYS 2 0 units may be in manual mode or in fault E5030 to Hard shutdown E5045 Nm mod OL ASTER Gen E5071 to Rien a 32 Indicates that group number 1 to 32 is in fault anne S E5086 T Alarm Fault will be activated E1997 In load sharing mode indicates that actual kW E2915 Uneven kW measure of the generating set is far from the E4111 average of the other groups er In load sharing mode indicates that actual KVAR measure of the generating set is far from E4114 the average of the other groups TABLE 34 POTENTIAL ALARM FAULT LIST 1 Foran external start module the alarm fault E2365 Engine not ready correspond to a lost of GE Ok signal E2515 113 A53 Z0 9 0020 N EN Techni
69. 0386 E1865 information that is reporting a problem with the engine system where the engine need not be immediately stopped Red lamp CT Red Message used to relay trouble code E0403 E1866 information that is of a severe enough condition that it warrants stopping the engine TABLE 66 119359 ALARMS FAULTS LIST 1 Allthresholds are those set in the ECU Note When the J1939 engine has been selected all control parameters are settable in the Configuration Engine J1939 MDEC menu A53 Z0 9 0020 N EN Technical documentation Chapter Communication 179 6 Custom frames Rx Custom frames If you need to get more values from the J1939 device than those available in the basic operations the system is able to read raw data from 2 different frames you can set to fit your needs The following variables are used to define those 2 custom Rx messages E2675 E2676 define the ID of the frames to be monitored The IDs are those defined by the J1939 71 standards The raw data is available as 8 bytes are described in the table below Custom RX Variable Frame Frame Raw data variables frame 1D E2675 E0410 to E0417 E2676 E0420 to E0427 TABLE 67 JIS39 TRAMES RX CUSTOM See J1939 71 standards in order to fin the frame ID that fits your needs Note There are no web pages to configure these RX custom frames Please use custom PLC equations to access custom RX variables The variables are only
70. 048 E4049 E0902 EEE EEE E0892 E4043 E4050 E0903 E0905 E4056 E0906 E4057 E0904 FEE FP Fenn E0907 E4058 0910 14081 E0913 E4064 NORMAL E0908 E4059 E0911 E4062 E0912 E4063 STOP a un me PL TABLE 42 FRONT PANEL INHIBITION Chapter Additional functions 138 A53 Z0 9 0020 N EN Technical documentation 15 ADVANCED MARINE FUNCTIONS Functions below have been developed for advanced load management in marine applications Associated parameters can be found in marine specific menus on the front panel or embedded Web site 15 1 HEAVY CONSUMER 15 11 INTRODUCTION Heavy consumer function is used in marine application in order to prevent to start an heavy consumer on a power plant that can t accept a such load Examples that use heavy consumer control using of a crane in a harbour manoeuvring a ship in out of harbour using bow thrusters etc Some external parameters must be analysed by GENSYS 2 0 units before accepting heavy consumer load e Analysis of available kW number of generators on Busbar or both e If Power Plant can accept load heavy consumer authorization output is enabled e lf Power Plant cannot accept load another engine is started e One GENSYS 2 0 input is used to start analysis of power available on plant e One GENSYS 2 0 output is used to accept heavy consumer request N Since firmware v4 55 v4 e Heavy consumer management can accept up to 4 different heavy consum
71. 083 temperature sensor sensor Output 2 function E1261 Pre lubrication 2084 FIGURE 50 CONNECTIONS FOR WATER PREHEAT PRE LUBRICATION AND PRE GLOW 1 6 MANUAL MODE Preheat is active when J7 is closed The water temperature sensor isn t required Pre lubrication is active when J8 is closed The oil pressure sensor isn t required Pre glow is active when J9 is closed when you push GENSYS 2 0 start button or if J10 is closed 11 6 2 AUTOMATIC MODE Pre heat is activated if J6 is closed and if temperature is under the pre set threshold E0030 lt E1154 Note The water temperature sensor is required in this instance Pre lubrication will be activated when engine is in pre start if pressure is under the threshold E0029 lt E1155 If the threshold E1155 is 0 then pre lubrication is active while the engine is in pre start In the last case the oil pressure sensor isn t required Pre glow is active when engine state is pre glow or start A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 90 1 7 AIR FAN J5 water temp input Water temperature Output 1 function E1260 Air fan 2215 sensor FIGURE 5 CONNECTION FOR AIR FANS Output 1 C1 Air fan relay In all cases the AIR FAN will be activated if J5 is activated or if the max water temp protection F6 F7 analogue input is configured and triggers 11 7 1 MANUAL MODE AIR FAN o
72. 085 mains return Change over time transfer E1459 TABLE 104 MAINS TIMERS CONFIGURATION 19 3 10 SYNCHIRONIZA TION 1 Synchronization check relay This menu allows setting the synchronization parameters used to allow the synch check relay to operate Parameter Comment var num E1127 busbar voltage that allows the synch check relay to operate E1128 busbar that allows the synch check relay to operate E1129 set and busbar for the sync check relay to operate E1432 breaker to allow sync check relay to operate E1433 of the breaker for the sync check relay to operate Min frequency The minimal percentage of nominal frequency allowed on both E1434 sides of the breaker for the sync check relay to operate E1435 sides of the breaker for the sync check relay to operate Fail to synch This timer will trigger a fail to synchronize protection if generating E1150 set has not synchronized within the time you enter E4108 breaker E1929 CT Fail synch This selects the course of action in case of impossible E1928 synchronization See 13 for more details TABLE 105 SYNCHRO CHECK RELAY CONFIGURATION Chapter Menu overview 1 This parameter can be modified using TXT file or modification by variable number menu 2 Available if option 8 is enabled 227 A53 ZO 9 0020 N EN Technical documentation 2 Frequency PID This menu allows tuning the frequency and phase synchronization PID in order to
73. 14 MODIFICATION BY VARIABLE NO This menu item is very useful when you are familiar with key variable numbers for example the ones you modify often Simply enter the variable number and then enter its value Note You can only change parameters settings E1xxx and E4xxxx Some of these settings are not accessible from other menus With the level 2 password you can configure the writing ability via Modbus or PLC equations This is also visible and settable in the third column of the parameters file Y Yes allowed N No not allowed See 16 3 2 for more details Modification by variable nb SD I La Gen nominal kW 1008 320 KW Writing by MODDUS PLC Denied v FIGURE 88 MODIFICATION BY VARIABLE NUMBER A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 232 19 4 SYSTEM MENU This will give access to the following menus which display system parameters some of them can be modified e Date Time Meters e Passwords Options e Screen saver e Languages e Communication ports config e GENSYS 2 0 gt PC file only on web site e PC gt GENSYS 2 0 file only on web site e Download logo only on web site e Update firmware only on web site with level 2 password e Reset factory settings only in level 2 e About 19 4 DATE TIME METERS 1 Date Time This menu allows modifying the date and the time Parameter Comment var num Select the date format day month y
74. 19 Integral of cos control E1121 TABLE 22 PID COS LOOP CONFIGURATION 230 A53 Z0 9 0020 N EN Technical documentation While you adjust the PID settings the following parameters are displayed e Generator active and reactive power P et Q e Engine speed e cos Q setpoint e cos Q by phase 1 2 and 3 e cos Q global 19 3 12 FIFO DATA LOGGER Log on off E1988 set to ON to enable the data logger Log Var 1 Log Var 10 Set here the variable value you want to watch When set to 1 the Log Var is disabled Data are recorded when the variable s value changes Each data is recorded in the following form jj mm aa hh mn ss label XXXX YYYY XXXX is the variable number and YYYY the value of the variable The recording can be downloaded from the web site Note The unit can save up to 2000 data This includes archived alarms and faults 19 3 MAINTENANCE CYCLE This menu allows resetting the maintenance cycle Only the configured maintenance cycle will be displayed Parameter Comment var num E4097 E4098 ae E4099 coo E4100 ResetMeter5 h Reset maintenance cycle 5 in hour ae riene co E4102 Chapter Menu overview ResetMeter3 d Reset maintenance cycle 3 in day E4104 a E4105 a E4106 TABLE lle RESET OF MAINTENANCE CYCLE ResetMeter2 d Reset maintenance cycle 2 in day E4103 251 A53 Z0 9 0020 N EN Technical documentation 19 3
75. 1929 set for the phase angle shift Synch check relay status Phase difference frequency difference voltage difference phase 3HzL I Cid 5 Hz AV 2 0 n ca 20 LT F200 4 ees ad Sync check relay amp Ap Not ok Phase AE Not ok Av P s Not ok ai sE Na 4 p5eg Not ok Phase Offset 07 FIGURE 87 SYNCHROSCOPE 19 2 5 ENGINE METERS These measurements provide information about the engine e Oil pressure E0029 e Water temperature E0030 e Engine speed E0033 e Battery voltage E0040 e two Spare analogue resistive sensors E0031 E0032 e Hours and minutes run meter E0065 E0891 e Total number of starts E0041 e User meters 1 amp 2 E2657 E2659 Note The oil pressure water temperature and speed engine can be measure by an analog input pick up or by J1939 see 17 3 2 for more details A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 207 If the unit is connected by J1939 to the engine some extra pages are available in order to display the measurement received from the engine See 17 3 2 for more details 19 2 6 INPUTS OUTPUTS STATE 1 Digital inputs 0 7 This menu shows the status of the Emergency stop input E2005 as the status of the 7 first digital inputs connected on the J terminal E2000 E2001 E2804 E2807 The name of each input is displayed with the status Input active 1 Input inactive 0 2 Digital
76. 2 Other equipments Table below shows some of many other types of equipment available in the CRE Technology product range Reference Description A53X0 Manual GENSYS 2 0 MASTER 2 0 test bench AO9Tx GCR digital Mains controller ref AO9TO for 100Vac AO9T1 for 230Vac and A09T2 for 400Vac A24Zx CPA Converts three phase active power measurements into a 20mA signal Exists for 100Vac 5A 230Vac 5A 400Vac 5A 1O0Vac 1A 230Vac 1A and 400Vac 1A measurements A61Y1 BSD Plus remote management box GPRS email SMS A25Z0 C2S Auto Synchronizer and Safety Column to safely control the paralleling of two alternating power sources TABLE 124 CRE TECHNOLOGY PRODUCT REFERENCE A53 Z0 9 0020 N EN Technical documentation Chapter References 249 e3 CRE TECHNOLOGY by 130 All e Victor Naudin Zone des Templier 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 Email support cretechnology com SKYPE support cretechnology com Re EN 1 i L E S Ww 1 NT TROIS MOULIN MT pm s ae Eaa 3 LAS VALMASQUE Gi sr BEN mm Re z ey PARC INTERNATIONAL RENARD G D ACTIVIT S DE SOPHIA ANTIPOLIS sormaannrous SCH MA DES ACCES ACCES n 20 All e Victor Naudin Cours pe FIGURE 98 ACCESS TO CRE TECHNOLOGY A53 Z0 9 0020 N EN Technical documenta
77. 2 0 IY 8 3 RROCEDURE EXAMPLE This example allows you to log the most significant variables of your application when an alarm occurs See also the application note A43Z090100A to configure the BSM II logging Download the text file level 1 equation Z090211a 1 txt to the GENSYS 2 0 as described in 17 7 3 or 19 4 7 Download the text file level 1 equation A43Z090100a_1 txt to the BSM II Archiving of data begins immediately Variables are stored in the BSM II at the rate of 1 sample per second when an alarm occurs 2 5 samples before the alarm 1 sample when alarm occurs 5 samples after the alarm See the application note A43Z090100A to retrieve archives from the BSM Il A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 125 The table below list the transmitted variables Var kW GE E0018 kW3 E0011 PwrMngt Status E2071 Hz GE E0020 COS Engine GE Status E0021 E2057 Sum f Digital JE Sum Digital each bit of this parameter represents a logic variable BitO breaker in mains E2000 Bit1 breaker in GE E2001 Bit2 gt Bit14 free Bit15 forbidden this bit gives the result a bad negative value Note With this configuration the BSM II node ID is equal to 1 Make sure that no other device on the CAN bus has the same node ID 14 8 4 CUSTOM PROCEDURE This procedure shows
78. 20 03 08 11 07 37 Water temp 2004 0ff 20 03 08 11 07 37 Water temp 2004 0n 20 03 08 11 07 27 Water temp 2004 0ff 20 03 08 11 07 27 Water temp 2004 0n 20 03 08 11 07 26 Input 4 2009 0ff 20 03 08 11 07 26 Input 4 2009 0n lt lt gt gt Refresh Reset FIGURE 92 FAULTS SCREEN Pressing Refresh will update the screen with last occurred faults s Pressing Reset in the Active faults page will reset the protection s which were triggered Note The condition triggering the protection must first be corrected before resetting the alarm failing to do this will trigger the protection again The Faults archive can be deleted in the System Date Time meter Meters reset menu by selecting the Event logger parameter E1988 19 5 2 ALARMS At any time and any level you can click on the Alarms link on your browser or press the ALARM key on the front panel Click BACK on your internet browser or press the button a second time to return to your previous screen The last 50 alarms will be displayed as follows dd mm yy hh mn ss_ protec label XXXX On or Off XXXX is the variable number By pressing lt lt or gt gt you can change between the active alarms 1 to 10 alarms 11 to 20 alarms Pressing Refresh will update the screen with last occurred alarms s Pressing Reset in the Active alarms page will reset the protection s which were triggered Note The condition triggering the protection m
79. 235 f activates with SHIFT keys or Manual U request E2236 In Auto mode these functions will control a speed voltage regulator requiring contacts You can configure the 2344 U no action range for the speed E1598 and for the voltage E1599 the impulsion delay for the speed E1600 and for the voltage E1601 2343 Will activate in stop sequence to stop the engine when 2223 Damper damping flap is fitted Will be activated when there is an engine fault 2046 This will activate the output whenever the light test key is 2232 Lamp test pressed on the front panel of GENSYS 2 0 or an input programmed for light test is active Output will be active when start sequence is completed and voltage is present at the generator In Auto mode the output Generator ready will be activated when the engine state is Gen ready In Manual mode the output will be activated when the speed E0033 is positive Output will be active when genset is at rest In Auto mode the output will be activated when the engine state is Waiting In Manual mode the output will be activated when there is no speed E0033 2331 2240 Generator stopped 2263 These key are useful in Manu mode to control the speed and the voltage 2056 Will be active when a second engine starting system is present 2267 Starter 2 and programmed in Configuration gt Start sequence menu Will be active when a third engine starting system is present 2268 Sta
80. 3 E0794 E0795 e Current for each phase E0799 E0800 E0801 e Active power for each phase E0802 E0803 E0804 e Reactive power for each phase E0805 E0806 E0807 e Power factor for each phase E0808 E0809 E0810 e Average active and reactive power frequency and power factor E0060 E0059 E0023 E0058 2 Mains Bus phase phase volt This screen displays the three phase to phase voltage measurements 3 Mains Bus phase neutral volt This screen displays the three phase to neutral voltage measurements 4 Mains Bus currents This screen displays the three current measurements 57 Mains Bus kW This screen displays the three kW measurements 6 Mains Bus kVAR This screen displays the three kVAR measurements 7 Mains Bus PF This screen displays the three power factor measurements 8 Mains Bus parameters This screen displays Mains Bus average active and reactive power frequency and power factor measurements 9 Mains Bus parameters This screen displays kWh and kVARh measurements 10 Mains Bus energy meters This screen displays kWh and kVARh measurements Note These display pages fit according to the voltage system selected see 14 15 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 206 19 2 4 SYNCHRONIZATION This page displays Synchroscope phase difference Differential frequency bar graph Differential voltage bar graph sequence Phase Offset shows the parameter E
81. 430 and Meas 2 hyst E1431 Will activate when the genset has completed its start sequence in auto mode can be used for external logic The output will be activated when GENSYS 2 0 is in Auto mode and the power State E2071 is not in fault Output activated when starting heavy consumer number 1 is allowed in the Heavy consumer control sequence See below 15 1 Output activated when starting heavy consumer number 2 is allowed in the Heavy consumer control sequence See below 15 1 Output activated when starting heavy consumer number 3 is allowed in the Heavy consumer control sequence See below 15 1 Output activated when starting heavy consumer number 4 is allowed in the Heavy consumer control sequence See below 15 1 A53 Z0 9 0020 N EN Technical documentation Chapter I O lines 104 1 Generates a 1s pulse on the output when Generator Mains breaker E2016 E2017 wants to close open l2 2 2 POLARITY For each of the five outputs two options are possible e NE normally energized the output will de energize when required according to its function e ND normally de energized the output will energize when required 12 3 ANALOGUE INPUT VIA CRE CONFIG SOFTWARE All analog inputs settings unit accuracy calibrage are done via CRE Config software or by the parameters file 12 3 1 OIL PRESSURE CONFIGURATION You can now choose units mBar Bar kPa PSI and degree of accuracy number of digits
82. 59 G59 is a protection norm widely used in the UK You can set and lock the following protections Mains Under Over frequency Mains Under Over voltage Vector surge ROCOF df dt SG SG SG SG When the protections are locked thresholds timers and controls are also locked 14 11 SCADA GENSYS 2 0 communication uses industrial standards This product is versatile and can be used with Modbus for example to be controlled by a SCADA system CRE Technology offers different solutions for such applications remote display remote control event and alarm management Contact us for more information A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 129 14 12 HOW TO SET A GPID 14 72 PRINCIPLE A GPID allows the control of any system in a simple way Figure 51 shows a typical GPID Deviation Measure G global gain P proportional gain integral gain D derivative gain FIGURE 63 TYPICAL GRID CONTROLLER The G parameter acts as sensitivity adjustment for the other parameters The P parameter adjusts the rise time time needed for the system to reach its set point for the first time By increasing P the rise time will decrease However overshoot will increase and may also render the system unstable fast hunting Using only the P factor will always leave a difference between the set point and the actual value this difference is also called droop The I pa
83. 8 Virtualin18 2301 00 00000 Virtualinput Spare19 Virtualin19 2302 00 00000 Virtualinput Spare20 Virtualin20 2565 00 00000 VirtualinputSpare21 0 Virtualin21 2566 00 00000 VirtualinputSpare22 Virtualin22 2567 00 00000 Virtualinput Spare23 Virtualin23 z 25688 00 00000 Virtual input Spare24 Virtualin24 a 2569 00 00000 Virtualinput Spare25 Virtualin25 p 2570 00 00000 Virtualinput Spare26 Virtualin26 F 2571 00 00000 Virtualinput Spare27 Virtualin27 d 2572 00 00000 VirtualinputSpare28 Virtualin28 2573 00 00000 VirtualinputSpare29 Virtualin29 A 2574 00 00000 VirtualinputSpare30 Virtualin30 5 2575 00 00000 Virtual input Spare31 Virtualin31 2576 00 00000 Virtual input Spare32 Virtualin32 2577 00 00000 VirtualinputSpare33 Virtualin33 2578 00 00000 Virtual input Spare34 Virtualin34 2579 00 00000 Virtual input Spare35 Virtualin35 2580 00 00000 Virtual input Spare36 Virtualin36 258 00 00000 VirtualinputSpare37 Virtualin37 2582 00 00000 Virtual input Spare38 Virtualin38 2583 00 00000 Virtual input Spare39 Virtualin39 2584 00 00000 Virtual input Spare40 Virtualin40 TABLE 50 VARIABLES WITH CUSTOMIZABLE UNIT ACCURACY VALUES 153 A53 ZO 9 0020 N EN Technical documentation 16 3 5 INITIALIZATION DEFINITION BLOCKS The beginning of these blo
84. 866 warrants stopping the engine TABLE 96 11939 PROTECTION CONFIGURATION Chapter Menu overview 220 A53 Z0 9 0020 N EN Technical documentation 19 3 6 PROTECTIONS All protections Generator Mains and Engine Battery work with e A threshold trigger level of protection e A timer time before trig the protection e Acontrol action to do when the fault is present See 13 for more details To configure these protections you can access to the following submenu e Generator protections e Mia ins protections e Engine battery protections 1 Generator protections Protection type Threshold Timer X Uneven kW E4109 E4110 E4111 Uneven kVAR E4112 E4113 E4114 Uneven load sharing TABLE 97 GENERATOR PROTECTIONS CONFIGURATION Control Note uneven kVAR protection requires the use of CAN bus communication between modules So it is not available when parallel lines are used for load sharing control 2 Mains protections Protection type Threshold Timer Control A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 221 Protection type Threshold Timer Control maxi kVAR E1411 E1412 E1413 mini kVAR E1408 E1409 E1410 E1070 E1071 ROCOF df dt E1072 E1073 TABLE 98 MAINS PROTECTIONS CONFIGURATION Note The parameter E1637 TM dfdt vect allows to set the time from which the vector jump and ROCOF protections are enabled 3 Engine Battery protections
85. 995 E E Breaker Feedback Close Open Close FIGURE 49 UNDERVOLTAGE COIL WARNING Never switch from one mode to another when the plant is in use An unwanted breaker state modification may occur 3 Close breaker condition To close the generator breaker the following conditions have to be met Voltage must be between 70 parameter E1432 and 130 parameter E1433 of the nominal voltage parameter E1107 or E1108 Speed must be between 70 parameter E1434 and 130 parameter E1435 of the nominal speed parameter E1080 or E1081 A53 ZO 9 0020 N EN Technical documentation Chapter Dedicated I O lines 38 1 42 FUEL amp CRANK The standard functions for these two relay outputs are for normal Fuel and Crank relay applications Crank is A1 OUTPUT 6 and Fuel is A2 OUTPUT 7 These two outputs are relays and are fully configurable through the Configuration outputs Relay outputs menu or through equations 1 5 CRANK FUEL STARTER 2 STARTER 3 FUNCTIONS If there is an external crank relay you can use the crank function E2018 on a digital output The behavior will be exactly the same as for the crank relay output terminal A1 If there is an external fuel relay you can also use the fuel function E2019 on a digital output The behaviour will be exactly the same as for the fuel relay output terminal A2 For multiple starters E1138 2 or 3 the outputs can be configured with the Starter 2 E2267 and
86. ATION COM amp COM2 161 A53 Z0 9 0020 N EN Technical documentation 17 2 COM CRE TECHNOLOGY INTER MODULES CAN BUS This CAN bus is used as a communication means between modules GENSYS 2 0 MASTER 2 0 from a single power plant Features are SG Active and reactive load sharing Automatic load unload Static paralleling Dead bus management Other data exchange SG SG SZS gt Standard CAN bus rules apply here Please refer to chapter above to connect your modules properly through CAN bus I7 2 1 CAN BUS FAULT CAN communication between CRE Technology modules is continuously checked by each module on the CAN bus The quantity of modules connected to the CAN bus should always be the same as the quantity of modules declared inside each product sum of GENSYS 2 0 MASTER 2 0 modules parameters E1147 and E4006 respectively Otherwise a CAN bus fault is triggered This can also be the case if Two or more units share the same module number check parameter E1179 on each module 1200 termination resistors are not used correctly see chapter above CAN bus cable is not properly connected This CAN bus fault can only be reset when the correct number of modules is seen on the CAN bus As with every protection the way to handle a CAN bus fault can be selected among the list below This is done using parameter E1259 E1259 value Behaviour when a CAN bus fault is triggered Gene
87. Alarm Message The GENSYS 2 0 is able to monitor diagnostic messages DM1 from the J1939 engine ECU Only relevant diagnostic messages are taken into account and used in the GENSYS 2 0 fault alarm system GENSYS 2 0 is able to understand and interpret messages for display process and protection RESET message DM3 is sent to the engine when internal GENSYS 2 0 RESET is activated RESET button or internal variable If the diagnostic message is not sent by the J1939 ECU for more than 3 seconds the corresponding fault alarm is automatically reset to OFF Each of the following J1939 messages alarms can be configured to serve one of GENSYS 2 0 protections see 13 for more details on protections J1939Alarm Message Fault control Alarm Message description 0 1 active E0332 E1857 high level threshold set E0358 E1862 high level threshold set E0343 E1859 severe high level threshold set E0356 E1861 severe high level threshold set E0339 E1858 low level threshold set E0355 E1860 low level threshold set E0359 E1863 related trouble code active Protection lamp CT Protection Message used to relay trouble code E0363 E1864 information that is reporting a problem with an engine system that is most probably not electronic subsystem related For instance engine coolant temperature is exceeding its prescribed temperature range Amber lamp CT Amber Message used to relay trouble code E
88. Analogin09 0294 00 16384 analogueinput10 Analogin10 0295 00 16384 analogueinput11 Analogin 11 0296 00 16384 analogueinput12 Analogin12 0297 00 16384 analogueinput13 Analogin13 0298 00 16384 analogueinput14 Analoginl4 0299 00 16384 analogueinput15 Analogin15 0300 00 16384 analogueinput16 Analogin16 0301 00 16384 analogueinput17 Analogin17 0302 00 16384 analogueinput18 Analogin18 0303 00 16384 analogueinput19 Analogin19 0304 00 16384 analogueinput20 Analogin20 0305 00 16384 analogueinput21 Analogin21 0306 00 16384 analogueinput22 Analogin22 0307 00 16384 analogueinput23 Analogin23 0308 00 16384 analogueinput24 Analogin24 0309 00 16384 analogueinput25 Analogin25 0310 00 16384 analogueinput26 Analogin26 0311 00 16384 analogueinput27 Analogin27 0312 00 16384 analogueinput28 Analogin28 0313 00 16384 analogueinput29 Analogin29 0314 00 16384 analogueinput30 Analogin30 0315 00 16384 analogueinput31 Analogin31 0316 00 16384 analogueinput32 Analogin32 0347 00 16384 analogueinput33 Analogin33 0318 00 16384 analogueinput34 Analogin34 0319 00 16384 analogueinput35 Analogin35 0320 00 16384 analogueinput36 Analogin36 0321 00 16384 analogueinput37 Analogin37 0322 00 16384 a
89. CORE is a Generator management module e Several power plants possibilities e Same motherboard as the GENSYS 2 0 product family GENSYS 2 0 CORE is able to perform all GENSYS 2 0 features GENSYS 2 0 CORE can be controlled using different ways A53 Z0 9 0020 N EN Technical documentation Chapter GENSYS 2 0 CORE 17 e Connected to a RDM 2 0 remote display module e Remotely using your favorite Internet Web browser and by using digital inputs programmed to be used as AUTO MAN START STOP OPEN CLOSE GENERATOR BREAKER OPEN CLOSE MAINS BREAKER buttons e 3 USER INTERFACE WITH A RDM 2 0 The RDM 2 0 is a remote display module that is connected through Ethernet to the GENSYS 2 0 CORE This way GENSYS 2 0 CORE can be easily controlled and set up in the same way as a GENSYS 2 0 module Please refer to the RDM 2 0 technical documentation A53 YO 9 0020 x En Technical documentation to connect your GENSYS 2 0 CORE to a RDM 2 0 2 4 USER INTERFACE USING DIGITAL INPUTS According to your application some digital inputs can be used to simulate the control panel buttons of a GENSYS 2 0 You have to select the following input functions to simulate the button Value Function Description 2227 Manual start request To be selected if a remote start command is to be installed To be selected if a remote stop command is to be installed 2228 Manual stop request H Note this is not an emergency stop 3336 Gen breaker Close To be selected if
90. DHCP usage on Ethernet bar graph will stop at 97 even if firmware was successfully upgraded Factory parameters inside the new firmware set up the Ethernet to use a fixed IP address so this disconnects communication between the module and your computer You can reset communication by setting back DHCP configuration for example using the module front panel Activate DHCP in menu System Communication ports config COM4 ETHERNET Switch your module OFF and ON again to initiate DHCP communication Otherwise please see 6 3 in this documentation to setup your computer for communication with factory setup modules 17 7 3EXPORT IMPORT A TXT FILE ON SD CARD N v3 These functions are featured starting from firmware v3 00 1 Export a text file to SD card Exporting a TXT file gives you the ability to save parameters and equations of your module into an SD card Exporting a TXT file can be done either from the front panel or from the embedded Web site Go into menu System Communication ports config COM6 SD CARD Module gt SD then select Yes and click on Save button Exported file name will be in the form of PARAMOOx TXT Exact name will be displayed on the screen The filename will use the smallest value available If none is available then existing file will be replaced A53 ZO 9 0020 N EN Technical documentation Chapter Communication 198 Mozilla Firefox Fichier Edition Affichage Historique M
91. Dead bus management will be done via inter GENSYS digital E1515 CAN bus COM2 port No 1 External logic controls dead bus management Voltage schema Triphase 120 0 Voltage system selection See 14 15 for more details E4039 Biphase 180 1 Monophase 3 TABLE 80 POWER PLANT CONFIGURATION 1 Only available on level 2 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 211 19 3 2 POWER MANAGEMENT SYSTEM Load dependant start stop This menu allows to set the parameters concerning automatic start stop of generating sets according to the load as described in 14 13 Parameter Possible value Comment var num E1258 load of the power plant number hour meter E1617 E1617 value should be different on each GENSYS 2 0 Optimised ctrl 0 No O Engine stops if the global load of the plant is below the 1914 1 Yes stop threshold 1 Engine stops if the remaining generating sets are not going to be loaded over the optimal load level esol __ engine wii be requested to start and sare the ad on E1256 engine will be requested to start and share the load des vilbesoppet Useguneneigiec nn Ee E1254 will be stopped Used when E1914 0 FE 8 S I for mamine enges Oe when E1915 E1914 1 a O censte owt as a generating set to siop sharing the ad E1257 GENSYS 2 0 will ask a generating set to stop sharing the load tess __ E E1255 sets in load unload management TABLE 8
92. E EE EE eanieahoes 240 Figure 91 Downloda 1090 STEP Javed 240 NNN 242 Figure 93 Information SCLEON ccccceeseevecsoeseesccsocssesccucessescenccsessceuscseescencessesscuccseessencessescenceseessesccsssscencesesscencessessensessess 243 Foure A Speed Tr gu OA T OS E EE EET EE ANETE E TEE 244 Figure 95 Voltage regulation GOLGI SEN 245 Figure 96 Several generators WALNING seeecccenneeeecccnseesececsauseeeesaausseeessauseeeeesaeeeeeessauusecessauusecessaunseeessauasecessauseesssagasses 246 Figure 97 One generator with mains warning seessseseesseeressserressserressreresssreresssreressserressserressreresssreressserresseerressrerene 246 Figure 9S Access tO CRE ENN riria oair n aa E EN OT E E AEA EA 250 Figure 99 CRE Technology Astors rsirrreiaren iis Annea EEA E RARA E EE EE EDE iA 251 A53 ZO 9 0020 N EN Technical documentation Chapter Overview 11 List of tables Tape OIG ee Ge OE EEE EE EE 18 Table 2 LCD screen AArader su 4avrvrvam pa ened eid dnne 22 Pen Er 23 K PA 0 SEE EEE EE ates dearer 24 Table 53 Control panel keys ERE EEE EEE 25 Table o C19 1184 91011 lt 1 9 EEE EE OANE ASETE EE EEE 26 Table 7 NNN 33 Table 8 Authorization levels and PaSSWOrdS sscccseeccsesetseseecenecccesescusessuseetsuscscusesseneesenecsauecsausesseesseneessusessesessanessansees 35 Table 9 Typical basic change over CONFIGUIATION c seccccseeececeesesccuescscsusececssesssuecstsusesecueesssuecsssuses
93. Excel logger CSW Fichier Edition Affichage Insertion Format Outils Donn es Fen tre DSA gahar amp SL Trier Arial 0 G 7 5 Filtrer E A v A 255 1 0 331 23 12 00 21 16 Formulaire A B Sous totaux 1 E2071 E2055 E2056 E0041 Meee Table 2 1255 10331 23 12 00 21 16 12 3 255 1 0 332 23 12 00 21 16 13 i 255 1 0351 231200 21 5 255 1 0351 231200 21 E 255 1 0 332 231400 21 255 1 0 332 231200 21 8 2551 0351 231200 21 ER 255 1 0332 231 A00 21 255 1 DER 231400 21 255 1 0 332 25 12 00 21 12 2551 D331 23 12 00 21 13 255 1 O 331 234200 21 14 255 1 D331 23 12 00 21 255 1 BEER 231400 21 qh 255 VNR 9384 900 1 M 4 H logger Pr t SG 16 14 Consolider 16 15 16 16 Var le iA Rapport de tableau crois dynamique 16 15 16 18 16 20 16 20 16 22 16 23 16 24 16 25 APA Grouper et cr er un plan Donn es externes Select the first column A with saved values Click on Data then convert Select limited Select Table Comma and Semicolon Click Next SZS gt SG Assistant Conversion Etape 2 sur 3 Cette tape vous permet de choisir les s parateurs contenus dans vos donn es Yous pouvez voir les changements sur votre texte dans l aper u ci dessous Separateurs if Tabulation Espace Autre Interpr ter des s parateurs identiques cons cutifs comme uniques Identificateur de texte i Point virgule Apercu d
94. Figure 37 Mounting brackets on GENSYS 2 0 scccccsssccccsssecccsescccaaesescaseccssusecssauseessuseecsaunecssaueeesauaecesauasessaussessuasessagaeeess 69 Figure 36 ET ON area 70 Figure 39 Power supply circuit DFCQKES cccccseecccsneeccnsuseccsausecsauusecsausecesausecssaueeessueessaunecssaueesauaecesauaeessauseessaueessaaaseees 70 Figure 40 Interconnection of all battery NEGATIVES ccccsseesecccssseseecccsusececcsusecessausecsssaussecsssaunsecsssaussecessauaseessaaaeseeeeas 71 Me go 0 E A A mee E POP ae ry bre Reet orn E ere are oper ee eran one ween eer en E E eer 75 Figure 42 CONNECTION NEROS 78 Fe 79 Figure 44 Caterpillar PEEC and ADEM connections rrrnnrrrrrnnnnnnrvrnnnnnnrrrnnnnnnrrnnnnnnnrrrnnnnnerrrrnnenrrrrnnnsesrrrnnnenrennnnesssnnnnnesssee 80 Figure 45 Speed and voltage control with Contacts PUISCS sssscseceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 80 Figure 46 Speed and voltage control pulses rrrrranrrrrnnnrrrnnnnrrrnnnnrrrnnnrrrrnnnrrrnnenrrrnnenrrnnnnrrrnnesrrnnnenrsnnnssrnnnnsrennnesrennnesrnnnnseee 82 ea 83 Figure 4g Breaker WING EEE EET EEE EE ETNE des 86 TN 88 Figure 50 Connections for water preheat pre lubrication and pre GIOW rrrrrnnnnnrrrrnnnnnrrrnnnnnnrrnnnnnnnrrrrnnenrrrrrnnenrrrrnnneneeee 90 FIGUrE 51 CONNECTION OP AF ONS ccasindececaccesixdundeniasedeoateats veasenaisdetieedaenalaiestectade pias teed EE ONER EA 91 Figure 2 92 FEN 93 F
95. Figures below show the difference between standard and optimised mode behaviour of a 4 100kW power plant with a load increasing linearly from 0 to 400kW and then decreasing to OkW In these examples engine 1 is always running When the load increases above the start threshold engine 2 starts to help engine 1 then engine 3 and engine 4 When the load decreases engine 4 is the first to stop later followed by engine 3 and engine 2 as the global load continue to decrease In standard mode start threshold E1256 is set to 80 and the stop threshold E1254 is set to 20 In optimised mode start threshold E1256 is set to 80 and the optimised load threshold E1915 is set to 65 In this mode we can see that when an engine decides to stop the load on the remaining running engines is just below the optimised load value set in parameter E1915 A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 131 100 20 100 20 100 20 100 100 20 100 20 100 20 100 1 N HH tttt Y 0 Nr ce 2 0 X 5 0 EEE ee E oO SM EP 5 h e
96. For further details on programming equations see 16 4 Note The L1 and L2 equations file size must not exceed 60 kB 16 3 7 END OF FILE Every text file must end with the END OF FILE statement The module will not try to read data following that statement so you can place your own comments here Note It is strongly recommended not to add too many comments after the End of File statement because the size of the file must not exceed 126 kB Warning This file is a text ONLY file Do not use word processors like Microsoft Word to edit this file it would include layout information and corrupt the file Use text editors only Notepad for example The file should not exceed 126Kbytes If you try to transmit a bigger file to a module it will be rejected Warning Power control and protections are disabled while the module is processing a file When you download or upload a file you have to disconnect all connectors except power supply You must be in manual mode with engine stopped A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 154 16 4 WRITING CUSTOM PLC EQUATIONS It is strongly advised that you follow a specific training before using custom PLC equations on a power plant Contact your local dealer for details on training sessions PLC equations use a simple language with a small number of commands The code is intrinsically linear each equation being executed on
97. GENSYS e O FAMILY technology e 20OLT CORE 2 0 MARINE All in one generating set control and paralleling unit Part Number A53 ZO 9 0020 i 7 i 7 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 E amp OE CRE TECHNOLOGY Q 130 All e Victor Naudin Zone des Templier 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 ia x NOTE Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Apply all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage Motors turbines and any other type of generator must be equipped with protections overspeed high temperature low pressure depending on the power plant Any changes of the normal use of the equipment can cause human and material damage For further information please contact your CRE Technology distributor or the After Sales Service Team All CRE Technology products are delivered with one year warranty and if necessary we will be happy to come on site for product commissioning or troubleshooting The company also pr
98. GURATION Mains brk ctrl E1992 Mains breaker control GE brk ctrl E1993 Generator breaker control 224 A53 Z0 9 0020 N EN Technical documentation 4 Expansion outputs To configure the expansion outputs the CRE Config software must be used For more details on the expansion outputs configuration see chapter 17 3 1 Chapter Menu overview 225 A53 Z0 9 0020 N EN Technical documentation 19 3 9 TIMERS This menu allows setting up the timers e Engine e Mains 1 Engine This page describes the settings for the engine start sequence See 8 for more details Parameter Comment var num E1990 E1145 cranking E1157 cranking E1135 start attempt E1633 E1146 E1136 Warm up time Time to wait before taking the load to allow the engine to warm E1139 3 up E1140 alarm because of an unstable speed E1141 alarm because of an unstable voltage E1514 when starting the engine Time after a sensor lost security fault will be trigger if no signal is E1458 read from speed measurement input E1142 E1143 E1144 being put at rest TABLE 103 ENGINE TIMERS CONFIGURATION Chapter Menu overview 1 Only available on level 2 2 Available if an external start module has been selected 3 Not available if an external start module has been selected 226 A53 Z0 9 0020 N EN Technical documentation 2y Mains Parameter Comment var num E1
99. HIFT keys A53 Z0 9 0020 N EN Technical documentation Chapter Operating mode 4A Using STOP button while generating set breaker is open will stop the engine after the standard cool down sequence A second STOP request will stop the engine without waiting for the cool down duration Using STOP button while generating set breaker is closed will start the standard unload sequence open the breaker and stop the engine after the cool down sequence GENERATING SET 1 When the generating set is running the Open Close generating set breaker button will switch the generating set on load Depending on its setup island mode paralleled with Mains or other generating sets GENSYS 2 0 will automatically use the appropriate process synchronization if bus bar is live closing the generating set s breaker loading ramp if bus bar is live Then it will manage the load depending on the setup load sharing fixed kW setpoint 2 When on load Open Close generating set breaker button will set the generating set off load unload ramp if paralleling mode is selected and open the generating set s breaker The generating set will be left running until the STOP button is pressed 9 EE ee Synchro egenset breaker Start sequence Generating set ready G Open breaker Cool down amp Stop Py On load Immediate v stop Open genset breaker amp Stop FIGURE 15 ASSI
100. ID of the CANopen extension module most modules use DIP switches to set their ID 2 The type of data contained in the message analogue or digital 2 The Number of input output channels in the message Note a CANopen message can handle a maximum of 4 analogue values or 64 digital values The total number of CANopen inputs outputs available is SZS 44 analogue inputs 128 digital inputs 32 analogue outputs 64 digital outputs SZS SG SG To ensure proper communication between GENSYS 2 0 and CANopen extension modules the following rules should be followed For a given CANopen module always group the maximum number of data of the same type in one message For example it is better to set up one message with 50 digital inputs than 2 messages with 25 digital inputs each Always group messages to from one CANopen module For example do not use output messages 1 and 3 with CANopen module number 1 and message 2 with CANopen module number 2 It is preferable to use messages 1 and 2 with module number 1 and message 3 with module number 2 CANopen inputs and outputs can be accessed using GENSYS 2 0 variables as described below GENSYS 2 0 variable Description numbers E0157 to E0284 CANopen digital inputs 1 to 128 E0285 to E0328 CANopen analogue inputs 1 to 44 TABLE 60 CANOPEN INPUT AND OUTPUT VARIABLES The lower variable number is associated to the lower message number configured
101. LOAD DEPENDANT START STOP CONFIGURATION 1 Only available on level 2 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 212 Heavy consumer control Q This menu is only available in modules from the MARINE range This menu allows the setup of parameters used for the management of heavy consumers as described in chapter 14 13 Parameter Possible value Comment var num Authorize on 0 Disable Inhibits heavy consumer control or select criteria used to E1913 1 kW authorize the use of a heavy consumer 2 Min No 3 kW amp Min No E1911 consumer n 1 E1912 consumer n 1 E4121 consumer n 2 E4122 consumer n 2 E4123 consumer n 3 2 Avail kW reg 4 Power that needs to be available in order to supply heavy E4125 consumer n 4 Min no GE rq4 Minimal number of running engines in order to supply heavy E4126 consumer n 4 Delay betw req Delay before processing a heavy consumer request after an E4127 authorization has just been issued for another request Power reserve Amount of kW that should always be kept available on E4128 running generating sets If this power is not available an additional engine will start Min no GE rq3 Minimal number of running engines in order to supply heavy E4124 consumer n 3 Chapter Menu overview TABLE 82 HEAVY CONSUMER CONTROL MENU 213 A53 ZO 9 0020 N EN Technical documentation Non essential consumer trip gt This menu
102. NTRODUCTION Non essential consumer trip is the ability to disconnect less important consumers to prevent a black if the power plant is overloaded If the generator reaches the overload or under frequency threshold for a given time GENSYS 2 0 activates outputs to trip non essential loads Chapter Advanced marine functions 15 2 2 SETTINGS Parameter var num comment Min Hz trip E1905 under frequency control for non essential consumer trip Min Hz level 1 E1903 First level of under frequency control l Second level of under frequency control H 2 E1904 a Eton Should be set lower than level 1 Max kW trip E1908 Enable disable overload control for non essential consumer trip feature Max kW level 1 E1906 First level of kW overload control 142 A53 Z0 9 0020 N EN Technical documentation Second level of kW overload control Max kW 2 E1907 sk Should be set higher than level 1 Level 1 delay E1909 Delay for the first level of control KW and Hz Delay for the second level of control KW and Hz eve Should be set shorter than level 1 delay TABLE 45 SETTINGS NON ESSENTIAL CONSUMER 15 2 3 RROCEDURE Using the two levels of thresholds and delays you can setup your system in order to react more or less rapidly depending on the severity of the situation When one of the two control levels is reached and its associated delay overdue variable E2729 Trip alarm switches to 1 and the trip
103. Output 7 gt Ww 2 55 12 To battery positive normally closed direct supply to crank and fuel relay outputs C1 to C5 Output 1 to 5 2 5 12 A53 ZO 9 0020 N EN Technical documentation Emergency stop Generator voltage measurement 100 to 480 Vac line to line Frequency 50 or 60Hz nominal measurement from 35 to 75Hz These lines must be protected externally with 100mA 600Vuc fuses Mains voltage measurement 100 to 480Vhc line to line Frequency 50 or 60Hz nominal measurement from 35 to 75Hz These lines must be protected externally with 100mA 600Vuc fuses Transistor output powered by the supply voltage lt 350mA per output Over current protected Reactive load Each output can be configured with a predefined function or programmed with custom equations see details in 12 2 1 C5 can also be used as a watchdog output by default Chapter Description 28 Terminal Terminal Description Capacity Comment mm AWG Two configurable relays with one terminal in common Factory setting uses one relay for closing and one EE 25 12 for opening the MAINS breaker Isolated contact 240V 5A See also 11 4 1 Generating set open 2 5 12 breaker Two configurable relays with one terminal in common Generating set close 2 5 12 ee Factory setting uses one relay for closing and one for opening the generating set s breaker Generating set 2 5 12 Isolated contact 240V 5A Se
104. Protection type Threshold Timer Control TABLE 99 ENGINE BATTERY PROTECTIONS CONFIGURATIONS Note The parameters E1183 and E1187 allow setting the protection direction of the spare analog inputs 1 amp 2 If we considered a maximum threshold or a minimum threshold to not cross O0 means a maximum threshold 1 means a minimum threshold 19 3 7 INPUTS 1 Digital inputs They are split between the dedicated inputs J1 to J3 and the configurable inputs J4 to J5 For more details on the digital inputs configuration see chapter 12 1 2 Analog inputs To configure the analog inputs the CRE Config software must be used Chapter Menu overview For more details on the digital inputs configuration see chapter 12 3 3 Expansion inputs a To configure the expansion inputs the CRE Config software must be used ke For more details on the expansion inputs configuration see chapter 17 3 1 O 222 A53 ZO 9 0020 N EN Technical documentation 4 Virtual inputs Virtual digital inputs are designed to offer more features to the end user They can be programmed via equations or can copy the status of external CANopen linked inputs Cx For virtual digital inputs 1 to 40 label validity direction and function have to be defined SR l Variable numbers E2283 to E2302 and E2565 to E2584 To configure the virtual inputs the CRE Config software must be used Label The name you give to the virtual inpu
105. R fully CW MX321 Al TRIM pot of AVR fully CW STAMFORD Al TRIM pot of AVR fully CW BASLER 7 Remove shunt AVC63 4A APR63 5 APR125 5 SSR63 12 DECS32 15 xxx Use VAR control included in the DECS DECS63 15 xxx DECS125 15 xxx DECS300 VAR SX440 MARATHON ELECTRIC BVRI0I 1100 e JAUPUER AuxinputB DvR2000 J o b AVK CosimatN 255 10 Pte Pt e a OOo O A1 MarelliMotori 470nF capacitor between 8 and M 470nF capacitor between 6 and M Jumpers have to be removed MECC ALTE SPA UVR6 Pot 50k0Q in serial with H2 0 LEROY SOMER R450 150 230 Pot input Pot input Add shunt to select 50Hz Remove LAM Pot input Pot input Pot input 7 Pot input Manufacturer AVR gain E1103 AVR offset E1104 TerminalH2 Terminal H4 Comment CATERPILLAR DVRKVAR PF 1300 200 B a o a a o o 1 5KQ in serial with H2 CDVR P12 6 P12 3 SINCRO EXTPOT EXTPOT Remove A ET shunt potentiometer V of AVR fully CCW TABLE 22 AVR PARAMETERS A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 85 NY RELAY OUTPUT 1 4 BREAKERS GENSYS 2 0 is equipped with 4 NO relays at rest for breaker control 2 relays to control the generator breaker one for opening E4 and one for closing E5 2 relays to control the mains breaker one for opening E1 and one for closing E2 Gensys 2 0 MAINS Functionning mode set with E1992 Mains Open breaker Mains Close bre
106. S OS AS EAS AS OAS S AS AS OS S AS AS OS S AS AS OS IAS OS RK AS S O you need only change the Chapter I O lines GEO Os Manalog input opare i QE oaa VEN ap QAAKKKKKAKKKKKK DS IS E DS S S E DE S KKK KKK KKK KK O SSS 108 A53 Z0 9 0020 N EN Technical documentation 13 PROTECTIONS Protections are triggered by different events digital inputs and logic sequences They take action to protect a process engine or alternator When configured they can take the actions listed hereunder 13 DISABLE This gives no effect 13 2 GENERATOR ELECTRICAL FAULT This action triggers a Generator electrical fault Protection will open genset breaker and try to re synchronize again Number of attempts can be configured 13 3 MAINS ELECTRICAL FAULT This action triggers a Mains electrical fault Protection will open mains breaker and will start the generator and take the load if the parameter E1841 start on fault is set to 1 Configuration Mains Bus mains electrical fault menu The mains back is validated by the timer E1085 Configuration Timers Mains menu In change over mode the time between the emergency open and the normal close is managed by the timer E1459 Configuration Timers Mains menu In no break change over mode the load transfer time between the normal towards the emergency and conversely are defined by the timers E1151 load ramp and E1152 unload ramp Configuration Gene
107. STED MANUAL MODE WITHOUT MAIN PARALLELING A53 Z0 9 0020 N EN Technical documentation Chapter Operating mode 45 MAINS Option 2 Mains paralleling must be enabled 1 When in On load state and if Mains Bus bar is live the use of Open Close Mains breaker button will trigger the appropriate sequence depending on the power paralleling mode setup Change over no break change over paralleled with Mains GENSYS 2 0 will synchronize the generating set if needed close the Mains breaker perform a load ramp Then it will manage the load depending on the setup load sharing fixed kW setpoint 2 When paralleled with the Mains pressing the Open Close breaker buttons will open the appropriate breaker and let the generating set running until STOP button is pressed No break change overmed Synchro amp Close Mains breaker Load ramp amp Open genset breake Synchro amp l Close genset breaker Start sequenc Genset Generating set ready ime dale stop Open breaker wo Cool down amp Stop Open breaker amp stop i Pen k ge Immediate Ser bre is Genset Genset Mains load Open genset breaker Cool down amp Stop Assisted manual mode FIGURE 16 ASSISTED MANUAL MODE WITH MAIN PARALLELING WARNING As the assisted manual mode is a kind of automatic mode variable E2055 Auto mode is equal to 1 and variable E2056 M
108. Starter 3 E2268 functions The number of attempts E1134 is the global number and not the number of attempts per starter For example The number of attempts E1134 is 4 The default starter E1602 is 2 The number of starters E1138 is 3 Output 1 terminal C1 is configured as Starter 2 E1260 2267 Output 2 terminal C2 is configured as Starter 3 E1261 2268 Should the engine refuse to start the sequence will be C1 activated crank rest C2 activated crank rest A1 activated crank rest C1 activated start failure Note For each starter s functions Starters 1 to 3 there are separate parameters for starter disengagement relative to engine speed which depend on starter type electric pneumatic These parameters are available in the menu Configuration Engine Crank settings Sta 1 drop out E1325 400rpm Sta 2 drop out E1326 380rpm level 2 Sta 3 drop out E1327 380rpm level 2 A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 89 1 6 WATER PREHEAT PRE LUBRICATION PRE GLOW FUNCTIONS J6 Spare Input 1 Preheating 2273 J7 Spare Input 2 Manual water preheat 2224 Pre heat relay J8 Input 3 Spare Manual oil prelub 2225 el alc J9 Spare Input 4 Manual preglow request 2226 Output 2 C2 Pre lubrication relay J10 Input 5 Manual start request 2227 Output 3 C3 Pre glow relay Water Oil pressure Output 1 function E1260 Water preheats 2
109. TCP communication ports 4 e Write access to date time counters Note that 32 bits variables must be written using function 0x10 only see table below e Global write access to all configuration parameters gt See chapter 19 4 55 for more details concerning Modbus access rights 189 A53 Z0 9 0020 N EN Technical documentation WARNING The autosave is not activated for the Modbus writing To save the modified parameter by Modbus see 6 2 2 32 bits variables Description E0025 Generator kWh E0061 Mains Bus kWh E0063 Mains Bus kVARh E0065 Engine running hours E0125 Generator kVARh TABLE 72 32 BITS VARIABLES USE FUNCTION OX10 GENSYS 2 0 registers start from address 0 Depending on your MODBUS master equipment and software you may need to use an offset of 1 when reading writing registers as addresses may start from address 1 In this case you will have to request address register number 1 to access variable E0000 inside your GENSYS 2 0 Refer to document Z0 90030 xIs to get the complete list of existing variables MODBUS communication is setup using menu System Serial ports configuration Communication parameters are listed in the table below Parameter Description and acceptable values MODBUS slave address E1634 MODBUS address of CRE Technology module in the communication bus This address must be unique and setup between 1 and 247 Note the module will not accept broadcast requests e requests
110. Table 37 Generator electrical fault cccccccssseseccccsesecccnseseccensaseeceesaseeeesseeseeseeseueeessaaunsesesaaensessssaansesessaunseesssaaaseseaas 119 Table 38 Wiring GENSYS 2 0 and Auto Start MOdUIe ccccccssecceecccesecceseccenecscuecscesessenesseneceesessesesseestenecseuseesesesuenes 120 Table 39 Wiring GENSYS 20 s gt TEM vasene 129 Table 40 Use of E1617 porame tel seinenc a a aaa eni r ina 134 EN NNN 136 oe 138 ENN NNN NNN 140 Table 44 Useful variables on heavy CONSUMET ssssccccuseseececsneseeccnsueneecccsneseeeessauneesesaauneeesssaunsesessauneeesssauasesessaueeeseas 140 Table 45 Settings non essential CONSUMET scccceeeceeescccesecceseccanecscscscsessesessenecssusesuesessenessesctsusessesesseseetenestssesuesessages 143 Table 46 Label definition DI OC eee 150 Table a7 CUSTONT logo Nr 150 FEN 151 TOS GE EG CO EE EEE NE AOE eo niaee 151 Table 50 Variables with Customizable unit accuracy Values rrrrrrrrrrrrrrrrnrnrrrrrnnrrsrrrrrssrsssssssssssssssssssssssssssssssssssssssssssseee 153 Fo 6 dd KEN B 4 E e EEE NE EE NES Pe ee ne eee eee ee ee A ee ee 160 Table 52 Maximal length communication speed rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrnrsrsrsrsrssrssssssssssssssssssssssssssssssssssssssssssssssssssssssee 161 Table 53 Speed communication COMI Sc COM 2 esirin ata EENET 161 De MN 162 Table 55 Broadcast data sent on inter module CAN DUS rrrrnnnrrnnnnrrrnnnnrrrnnnnrnnnnnrrrnnnnrrrnnnrrrnnenrrrnn
111. The following example will help you understand the relationship between GENSYS 2 0 CANopen variables and physical CANopen I Os A53 ZO 9 0020 N EN Technical documentation Chapter Communication 171 2 CANopen mapping example In this example 3 CANopen modules are connected to CAN bus COM2 of GENSYS 2 0 All these modules offer different kinds of input CANopen Physical I O on the CANopen coupler extensions 4 analogue inputs 4 20mA 1 2 analogue inputs PT100 Coupler ID 2 logic inputs 2 thermocouple analogue inputs 2 ro a Q O QO 4 logic inputs 3 10 thermocouple analogue inputs Coupler ID CANopen input message setup Message n 1 ID 1 Type Analogue No of inputs 4 Message n 2 Di I Type Analogue No of inputs 2 Message n 3 ID 1 Type Logic No of inputs 2 Message n 4 ID 2 Type Analogue No of inputs 2 Message n 5 ID 2 Type Logic No of inputs 4 Message n 6 ID 3 Type Analogue No of inputs 4 Message n 7 ID 3 Type Analogue No of inputs 4 Message n 8 DER Type Analogue No of inputs 2 TABLE 6 CANOPEN CONFIGURATION EXAMPLE A53 Z0 9 0020 N EN Technical documentation Input variables E0285 E0286 E0287 E0288 E0289 E0290 Chapter Communication 172 17 3 2 COMe COMMUNICATION J1939 J1939 is a CAN protocol used with modern electronic ECU It allows reading engine data oil pressure water tempera
112. This language uses simple keywords in an ASCII text file It is stored as a binary program for use with flash memory A copy of the source file is also stored on module for documentation and readability purposes This copy can be retrieved at any time to be modified or transferred to another module These equations can be used to add a logic equation and or conditional function if your application requires non standard functions It is also possible to change the predefined behavior with custom applications The PLC provided has a loop time of 100ms and a special code can be defined to run the first time only INIT This chapter provides all resources for PLC programming A text file can be transferred to 19 4 7 or from 19 4 6 the module to set or retrieve the whole setup of the module The text file allows you to Set the value of every parameter Change the units of analogue inputs example V mbar PSI Change the accuracy when displaying analogue values example 24V or 24 0V Change the labels of some custom inputs and the screensaver Transfer custom equations to the embedded PLC 16 2 VARIABLE NAMING The file named A53 ZO 9 0030x xIs gives an explanation of each variable The variable number always uses the same format the letter E followed by 4 digits EXYYY The first digit X is the type of variable 0 and 5 Measurement or real time value Ex Voltage phase 1 CAN Bus Fault
113. UPDATE FIRMWARE This menu is only available in level 2 and on computer It allows updating the software with the latest version See 17 7 2 for more details 19 4 10 RESET FACTORY SETTING This menu is only available in level 2 It resets the factory settings of the module parameters labels equations See 16 6 for more details 19 4 ABOUT This menu displays some information on module and on Ethernet connection e Serial number e Software version e Boot software version e Module name e IP address e Gateway IP address e MAC address e DHCP status e Copyright for lwip See 17 5 2 19 5 DEDICATED SCREENS The dedicated screens are e The faults page e The alarms page e The information page 19 5 FAULTS At any time and any level you can click on the Faults link on your browser or press the FAULT key on the front panel Click BACK on your internet browser or press the button a second time to return to your previous screen The last 50 faults will be display as follows dd mm yy hh mn ss_ protec label XXXX On or Off XXXX is the variable number By pressing lt lt or gt gt you can change between the active faults 1 to 10 faults 11 to 20 faults A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 241 Faults 1 5 20 03 08 11 07 38 Input 4 2009 0ff 20 03 08 11 07 38 Input 4 2009 0n 20 03 08 11 07 38 Water temp 2004 0ff 20 03 08 11 07 37 Water temp 2004 0n
114. W This chapter describes how to interface GENSYS 2 0 with an engine featuring its own automatic start module In this case GENSYS 2 0 internal start sequence must be inhibited The following diagram shows the main functions of each device Note starting from firmware v4 00 GENSYS 2 0 features an easy configuration whereas older firmware versions require the use custom equation s In this case contact your local distributor or the CRE Technology technical support Auto Start GENSYS 2 0 Module Synchronisation Electrical protections Start sequence GE breaker control PF control kW control Monitoring Engine protections FIGURE 59 WIRING GENSYS 2 0 AND AUTO START MODULE ENSY Signal description Direction Auto Start Module ASM 5 2 2 Start request Fuel GENSYS 2 0 gt ASM ootionnel ASM gt GENSYS 2 0 Digital output Engine Alarm ASM gt GENSYS 2 0 Digital output Engine Fault ASM gt GENSYS 2 0 Digital output TABLE 38 WIRING GENSYS 2 0 AND AUTO START MODULE 1 See below if your external start module doesn t have a Genset Ready output 2 This is only an example Other GENSYS 2 0 inputs can be used Note The GENSYS 2 0 doesn t need the oil pressure and water temperature digital inputs A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 120 External Genset ready E2515 Engine ready Generator ready Waiting external Gen
115. WER PLANT WITH SEVERAL GENERATORS Variable Variable label Variable value number 1179 My Number 1 to 32 this value must be different for each device on the same bus 1147 Nb of gen 2 lt N lt 32 4006 1148 NoCh over 1153 X 1158 CAN bus 1177 1515 DeadBus manag Yes 1258 X TABLE 1 TYPICAL BASIC MULTI GENERATOR CONFIGURATION In this mode CAN bus on COM1 inter GENSYS 2 0 is used to manage the different units on the same bus This mode has better reliability and accuracy than equivalent analogue solutions A53 ZO 9 0020 N EN Technical documentation Chapter Predefined configuration 55 9 4 GENERATORS PARALLELING WITH GENSYS 2 0 AND PARALLEL LINE MODULES Analog load sharing lines I Ei FIGURE 23 GENERATOR PARALLELING WITH PARALLEL LINES Variable Variable label ET g ET ERE number 1179 My Number 1 to 32 this value must be different for each device on the same bus 1147 Nb of gen 2 lt N lt 32 4006 Nb of Master 1148 NoCh over 1153 X 1158 Analog 1177 1515 1258 Inhibited 1259 0 No action TABLE 12 TYRICAL BASIC CONFIGURATION FOR GENSYS 2 0 WITH PARALLEL LINE MODULES When GENSYS 2 0 is in analog load sharing mode the active power sharing is handled via the parallel lines You have to disconnect the AVR output H2 H4 and have an external device control the reactive power CT droop This mode is only recommended for use if you have older devices which are not co
116. YS 2 0 COMPATIBILITY esnenrerrannnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnennenen 157 16 6 RESETTING TO FACTORY PARAIVIE TER NN 159 16 7 DOWNLOAD A CUSTOM LANGUAGE FILE s sccossscccsscosnscvssscnuscnunscnscovauecensconssevsnscnsscnuuscnssevauacenscovssevsnscnnscnunscnscs 159 TT MINN 160 17 1 CAN BUS GOOD PRACTICES aes cias a snsatncetinccen to nR nan RANE E E RIN a RANEE R riai 160 17 2 COM1 CRE TECHNOLOGY INTER MODULES CAN BUS vavannerarnennrnennnnennnnennnnennnnennnnnnnnnnnnnnnnennnnennnnennnnennnnennnnnnnnnennnnene 162 17 3 COM2 CAN PROTOCOLS CANOPEN J1939 MTU MDEC ccccccccccccseccccenecsseenecseeeceseeeeucsseeueceeeueeeeeeeesseeaesess 169 A53 Z0 9 0020 N EN Technical documentation Chapter Overview e LOND ET EE one nalts EE RE NE saad EE EE EN tnaets 187 17 5 CINA ETE NET NN 187 17 6 COMS MODBUS RTU ON SERIAL PORT RS485 i vannenenvenenvnnenvunennunennnnennnnennunennunennunennunennunennunennunennnnennunenenneneuneneen 189 17 7 ENG DN 193 18 SUPPORT TROUBLESHOOTING eien 200 t19 NENUDMNENNEN errenneren iranerne 203 19 1 MENU INTRODUCTION noaren ner EEE E EA ES E RENA 203 19 2 PPT 203 19 3 CONFIGURATION MENUx eeresvevenvenenvenenvnenennsnnnnennnnennnnenennennuneneuneneuneneuneneuneneuneneuneneuneneunennunennuneneuneneuneneunennuneneen 210 19 4 STP 233 19 5 VET EN wea cesta ese tec see ated nite ain ti EEE wares EAEE EE 241 20 USEEFUL INFORIMATION ivssstistcicrcsccnevvics
117. Z0 9 0020 N EN Technical documentation E0022 Mains voltage E2201 Start request on J3 E2000 Mains breaker E0003 Genset voltage E2001 Genset breaker FIGURE 30 TYPICAL SEQUENCE IN PERMANENT MODE ON START REQUEST T1 Genset ready T2 Synchronization T3 Load ramp T4 Unload ramp A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 63 9 7 POWER PLANT PARALLELED WITH MAINS USING MASTER 2 0 OR GCIR Analog load sharing lines Synchronization bus kW kVAR cosphi CAN bus Load FIGURE 3 POWER PLANT PARALLELING WITH MAINS This application requires additional modules to manage the mains power supply Additional modules can be MASTER 2 0 recommended or GCR CPA not recommended for a new installation MASTER 2 0 uses all digital technology whereas GCR uses analogue load share lines sometimes called Parallel Lines With this setup base load or peak shaving regulation can be selected depending on your settings In base load mode GCR doesn t require CPA This chapter is a basic overview Full MASTER 2 0 functions can be found in the MASTER 2 0 technical documentation number 1179 Gen number 1 to 32 this value must be different for each device on the same bus 1147 Nbof units 2 lt N lt 32 VEELE Variable label Variable value Load Unl
118. act CRE Technology or your local distributor if your engine is not mentioned in this document The speed communication is fixed to 250kbits s A53 Z0 9 0020 N EN Technical documentation Chapter Communication 173 2 Supported manufacturer and ECU Manufacturer ECU Measure by J1939 Control by J1939 E4034 E4068 Oil Water Engine Speed Start Stop pressure temperature speed er h 0 SCANIA VOLVO EN ps a PERKINS GENERIC 0 3 IVECO 4 5 CUMMINS GENERICO KKK 7 EE ME VE NG ER m850 2 KK EE EE EE EE o JEC KK DET GENERIC O x xx 10 fun ta ta S EMR PP Pr EMR3IB KK MTU GENERICO xo xx x o 11 aDec 2000 1 KK ADEC 4000 2 x 1 xx 1 xp MDEC 13 To configure MTU MDEC see 17 3 3 TABLE 63 11939 MANUFACTURER ECU LIST x lt x lt x lt x xX xX xX xX xX a x xX Xx i aa XXX KK gt XXX X X XxX KX XX X x X DX Chapter Communication x lt 1 By default the output relay FUEL is inverted for the SCANIA engines If need the output can be set to initial state by setting the output relay FUEL as Unused 2 On IVECO engine the ECU is powered by the output FULE of the GENSYS 2 0 The output CRANK is activated with a 2 seconds delay by default settable by E4079 3 By selecting CUSTOM engine you will be able to define manually the frames to send 4 Cummins ECU can contain
119. ailure to follow instructions can cause personal injury and or property damage Contact your CRE Technology distributor for course training NOTE FOR GENSYS 2 0 LT This logo indicates that the function described in the chapter is not available in LT modules such as GENSYS 2 0 LT and GENSYS 2 0 LT MARINE The main features unavailable in GENSYS 2 0 LT are the support of custom equations and CANopen I O extensions If you ever need one of these features please use a standard GENSYS 2 0 module This logo applies to all MARINE units It is used in this documentation to highlight features that are specific to marine units or applications A53 Z0 9 0020 N EN Technical documentation Chapter Overview Table of content 1 OVERVEIE 15 1 1 EUROPEAN UNION DIRECTIVE COMPLIANCE CE ccececcecececcccecceceaccceacecsccecenceceacecenceceaceceaceceacecsaceeencecsaceceuceeeaceneaceneas 15 1 2 ENVIRONMENT aerea E sessions bandied oneal de clot eioamau ume seats A 15 1 3 IAB ACT ERIS UIC 5 suatacdcioenmaatteccinms ta aaa lseataceasine ciomaaianatlwedtsaadatss AAEE ne ticle scineadoemnac cmon atnadoanseatamenneste 16 2 GENSER 17 2 1 CHARACTER aaa A E E ETEA A ETEA 17 2 2 VEPS 17 2 3 USER INTERFACE WITH A RDM 2 0 ia ccscucclecsavesnwscudaulectauudiasseuwe lena usdumautiesloauiiadoaniesealebouslomaedeeladunued ieaiveralasueuesumses 18 2 4 USER INTERFACE USING DIGITAL INPUTS ccceccecececccceccececceceaceceaceceaceceacecsacecsacece
120. ain unchanged For the same reason a text file uploaded with PC language set to French will display only French labels You must switch to the desired language before uploading downloading a text file Change the language menu System Back light timer Languages Local language before changing the desired label 16 3 4 UNITS AND ACCURACY DEFINITION BLOCK The beginning of this block is shown by a UNITS statement This block defines what kind of units and accuracy will be associated with each analogue value input analogue inputs virtual inputs and CANopen analogue inputs You only need to define the unit of the analogue input itself All associated parameters thresholds for instance will automatically be modified in accordance This includes native analogue inputs extension CANopen analogue inputs and virtual inputs A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 150 The table below lists the different units supported by the module Only the 4 analogue inputs have an entry in this bloc see file named Z090030 xIs for variable number 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 input is as follows CONTES VIGO G U23 00 A0029 0000032768 The tables below give you the list of codes which correspond to the supported units an
121. ains U lt V1066 0 Za V2157 Mains U lt V1069 0 59 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 239 19 4 7 PC gt GENSYS 2 0 FILE This menu is only displayed on the computer It allows sending parameters file equations file or language file Use the Browse button to choose the file to download and click on save button When the operation is completed a screen will appear showing Compilation result Compilation successful Available space 63766 49 Esc Faults Alarms Information save modified parameters FIGURE 90 COMPILATION RESULT SCREEN Notes We recommend you first save the current configuration using the GENSYS 2 0 gt PC menu before making changes File transfer is only possible when engine is stopped 19 4 8 DOWNLOAD LOGO This menu is only displayed on the computer This menu allows you to change the screen saver logo on the module front panel Use the Browse button to choose the logo to download and click on save button When the operation is completed a screen will appear showing Compilation result Download successful Esc Faults Alarms Informations FIGURE 9 DOWNLOAD LOGO SCREEN Notes The picture must be a monochromatic BMP file of 72 54 pixels File transfer is only possible when engine is stopped A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 240 19 4 9
122. aker Mains Common GENERATOR Functionning mode set with E1993 Gen Open breaker Gen Close breaker Gen Common FIGURE 48 BREAKERS WIRING These outputs allow you to control various types of breakers This chapter explains available setups and their associated variables Variables E2001 E2016 E2017 E1149 E1992 E1993 E1994 E1995 E1893 TABLE 23 USED VARIABLES FOR BREAKERS SETTING Variables E2016 and E2017 let you see the breaker output control Whatever the type of breaker control a value of 1 mean close the breaker while a 0 mean open the breaker Variables E2000 E2001 and GENSYS 2 0 front panel let you see the breaker feedback 1 when breaker is closed When GENSYS 2 0 tries to open close a breaker a maximum is allowed before getting the corresponding feedback from the breaker This delay is set to 5 seconds factory and can be changed by adjusting parameter E1149 in menu Configuration Modification by variable n 1 Working modes The Configuration Outputs Breakers menu allows you to choose the working mode of these relays via parameter E1992 for the MAINS and E1993 for the generating set Table below explains the different working modes featured by GENSYS 2 0 E1992 MAINS Relay output Chronogram mode E1993 GENSET Continuous contact to open E1 Mains E4 Genset Positive pulse to close E2 Mains E5 Genset CLOSED OPEN 1 Con
123. alue isn t changed at every cycle Otherwise you may miss some values A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 155 16 4 EASY PLC CRE technology has developed a graphical tool to help you design equations that will help you adapt your module to your specific application File Edit Tools Help aca H sje oljene Sef me Projects 3 Libraries EJ Examples Ed Logic Y Multiplexer cre Execute sheet when E2810 0 v Comments AND D Output X2441 will be setto 1 whe 3 NAND D Filter cre input J15 is active during at least D OR D Logic_l cre It is reset if J13 is inactive C XOR D Logic_2 cre D NOT Arithmetic cre Reverse Comparisons cr Rising edge Falling edge g Arithmetic kE RE rh Category Variable Name Existing variables Constant E0000 Generator V1 E0001 Generator V2 E0002 Generator V3 E0003 Generator U31 E0004 Generator U23 E0005 Generator U12 Easy PLC 2012 CRE technology Easy PLC will check the syntax of your design and generate equations that you can then send to your GENSYS 2 0 unit using CRE Config software or the GENSYS 2 0 internal Web site Easy PLC is available for free on our Web site www cretechnology com Refer to Easy PLC manual for more details 16 4 2 ADVANCED PLC PROGRAMMING Advanced applications may require complex equations manually written using PLC programming la
124. anu mode is equal to 0 To determine the actual running mode you may prefer using LED status variables Chapter Operating mode 46 A53 Z0 9 0020 N EN Technical documentation 7 2 AUTOMATIC MODE Speed and voltage droop are inhibited in this mode the system is running isochronously i e the speed and the voltage remain unchanged whatever the load This mode has 4 main ways of operating 7 2 1 ONE GENERATOR WITH CHANGE OVER The generator starts with a remote start or in the case of mains failure When the generator is ready voltage frequency the mains breaker is opened and the generator breaker is closed Should the mains return to normal conditions or remote start is off after a programmed delay the generator breaker is opened the mains breaker is closed and the generator set is stopped 7 2 2 ONE GENERATOR PARALLELING WITH THE MAINS The generator starts with a remote start or if there is a mains failure Paralleling depends on configuration NO CHANGE OVER NO BREAK CHANGE OVER PERMANENT Load sharing can be on a base load or peak shaving peak lopping basis Depending on the configuration the generator will stop either when there is a remote stop or when mains power returns to a stable level 7 2 3 POWER PLANT WITH SEVERAL GENERATORS WITHOUT AUTOMATIC LOAD UNLOAD The generator starts with a remote start signal and parallels with the bus If there is a dead bus GENSYS 2 0 will check with t
125. ards up to 2 GB on boot firmware v2 xx and v3 xx Boot firmware v4 00 and above accept FAT32 SDHC cards To check your boot version go into menu System About To upgrade your module firmware please follow those steps SZS Connect your PC to the module internal Web site using password level 2 Backup parameters and equations if necessary e Copy the new firmware on an SD card and insert it into the module Filename must respect format XXXXXXXX H86 and the file should be provided exclusively by CRE Technology or its distributor network Go into menu System Firmware upgrade Click on List files Select the file you want to program into the module Click on Upgrade firmware SG oe e SZS SZS SZS Moteur arrete uniquement une mise a jour peut prendre jusqu a 5mn ne pas couper l alimentation Lister les fichiers Selectionner un fichier w Mise a jour du Firmware RECOVE 1 H86 RECOVERY h86 Esc Defauts Alarmes Information Shift I A bar graph indicates the progress of the process A53 Z0 9 0020 N EN Technical documentation Chapter Communication 197 Moteur arrete uniquement une mise a jour peut prendre jusqu a 5mn ne pas couper l alimentation Lister les fichiers RECOVERY h86 v Mise a jour du Firmware Mise a jour reussie Esc Defauts Alarmes Information Shift I Note If your module was setup for
126. arque pages utils 7 E http g2lab010a5320 q001 htm gt grlaboi0as320 9001 Atm Module gt SD Download text file Esc Faults Alarms Information Save modified parameters Note Exported content depends on the actual password level If you entered password level 1 custom level 2 equations that may be running inside your module will not be exported into the TXT file 2 Import a text file from SD card This feature gives you the ability to load parameters and equations from a file on an SD card into your CRE Technology module Importing TXT file can be done either from front panel or from the embedded Web site using menu System Communication ports config COM6 SD CARD SD gt Module File to be loaded must have a name respecting format PARAMOOx TXT Select the file of your choice and click on Save button Y Mozilla Firefox Fichier Edition Affichage Historique Marque pages utils 7 c I hitprltgalabo10a5320 9002 htm O Pl gt gAab0l0a53z0 g002 hem O D SD gt Module O QO Upload text file T PARAMOO1 TXT 2 am UO Esc Faults Alarms Information Save modified parameters WARNING For safety reasons parameter E1929 Phase offset Used for example with Dyn11 transformers will not be changed when importing a text file This parameter must be adjusted manually Note Imported content depends on the actual password level If you entered password lev
127. ast data are not influenced by the value of these inhibition variables so it is still possible to send and receive broadcast values between inhibited GENSYS 2 0 Example below shows a power plant made up of 4 generators that can be split into two power plants of two generators each GENSYS 2 0 units are connected together with a CAN bus on COM1 If it is necessary to split the complete plant using a tie breaker then it is necessary to modify normal functioning When the tie breaker is closed each GENSYS 2 0 communicates with the 3 other units CANBUS inter GENSYS 2 0 DGI DG2 DG3 DG4 CBI CB2 CB3 CB4 Tie breaker FIGURE 82 CAN BUS INHIBITION SCHEMATIC EXAMPLE When the tie breaker is closed all four GENSYS 2 0 units should communicate with each other for power management so variables E2691 to E2694 should be set to 0 zero on every GENSYS 2 0 unit no CAN inhibition When the tie breaker is open generators DG1 and DG2 should communicate together but ignore data coming from DG3 and DG4 In the same way generators DG3 and DG4 should communicate together but ignore data coming from DG1 and DG2 To do so inhibition variables should be set as shown in table below 4 generating sets power plant 2 2 generating sets power plant E2691 E2692 E2693 E2694 E2691 E2692 E2693 E2694 0 0 0 0 TABLE 59 TIE BREAKER EXAMPLE When the tie breaker is open all GENSYS 2 0 units need to know that they have to
128. atch OK NOK breaker is open Voltage match OK NOK Phase match OK NOK Generator KW in large font When the When the overview Voltage in large font generator generator breaker Running hours in large font breaker is closed is closed Engine overview Crank relay output In start and fault When you press Fuel relay output state start or when in Water temp digital output fault state Oil pressure digital output Emergency stop Remote start No of start attempts Battery voltage bar graph Engine speed bar graph Customized 4 custom lines In wait state In other cases screen Customer logo engine stopped Current date and time TABLE 116 SCREEN SAVER MODE 2 Menu Parameter Comment var num TM scr saver Time in minutes after which the front panel display will exit E1266 menus and show the screen saver TM backlight Time in minutes after which the front panel display backlight will E1014 be switched off The light will be switched on again as soon as a key is pressed on the front panel Adjust the LCD backlight from 0 to 100 of the maximum backlight E4095 intensity The 4 lines of text displayed in the Customized screen can be modified as well Each line can be up to 28 characters in length TABLE 117 SCREEN SAVER Note If you change this text from your computer make sure your PC language is the same as the local language as the text displayed is local language related A53 Z0 9 002
129. ates independently from the prime mover control device When a power plant has several generators each GENSYS 2 0 must have a different number Genset number variable E1179 If two have the same number there is no conflict but there will be some operating problems A53 Z0 9 0020 N EN Technical documentation Chapter Precautions 247 ee REFERENCES 22 PRODUCT REFERENCE Reference Description GENSYS 2 0 all in one door mounted genset control and paralleling unit with integrated PLC GENSYS 2 0 CORE all in one back panel mounted genset control and paralleling unit with integrated PLC A53Z0 A53Z1 A5372 GENSYS 2 0 LT all in one genset control and paralleling unit GENSYS 2 0 MARINE all in one door mounted genset control and paralleling unit with integrated PLC and with marine functions GENSYS 2 0 CORE MARINE all in one back panel mounted genset control and paralleling unit with integrated PLC and with marine functions GENSYS 2 0 LT MARINE all in one genset control and paralleling unit with marine functions TABLE 122 GENSYS 2 0 PRODUCT REFERENCE Full reference follows this format A53Z0 LOOxx xx value depends on factory installed options Standard product is A53Z0 LO001 Contact your local dealer for complete reference Le2 2 OPTIONS Each of the following options can be selected and is password activated contact your dealer for procedure OPT2 Mains paralleling option for sing
130. ation 17 7 2 FIRM WARE UPGRADE USING SD CARD Starting from firmware v3 00 it is now possible to upgrade the firmware with a new version using a computer the embedded Web site and an SD card This way you can add new software functions to your module N Notes Programming a new firmware in your module will erase its actual setup parameters equations custom texts and replace it by the factory setup of the new firmware Save your actual setup if you want to keep it for future usage Only software options will be kept in memory during firmware upgrade process 196 A53 Z0 9 0020 N EN Technical documentation Parameter E1929 Phase Offset Option 8 will be reset as all other parameters during upgrade process Set it back to the desired value if needed use of Dyn11 transformer for example WARNING e Always disconnect your module from other CRE Technology products when upgrading firmware disconnect it from the inter GENSYS CAN bus It is advised to disconnect all connectors from your module except power and Ethernet during upgrade process After upgrading enter the proper module number in your product before connecting it to the inter GENSYS CAN bus Otherwise other modules may behave abnormally Do not upgrade firmware on a running product ATTENTION Boot firmware v2 xx and v3 xx do not support high capacity SDHC cards cards above 2 GB or cards formatted using FAT32 Only use FAT16 SD c
131. ays a GENSYS CAN Bus fault If the fault appears during parameter backup check the connection between GENSYS 2 0 units Check the number of units available and their ID CAN number in the Display Power plant overview menu Note Each GENSYS 2 0 must have a different ID CAN number Check the CAN bus wiring end of line resistor in the wire or on the GENSYS 2 0 GENSYS 2 0 displays breaker failure Check that control switch is in manual mode Check that J2 back breaker is activated If this entry did not have time to activate you can increase the E1149 variable delay by default 5 0s This fault can occur if the opening of the circuit breaker has not been controlled by the GENSYS 2 0 Check if another module is able to control the circuit breaker A53 Z0 9 0020 N EN Technical documentation Chapter SUPPORT Troubleshooting 200 The engine starts but runs above below nominal speed Check the wiring Same OV connection between GENSYS 2 0 and the governor Check the fuel supply Check the speed output This output G9 G11 is used to interface with the speed governor The target is to bias the speed fuel rack for synchronizing load sharing ramping load up and down This output only alters the power kW can be set by parameters E1077 Offset and E1076 Gain When connecting this output you must know the details of the input you are using For example a Woodward 2301A uses 2 5 Volts input around OV
132. brication pump N O _ 3 4 5 Can be used for cylinder pre heating plugs Can be used for external crank relay 2019 Can be used for external fuel relay Can be used to activate an external AVR in a static synchronizing configuration see Configuration gt power plant overview EEE Will activate an external excitation relay when engine state is engine ready generator ready wait after stop request cool down In the case of dynamic paralleling E1177 0 the output will also be activated in the start warm up and nominal speed states Can be used for an external relay if fuel solenoid has to be energized to stop the engine Will activate an external fuel Fuel energize to relay Energize to stop when engine is running E0033 gt 0 and stop if there is an engine fault E2046 or a stop request In Manual mode the stop request will be the Stop key E2047 or the Manual stop request E2228 or no fuel E2019 off Can be used to open or close genset breaker The outputs configured with this function will have exactly the 8 208 208 2 md g 2211 2212 Generator breaker 2016 order same behavior as the outputs for the Generator breaker E4 to E6 Can be used to open or close genset breaker Mains breaker order The outputs configured with this function will have exactly the same behavior as the outputs for the Mains breaker E1 to E3 5316 Will activate an output when there is at least
133. ca Engine meas 2 T Engine meas 2 FO Shied H 20mA 20mA u N 1 Shieid Parallel Ei Parallel amp MO 00 SOM OY da OD IA wo D ozz gt m Zz oR Z 2246 vi Se j ONDOA UON 9 ZZ2000Z090 23869225296 5 Z N E i Bf O i ro LJ 2209902900902 65S lt lt 5 lt 36 a a My ale a fm Oo g ad Stry gen jo s Kiowa 9W09 Pickup input Pickup 2 t Pickup analog Speed out p an a ie AVR out 73 AVR out TF Shield 1 Gen 1 l 200 Ger L2 5 Gen L3 P Gen N i4 18004400 Gen 13 S Gen 2 Gen 12 Gen 12 B Gen i 9 Gen 11 Y Gen Open Breaker T Gen Close Breaker Ey p Gen Common 3 Mains Open Breaker Mains Close Breaker fv Mains Common Li Bus Mains I 5 Bus Mains 11 i Bus Mains 1 Bus Mains 12 Bus Mains 13 Bus Mains 13 Bus Mains L1 Ed Bus Mains L2 BI Bus Mains L3 S Mains breaker IN Gen Breaker IN Remote start stop Spare JA Oil press Spare J5 Water temp i Spare inpul J6 Spare input J7 Spare input J8 Spare input J9 Spare input J10 Spare input 111 swye OZ L Y Spare input J12 E Spare input J13 H Spare input J14 Z Spare input J15 E jeiaaas USYM st ION SJOJEJSU vara cs uy Zd E
134. cal documentation Chapter Predefined configuration 58 5 6 SINGLE GENERATOR PARALLELED WITH MAINS This function needs OPTION 2 to be installed 5 6 CONFIGURATION Functions Manual mode Auto mode Test mode aar three or angle phae Nb of running hours Eletncd protetions Analog logical mputs EV lt V gt f lt f gt Q Oil Pressure P2L Watertemp remote start Hmergency stop Genset breaker aux Mains breaker aux Pickup frequency Spares Logical outputs Crank Fuel solenoid Mains breaker Genset breaker Spares Analog output analog signal to speed regulator Stat top Al arms FIGURE 26 PARALLELING WITH MAINS In permanent mode E1148 and peak shaving mode E1153 a mains power measurement is required e internal via L1 L6 inputs Mains 11 12 13 e or external via G1 G3 inputs 0 20mA Variable Variable label Variable value number 1179 My Number 1147 Nb of gen 4006 Nb ofMaster O o 1148 Mains parallel NoBreak CO Permanent 1153 Base load Peak shav A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration Variable Variable label ETE ERE number 1158 Load sharing CAN bus 1177 Staticparalleling No gt TABLE 14 TYPICAL BASIC MAINS PARALLELING CONFIGURATION In all mains paralleling modes if a mains electrical fault is set via protections or digital inputs the generator starts
135. cal documentation WM ADDITIONAL FUNCTIONS 14 LOAD SHARING USING INTEGRAL DE DROOPING 1472 72 INTRODUCTION This function is for generators in island mode no mains it allows perfect load sharing at the right frequency even if the generators are not the same When several generators are on the bus bar one takes a central role with a fixed frequency of 50Hz The other generators determine load sharing using an integral so that each one has a perfect share The set point of the central frequency is the parameter E1080 or E1081 if selected When the GENSYS 2 0 starts one genset is elected to be the master the first one on the bus The master determines the central frequency and load sharing is without an integral The other gensets determine the load sharing with an integral but without using the central frequency When you have several generators paralleled with mains the central frequency is disabled 14 12 PROCEDURE 1 In Manu mode using and adjust the speed control output G9 G11 to obtain the desired frequency 2Hz for each genset 2 Test that load sharing is working properly default values inhibit the integral 3 Activation of central frequency on first genset On the front panel of the GENSYS 2 0 or on the PC In the menu Configuration Modification by variable n set e E1476 on 2 e E1900 on 5 Proportional kW load sharing e E1901 on 2 Integral kW load sharing Access i
136. cks is shown by the statements INIT1 or INIT2 depending on the level of access 1st or 2nd level password A user connected in level 0 no password cannot read equations from or transfer equations to the module A user connected in level 2 will get access to INIT1 and INIT2 blocks A user connected in level 1 will only get access to the INIT1 block INIT equations are only run once by the PLC when it is powered on They won t be run again until power supply is switched OFF and ON again INIT blocks are typically used to set the initialization values of outputs timers or counters associated to custom equations or custom parameters For further details on programming equations see 16 4 16 3 6 EQUATION DEFINITION BLOCKS The beginning of these blocks is shown by the statements EQUATIONS L1 EQUATIONS L2 depending on the level of access 1st level password or 2nd level password A user connected in level 0 no password cannot read equations from or transfer equations to the GENSYS 2 0 A user connected in level 2 will get access to EQUATIONS L1 and EQUATIONS L2 blocks A user connected in level 1 will only get access to EQUATIONS L1 block The purpose of these blocks is to provide custom equations to the user These equations are run every 100ms PLC cycle time Custom equations can be entered here to handle user defined features like thresholds Input Output expansions or any other application specific feature
137. cond GE Je 100 KW time Heavy Consumer authorization time FIGURE 70 HEAVY CONSUMER CONTROL WITH ACTIVE POWER ANALYSIS Power Plant 3 GEs Min Nb of GENSET 2 Heavy Consumer demand time Nb Gensets on the busbar Start and Synchronisation of second GE A time Heavy Consumer authorization time FIGURE 71 HEAVY CONSUMER CONTROL WITH NUMBER OF GENSETS ANALYSIS A53 Z0 9 0020 N EN Technical documentation Chapter Advanced marine functions 141 15 1 4 TYPICAL WIRING Heavy consumer request 1 2 3 Heavy consumer request 1 2 Heavy consumer authorization 1 2 3 Heavy consumer authorization 1 2 FIGURE 72 HEAVY CONSUMER TYPICAL WIRING In the case above the power plant accept 5 different heavy consumer requests e 3 heavy consumer requests are managed by GE 1 e 2heavy consumer requests are managed by GE 2 e Qheavy consumer request are managed by GE 3 Each heavy consumer request input fit with an heavy consumer authorization output Notes The power used by heavy consumer 1 from GE 1 can be different from the power used by heavy consumer 1 from GE 2 The heavy consumer 1 from GE 1 is linked to heavy consumer authorization 1 from GE 1 There is no relation between the heavy consumer 1 from GE 1 and the heavy consumer authorization 1 from GE 2 15 2 NON ESSENTIAL CONSUMER TRIP 15 2 1 I
138. consumer trip Output activated by the protection in the Non essential consumer trip sequence See 15 2 This is the 5th trip activated E1894 sec after the previous one Non essential consumer trip Output activated by the protection in the Non essential 2774 TripOut direct consumer trip sequence See 15 2 This one is activated directly Non essential consumer trip Output to be used if external speed controller has smoke limit input Will activate an output upon start In Manual mode when GENSYS 2 0 start button is pressed or with a manual start request In Auto mode when engine state is Start Warm up and Nominal speed This output will activate when engine is warming up Will activate an output at start In Manu mode when GENSYS 2 0 start button is pressed or with a manual start request and while the warm up timer E2061 is different from 0 In Auto mode when engine state is Start and Warm up Can be used for external horn or flashing light relay output will activate whenever a protection triggers The output will be activated when a generator electrical fault E2200 mains electrical fault E2201 alarm E2202 fault E2203 or security E2204 triggers and will reset when the GENSYS 2 0 horn button is pressed Parameter E1991 can be used to select the maximum duration of horn activation 0 means the horn will buzz until being manually stopped Value 2725 Trip out 2 2726 Trip out
139. csv Fichier Edition Affichage Insertion Format utils Donn es Fen tre 7 Do a es w g A vi AR a ia A GE om aa Arial il vr G Z 5 SE B14 Y fe E2071 E2055 E2056 E0041 1 0 Fr oo ba Ei M CREVTECHNIQUE WORKSPACES Jean Francois GENSYS 2 0W2 030045D_Card logg L Bl Fichier Edition Recherche Affichage Format Langage Param trage Macro Ex cution TextFx Plugins Document 7 AABERGE E A E AX AEA 1 Eale l logger cev E0041 E2055 E2056 E2071 E0072 E0071 E0070 nb char 42 Ln 2 Col 1 Sel Variable E4041 allows you to choose the recording time in seconds As soon as the SD card is inserted into the GENSYS 2 0 the recording will start every E4041 seconds Every E4041 seconds all the variables entered in the first line of the logger csv file will be saved to the file Note If the variable E4041 is set to 0 the recording stops Chapter Communication NOTE Do not remove the SD card from its slot when it is being accessed by GENSYS 2 0 or it may corrupt your file To avoid damaging data make sure to e Set parameter E4041 to 0 in order to stop data logging on SD card e Check that top right LED of the front panel picture below is turned off 5 You can now Safely remove your SD card from its slot To view the archive open the logger csv file using Excel Each line of recording is date marked A53 ZO 9 0020 N EN Technical documentation 1 94 E Microsoft
140. ct a 3V battery to the ST1 jumper battery ST1 up battery ST1 down Battery maintenance must be provided separately from the GENSYS 2 0 unit 10 4 BEFORE COMMISSIONING 10 4 7 SCHEMATICS CHECK Be sure you have the latest power plant schematics in order to check the presence on site of the wires CAN bus shielded wires Speed governor GENSYS 2 0 Interface Be sure that you save your configuration file into an electronics format 10 4 2 CHECK THE LIST OF INPUTS OUTPUTS Check if the required function is present in the list of preset functions in order to evaluate if an input output needs an extra equation If case of doubt contact your local distributor 10 5 DURING COMMISSIONING 10 5 1 START WITH SAFE CONDITIONS Disconnect the GENSYS 2 0 breaker control connector labelled as E Chapter Installing and commissioning a GENSYS 2 0 application Check your speed governor settings and your AVR control settings Check important GENSYS 2 0 parameters voir 89 Ask the technician who wired the power plant to lock the generator breaker open Check the fuel input Check the battery voltage Check the emergency stop input 71 A53 Z0 9 0020 N EN Technical documentation 10 5 2 CHECK THE PROTECTIONS Check the 6 minimum protections before carrying out any other tests SG Over speed Over voltage Emergency stop Oil Pressure Water temp Reverse kW SG SG SG SG
141. ction to 2514 e Set parameter E1328 VIO1 function to 2514 e Write 1 or 0 into E2283 Virtual in 01 using Modbus to set virtual input to the desired value 5 This way both physical input J8 and virtual input 1 are considered as inputs controlling variable E2514 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 191 3 Modbus communication example Table below gives an example of a MODBUS master sending a reading request function 04 of 3 registers starting from variable E0007 This request is sent to a GENSYS 2 0 setup as slave number 5 MODBUS RTU request answer example Master request GENSYS 2 0 slave answer Field Value Field Value Slave address 05 Slave address 05 Function request 04 Function 04 Starting register MSB 00 Data bytes 2 Number of requested registers 06 Starting register LSB 07 Value of register E0007 MSB DO Number of registers MSB 00 Value of register E0007 LSB D1 Number of registers MSB 03 Value of register E0008 MSB D2 CRC16 MSB 00 Value of register E0008 LSB D3 CRC16 LSB 4E Value of register E0009 MSB D4 Value of register E0009 LSB D5 ERIE SB XX CREE LB YY TABLE 76 MODBUS COMMUNICATION EXAMPLE Chapter Communication 192 A53 ZO 9 0020 N EN Technical documentation 7 7 COME SD CARD GENSYS 2 0 is equipped with a SD card slot that adds different functions using a FLASH memory SD card e Data logger e Firmware u
142. ctivated with logical input or equations E1007 CT ratio Ratio of the current transformers Ex 100A to 5A type in 20 E1008 Maximum ratio is 3250 Representing e g 3250 1 or 16250 5 cos d setpoint Power factor set point when running parallel to the mains E1110 amp Note this is an inductive power factor meaning that reactive power will be positive KVAR will be exported from the generating set into the Mains TABLE 84 GENERATOR 2 CONFIGURATION 1 Only available on level 2 2 Generator 2 2 Parameter comment var num kW low lim Lower power limit of the generating set enter a value in kW that kW high lim Upper power limit of the generating set enter a value in kW oe ee power imate generating ene eset E1093 Chapter Menu overview E1094 activated with logical input or equations E1151 E1152 E1091 TABLE 85 GENERATOR 2 2 CONFIGURATION 1 Only available on level 2 215 A53 Z0 9 0020 N EN Technical documentation Generator electrical fault This menu allows to set the parameters used when a generator electrical fault occur See 0 for more details Parameter comment var num Delay before the generator tries to re synchronize with Mains E1843 after a Generator electrical fault Attempts sync Number of attempts to re synchronize E1844 TABLE 86 GENERATOR ELECTRICAL FAULT CONFIGURATION Note In case of a generator electrical fault the generator br
143. d accuracies In the examples above input E2584 has no specific unit while input E0029 will be displayed in Volts Unit code 01 and with 2 decimal digits Accuracy code 32768 Code Accuracy 00000 1 16384 0 1 32768 0 01 49152 0 001 TABLE 48 ACCURACY CODES Code Unit Code Unit Code Unit Code Unit Code Unit Electrical Pressure Volume 07 kW 13 Bar 08 kWh 14 mBar 09 KVAR 15 kPa 10 kVARh 16 PSI Rotating speed Temperature Chapter Text file amp PLC 11 rom Frequency Percent 12 TABLE 49 UNITS CODES Code Variable Default Default Description number unit code accuracy code Native analogue inputs 0029 14 00000 Analogue measure of oil pressure 0 Al oil press 4000 0030 00000 Analogue measure of water temp 0 4000 A53 Z0 9 0020 N EN Technical documentation 1 5 1 Code Variable Default Default Description number unit code accuracy code 0031 Analogue measure of analogue 1 0 Al spare 1 10kQ 0032 a 00000 Analogue measure of analogue 2 0 Al spare 2 10kQ 0285 00 16384 analogueinputt1 AnaloginOL 0286 00 16384 analogueinput2 Analogin02 0287 00 16384 analogueinput3 Analogin03 0288 00 16384 analogueinput4 Analogin04 0289 00 16384 analogueinput5 Analogin05 0290 00 16384 analogueinput6 Analogin06 0291 00 16384 analogueinput7 Analogin07 0292 00 16384 analogueinput8 Analogin08 0293 00 16384 analogueinput9
144. different firmware depending on their provenance Cummins CPG Cummins Power Generation ECU may not support speed control through J1939 ECU with Cummins G Drive firmware should support the speed control by J1939 174 A53 Z0 9 0020 N EN Technical documentation 3 J1939 measures If a J1939 engine is selected the module is able to read the following information They are displayed on 5 pages on the Display Engine meters menu To get more information on these measures unit accuracy see the J1939 norm SAE J1939 71 Measure PGN SPN Description FUEL_RATE OxFEF2 183 Amount of fuel consumed by engine per FUEL_PRESSURE OxFE8B 1390 The absolute pressure at the inlet of the eae COOL_FILTER_DIFF OxFEF6 112 Change in coolant pressure measured E2881 across the filter due to the filter and any accumulation of solid or semisolid matter on or in the filter AIR FILTER DIFF OxFEF6 107 Change in engine air system pressure E2880 measured across the filter due to the filter and any accumulation of solid foreign matter on or in the filter PARTICULATE TRAP INLET OxFEF6 81 Exhaust back pressure as a result of E2879 particle accumulation on filter media placed in the exhaust stream E2878 leaving the engine E2877 manifold or air box CHARGE AIR TEMP OxFEF6 105 Temperature of pre combustion air E2876 found in intake manifold of engine air supply system BOOST PRESSURE Gage pressure of air measu
145. digital outputs C1 to C5 For each digital output the settings are e Function The function associated to the digital output For more details on the available functions see chapter 12 2 1 e Polarity NE normally energized the output will de energize when required depending on its function ND normally de energized the output will energize when required Output Function Polarity E1260 E1436 E1261 E1437 E1262 E1438 E1263 E1439 E1264 E1440 TABLE 100 DIGITAL OUTPUTS CONFIGURATION 2 Relay outputs The Crank and Fuel relay output A1 and A2 respectively can be configured to other functions Parameter var num Crank relay l E1989 Function of the A1 output Fuel relay I E1916 Function of the A2 output TABLE 101 RELAY OUTPUTS CONFIGURATION Comment Notes If E1916 Unused the default parameter are used with E2019 set on A1 output Fuel If E1989 Unused the default parameter are used with E2018 set on A2 output Crank The polarity can t be changed on these outputs Chapter Menu overview 3 Breakers This menu is used to set the breakers configuration generator and mains Each breaker can be configured with one of the 6 values below see 11 4 1 for more details Open contact Close pulse Open contact Close contact Open MXcoil Close pulse Open MXcoil Close contact Open pulse Close pulse Open pulse Close contact TABLE 102 BREAKERS CONFI
146. e see Y JO above 7 4 100 MANUAL MODE The 100 MANUAL mode is activated by setting the parameter E1621 to O Menu Configuration Modification by variable n Then 100 MANUAL mode replaces the ASSISTED MANUAL mode that is not available anymore In 100 MANUAL mode it is possible to control the generator with the front panel of the GENSYS 2 0 All steps from engine start to paralleling are controlled by pushing keys To start the engine push the START key and hold down until the oil pressure fault disappears If a speed governor is connected to GENSYS 2 0 it is possible to increase the speed with the key and decrease it with the key If a voltage regulator is connected to GENSYS 2 0 it is possible to increase and decrease the voltage with the SHIFT keys and SHIFT keys As the generator starts the synchroscope appears on the screen It is then possible to synchronize using the and keys and then close the breakers with the 0 I keys Note The internal synch check relay is always active i e it is impossible to close the breaker if the conditions for closing are not satisfied When the breaker is closed Mains breaker feedback is connected the corresponding Led on the front panel should light up As soon as the generator breaker is closed the GENSYS 2 0 is switched to DROOP MODE for speed and voltage i e the speed and the voltage will decrease when the load increases In
147. e after the other without any loop Level 1 equations are executed first followed by level 2 equations This way level 2 equations will overwrite any conflicting level 1 equation result All the module variables can be used in the equations in the way defined below e EOxxx and E5xxx are read only as measurements inputs They can t be changed by equations e E1xxx and E4xxx parameters can be read by equations If allowed they can also be modified using MODBUS or equations downloaded via the text file See PARAMETERS section of the text file chapter or MODBUS chapter for more details concerning read write attribute of these parameters e E2xxx are PLC output variables that can be read and written by equations Yet write access should be used with great caution as some variables are internally used for the proper management of the generating set and its protections Starting from v4 55 a maximum of 10 modified parameters E1xxx and E4xxx is saved per PLC cycle Variables E2xxx are not affected by this limitation This is to prevent processor overload if too many parameters are changed using equations v4 58 If you change more than 10 parameter values in a single PLC cycle 10 of them will be saved at the end of the PLC cycle 10 other parameters will be saved at the end of the next cycle if their values have been changed during that second cycle and so on This means that you can still modify many parameters in your equations if their v
148. e also 11 4 1 common Engine meas 1 2 5 12 shielded Ea 0 to 10kQ resistive sensors with programmable E2 menemeni 25 12 gain See details in 12 3 shielded Engine meas 2 2 5 12 shielded l 0 to 10kQ resistive sensors with programmable Generator current measurement O to 5A Maximum rating 15A during 10s 1VA consumption External current transformers are normally used Maximum ratio is 3250 meaning 3250 1 or 16250 5 D D D D D 1 2 3 5 7 E1 E2 E3 m D m UT m OY gain See details in 12 3 Engine meas 2 25 12 shielded Shield 25 12 Must be used to protect shielded signals Water temp meas 2 5 12 shielded TI TI TI BP W e F5 F6 0 to 4000 resistive sensors See details in 12 3 F7 Water temp meas 2 5 12 shielded A53 Z0 9 0020 N EN Technical documentation Chapter Description 29 Terminal Terminal Description Capacity Comment mm AWG 00 25 12 shielded Oil pressure meas 0 to 4000 resistive sensors See details in 12 3 7 Oil pressure meas 25 12 shielded G md 20mA 2 5 12 10V 20kQ input or 20mA 500 input Or 10V shielded single generator Shield 25102 Used as synchronization input from GCR External Sake 25 12 analogue synchronizer ex GCR terminal 42 or shielded MASTER 2 0 by parallel lines in applications with Or 10V several
149. e avec tora np onion ne rohan nen lae sou ravenpnuntnn carota rracsiacnisatinnanenionnd E 179 es 180 Table 68 J1939 Custom engine CONFIGUIATION ccccceeeececesececcseccccesesesesecscsusecesueecsssusececeueesesueesssuecssseeessseeeessseeesenees 181 Tape SE VP CONNEXION EE EE EEE EEE een EE ENE 183 VENNINNEN 184 Table 71 Modbis Junctions handled seriais nanio i nT NAAA EDINA EE AE 189 Table 72 32 bits variables Use function OX10 s sssrsrrssrssseserevaserensssserorrsavessssesorreserasrvesrosnsscrssoserovsssetssnssersarerosvsssronsss 190 Table 73 Modbus CON GU ON parameters desk 190 PENN NNN ar 190 Table 75 Modbus parameters for Alerm Fault management unnnrnnnnnnnnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnrvvvnvnnnnnnnennssereeeneerrrvvvvvnn 191 Table 76 Modbus communication EXample rrrrrvrrrrnrrrnnnrrrnnrrrnenrrnnnrrenerrrnerrrnenrrnnerrnnerennerennesrrnnerennesennesennessnnessennesenner 192 Table 77 DOT backup FHC SIZE ernan anr EEN EAEE TEE EERE AEE EER NEET 196 Table 78 Ac ve mers vvs de 209 Te 209 en FOwWET Pan con GUO OT aroraa E EEE E AAA E ETE ETT ER 211 Table 81 Load dependant start Stop Configuration rrrrrrrrrrrrrnnrrnnrrrnrrnnnrrrnrrnrrrrsrssssrsrsssssssssssssssssssssssssssssssssssssssssssssee 212 Table 82 Heavy consumer control MenU eessseesessessseeserseseressrrreseressrrreseressrrrssrrrssrrresrressrresseressrresseresserrssereseeressereeeerre 213 Table 83 Non essential consumer trip MONU
150. e donn es ESS O0 z3rlzr z3rlzr Psy le oo Pole 00 Annuler lt Pr c dent Suivant Terminer The variables values dates and times are now laid out in columns A53 Z0 9 0020 N EN Technical documentation Chapter Communication 195 DER ofa er EA Microsoft Excel logger csv Fichier Edition Affichage Insertion Format Outils Donn es Fen tre DRAA SRY BE JS ora Gr AAZ Bim B Arial 10 G Z S S aH BSE ooo ts H9 f EER C E F G i Ct E2071 E2055 255 SS ee ee ee ee ee E2056 moo oc0T 7 Cc 0c 0c 0 Cc ccc Coo 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 23 12 2000 i 255 M 4 bl logger Pr t The backup file size is computed from the following equation 21 16 12 21 16 13 21 16 14 21 16 15 21 16 16 21 16 16 21 16 18 21 16 18 21 16 20 21 16 20 21 16 22 21 16 23 21 16 24 21 16 25 21 16 25 21 16 25 21 16 28 21 16 29 21 16 30 3 x number of variables 12 x recording time in second file size bytes Recording period in second Here some file size examples Number of Recording time File size variable 780kbytes 1 5Mbytes Recording period 24h 8 1kbytes 30 days 10s 22 5Mbytes TABLE 77 SD CARD BACKUP FILE SIZE Chapter Communic
151. e even if you press the GENSYS 2 0 Manu key 2261 VE ME Will put GENSYS 2 0 into Manual mode Will have the same effect as the GENSYS 2 0 Manu key All h i in A ith lleli 2661 Running with breaker open ows t e engine to run in Auto mode without paralleling or closing its breaker Value 2241 Priority generator 2260 BEEBE OBE N N 79 2 2 251 Will select the second nominal power active and reactive Can be chosen if a coolant pre heating system is installed 2273 Preheating can be used in conjunction with a digital transistor output Will work in auto mode To be selected for a manual fuel refill to be used in 2252 Manu fuel fill l e isan conjunction with digital outputs To be selected for a manual coolant refill to be used in 2253 Manu cool fill ee conjunction with digital outputs Pe To be selected for a manual lubricant refill to be used in 2254 Manu oil fill conjunction with digital outputs Heavy consumer request 1 Heavy consumer request 2 To be selected to activate Heavy consumer control N 00 Chapter I O lines N 00 wip Heavy consumer request 3 sequence See 15 1 for more details Heavy consumer request 4 5000 Unload brk1 in Order output to close generator breaker n 1 upon startup if the nominal power lt E4001 5001 Unload brk2 in Order output to close generator breaker n 1 upon startup if the nominal power lt E4002 5002 Unload brka in Order output to
152. e inputs from BSM II to GENSYS 2 0 Analogue input GENSYS 2 0 Variable All gt Al44 E0285 gt E0328 Transfer a variable from GENSYS 2 0 to BSM II To do this write the equation below in level 1 Example This example copies the KW measurement E0018 to Analog Output 1 E2432 Allocate AO1 E2432 to the measure of kW E0018 E2432 E0018 Transfer several digital variables max 15 via one analogue output Each bit of the AO is equal to a digital variable Example allocate AO8 to digital outputs Breaker mains b6 6 Digital Outputs DO6 b5 gt DO1 b0 E2439 0 E2439 X2439 64 E2000 32 E2445 16 E2444 8 E2443 4 E2442 2 E2441 E2440 Note In the PLC equation variables are considered as signed integers This means that bit 31 is the sign and cannot be used A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 127 14 9 GENSYS 2 0 WITH TEM COMPACT This chapter describes how to interface the GENSYS 2 0 with the TEM compact from Deutz Engines The association of the TEM and the GENSYS 2 0 is an excellent solution to parallel a generator set with a Deutz Engine prime mover Some functions are redundant the kW regulation and the start sequence The following diagram shows the main function of each device GENSYS 2 0 Remote I O Start sequence Synchronisation Engine protections Electrical protections kW control kW measurement Gas protections GE
153. e now in synchronization mode using the information screen key i When the GENSYS 2 0 is ready to synchronize synchroscope to noon check the phase sequence and check that the phases match in upstream and downstream of the breaker i e low voltage difference between phase n 1 generator and phase n 1 bus and so on for the other phases If one of these checks is not correct you have to check the wiring of the generator voltage and mains voltage When you are sure there is no wiring problem stop the generator by pressing Stop button Activate the breaker control Plug connector E Start the generator in Manu mode by pressing Start button Press the generator breaker 0 1 key The generator must be paralleled without difficulties Note If the generator sweep around the synchronization point or if the synchronization is too slow adjust the synchronization gain in the menu Configuration Synchronization Phase synchro Method to set the synchronization PID If the point oscillates quickly around the top synchro decrease the gain If the point oscillates slowly around the top synchro and is hard to stabliz decrease the integral If the point rotates slowly or quickly increase the integral then the gain if necessary 10 5 6 CHECK OR IMPROVE LOAD SHARING KW REGULATION For this application check the stability of kW and kVAR regulation After the mains breaker closes check load ramp P C
154. eaker is opened and the GENSYS 2 0 is in state 40 In this state the alternator is de excited if wired during a delay E1265 After this delay if the fault is still present there is a hard shut down otherwise GENSYS 2 0 tries to re synchronize AVR control This menu allows setting the AVR control See 11 3 for more details Parameter comment var num AVR gain l E1103 AVR trip to be set between 0 and 255 V uaa Output voltage to AVR to be set between 0 and 255 U31 Display the phase phase voltage U31 Volt droop Droop sent to AVR if reactive load sharing is undertaken with E1105 droop if not using inter GENSYS 2 0 CAN bus or in manual mode E0003 AVR output l E2040 Display the sum of the AVR correction signals TABLE 87 AVR CONTROL CONFIGURATION Chapter Menu overview 216 A53 Z0 9 0020 N EN Technical documentation 19 3 4 MAINS BUS Parameter Possible value Comment var num Teo apoeni n peksta E1096 LL Second mains power set point in peak shaving mode E1097 activated with logical input or equations kW measure Calculation of mains power from the single phase E1464 measurement of the GENSYS 2 0 mA G1 G3 2 Measure of mains power by external power transducer G1 and G3 terminals CT ratio Ratio of the current transformers Ex 100A to 5A type in E1930 20 Maximum ratio is 3250 soit 3250 1 ou 16250 5 Power measured by an external transducer deli
155. ear or month day year E1516 E0067 E0068 E0069 E0070 E0071 TABLE 113 DATE AND TIME SETTINGS 2 Meters reset This menu allows resetting the following meters var num Comment E0025 E0125 kVAR generator sum E0061 Chapter Menu overview TABLE 114 METERS RESET 233 A53 ZO 9 0020 N EN Technical documentation 3 Meters preset This menu only available in level 2 allows presetting the following meters var num Comment TABLE 115 METERS PRESET For the two dedicated meters E2657 and E2659 you can modify e The meter name e The meter unit e The meter accuracy User meters are 4 user variables E2657 to E2660 stored in a non volatile memory Their value is stored even in case of a loss of power supply These data can be set through custom equations or Modbus access for example Displaying variable E2657 or E2659 on an information page for example will in fact display the combination of variables E2657 and E2658 or E2659 and E2660 as if it was a single 32 bits variables allowing to display values higher than 32767 Note It is only true for display No real 32 bits computation is done internally For example continuously incrementing variable E2657 will never end up in incrementing variable E2658 and the same applies to variables E2659 and E2660 19 4 2 PASSWORD OPTIONS 1 Password This screen allows you to change passwords from
156. ecccccceceacececcececcecencecencecencecencecenceeeeceaeeseceeceeeececeeceeececesceeeceaeecs 51 9 2 SINGLE GENERATOR IN NO CHANGE OVER MODE cccececceccccececccccccccececcecencecencececcececcecenceceeceaeececenceeeceaeeceeeseeeseaeecs 54 9 3 GENERATOR PARALLELING WITH DIGITAL BUS sive csscicascsnassieviisnasiss banne amt cowsalsisemsanstnine da noeledvulenemsi ensue den veeumaweldeeauinvdawoetienesmcad sen 55 9 4 GENERATORS PARALLELING WITH GENSYS 2 0 AND PARALLEL LINE MODULES cccececccceccccececceceacecececeaceceacecececeacenes 56 9 5 MULTIPLE GENERATORS WITH STATIC PARALLELING cececccceccccccecccceccccecceceaceceacecenceceacecsaceceacecsucecenceceaceceuceteaceceaceneas 57 9 6 SINGLE GENERATOR PARALLELED WITH MAINS cccececcecccccccccacccecccccnceceacecencecencecencecencecencecenceaeeceaeeceaeecsueececeeseaeeseaeecs 59 9 7 POWER PLANT PARALLELED WITH MAINS USING MASTER 2 0 OR GCR 2 2 2 ccceccececcececeacecencececcececceceacecenceceaceceaceceaceneas 64 9 8 POWER PLANT PARALLELED WITH SEVERAL MAINS USING A MASTER 2 0 OR GCR PER MAINS ececcececceccccccsceccecsacecenceceas 66 10 INSTALLING AND COMMISSIONING A GENSYS 2 0 APPLICATION ccccccccccccccccccccccccccccccccccceccccccecccccceccs 67 10 1 NMINMUVMIRING DIAGRA Men usccctcccconadmanidalowcaaneedacaabedsendodeadachd bademenumandanasnesesasobendenbcbalansanaasimnedaecoxedetedGecacneteweeesatas 67 10 2 COMPLETE WIRING DIAGRAM sa acchdcivinoeeiaescuuedounatnaad
157. ed ref wire only G11 Check that the negative speed governor power supply is shared with those of the GENSYS 2 0 Goto menu Configuration Engine Speed control settings Speed governor settings Set the gain E1076 and offset E1077 as described in the Table 18 below if not in the list contact CRE Technology Start the generator at 1500 RPM in Manu mode by pressing Start button Measure the voltage on the speed governor terminal and adjust offset E1077 on GENSYS 2 0 in order to get the same voltage on G9 G11 terminals Connect the speed control Speed out G9 and refine the nominal frequency by adjusting the offset E1077 Check the speed variation range by pressing and button in Manu mode The speed variation range must not exceed 3Hz and must not be lower than 2Hz The best settings are reached when the GENSYS 2 0 is able to control the frequency with 2 5Hz around the nominal frequency If the speed variation range is too wide or too narrow adjust the gain E1076 Deviation ESG amplitude E1076 Speed out ESG offset E1077 Speed ref FIGURE 4 SPEED OUTPUT A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 75 The ESG offset adjustment E1077 can be set between 100 and 100 10VDC to 10VDC and is added to the external speed reference G11 Notes The Speed ref G11 doesn t need to be connected if there is
158. edaneladeedaumuetuleisladsamastaradwactidebdand sundelsuindcamaedenaewauil Sekwecdinedenesecuuncuteacd 68 10 3 NNN TT 69 10 4 pe ES ENE 71 10 5 DURING OMF ON 71 ll DEDICATED OLNE ph 75 11 1 SPEED OVNEN NE 75 11 2 SPEED AND VOLTAGE CONTROL WITH CONTACTS PULSES sssccccsececccscceccccccceececcucecececceccecececaucececueceeaucesecaueeeecanscs 80 11 3 ANALOGUE AVR AUTO VOLTAGE REGULATOR CONTROL rannnnnnnnnnnrrnnnnnnnnnnnnnnnnernnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnneennnnnnnnnene 83 11 4 FA NTN 86 11 5 CRANK FUEL STARTER 2 STARTER 3 FUNCTIONS avunnnnvvennnnnennrnnnennrnnnnnnnnnennrnnsennnnneenenunennrnnvenrnunenrnevennrnnenenuneenrneneeenn 89 11 6 WATER PREHEAT PRE LUBRICATION PRE GLOW FUNCTIONS errnvrernnnvrennnvnennnnenennnnnnennnvnennnnenennnnnnenenenennnnnnennnensenenenenene 90 A53 Z0 9 0020 N EN Technical documentation Chapter Overview 11 7 FN EE NE NE EN EEE NE E nadie NE EN EE EE 91 11 8 FUEL FILLING COOLANT FILLING OIL FILLING vuornnenernnnvnennnnvnennnenennnnvnennnnnnennnenennnnnnennnennensnenennnnnnenenenennnneneneneneenenenenenn 92 11 9 ANALOGUE LOAD SHARING LINE eee mansndsamaneeauetis 95 11 10 VPN he 95 2 VONE oa A E 96 12 1 MN he 96 12 2 BE GO EE EEE EE EE EE EEE EE 100 12 3 ANALOGUE INPUT VIA CRE CONFIG SOFTWARE scccccsseccccceesecccceeuseccceeuesecceeeuesecceseueeccseseuuecessuueeceessuueesessueneeeeees 105 13 PROETINN ne 109 13 1 DP 109 13 2 GENERATOR BEGRUNNE 109 13 3 NETT IU ae cite cince
159. eed stabilisation delay E1140 T9 Voltage stabilisation delay E1141 T10 Safety on delay E1514 T11 Normal running T12 Cooling delay E1142 T13 Engine stop T14 Rest delay after a normal stop E1144 49 A53 Z0 9 0020 N EN Technical documentation Analogue sensors The analogue oil pressure and water temperature sensors are used before start up for the preheat and pre lube checks the water temperature E0030 and oil pressure E0029 must be ABOVE their respective thresholds E1155 amp E1154 for the engine to be allowed to start The default setting for these thresholds is zero When the thresholds are set at zero the readings from the analogue sensors are not checked before start up See the chapter concerning Preheat Pre lube Plug preheat The water temperature E0030 and oil pressure E0029 variables can be used in equations Failure to start In case of insufficient oil pressure or water temperature post start up or in case of excess oil pressure or water temperature digital inputs during start up an Engine not OK warning will appear Please check your oil pressure and water temperature sensors and their parameters WARNING The module doesn t take into account an oil pressure fault during the start sequence A53 Z0 9 0020 N EN Technical documentation Chapter Start sequence 50 5 PREDEFINED CONFIGURATION 9 SINGLE GENERATOR IN CHANGE OVER MODE Functions Manual m
160. el 1 custom level 2 equations that may be in the TXT file will not be imported 199 A53 Z0 9 0020 N EN Technical documentation 18 SUPPORT TROUBLESHOOTING GENSYS 2 0 displays a sensor lost fault when starting In Configuration Engine Speed control settings menu check that the speed measure configuration is consistent with your system Speed measure E1078 Magnetic or Alternator Check the voltage presence on terminal B1 to B4 if soeed measure by Alternator Check the engine speed increase until 1500rpm If soeed measure by Magnetic sensor If you don t have these values and engine stops in time increase the sensor lost timer E1458 default value 10 sec This timer is available in level 2 in Configuration Timers Engine menu GENSYS 2 0 displays oil pressure fault or not ready when starting Check the connection between the J4 terminal and the oil pressure contact Check that the configuration of this sensor is correct in Configuration Inputs Digital inputs It means that the DIJ4 function E1996 must be set on Oil pressure fault if it s a standard pressure sensor Enable Close when the engine is stop Some LEDs blink when GENSYS 2 0 is powered If some LEDs blink 3 vertical LEDs on the left horizontal LEDs 3 vertical LEDs on the right the unit detects a problem because of a wrong operation The GENSYS 2 0 must be returned to CRE Technology or your local distributor GENSYS 2 0 displ
161. encesesscencesesscencesesseess 227 Table 106 Phase synchro PID CONFIGUIATION cccccceesesvecueevesvecuonsessecuceveesecucesessccuceseesconcesesscencesssscencesssscencesessceneesesseess 228 Table 107 kW sharing loop PID configuration cccccccsssesecccssnsecccnsueseeescsuunsesesscuseesssaueesessausseeessauneesesaaunseesssaeaseeeeas 229 Table 108 Ramp constant KW PID configuration cccccccccccccccccccecccccecececcececscsececsecscesececeesecseceseseseesseseeessseeeessesesseaaess 229 Table 109 PID Hz loop configuration xiecdercessctannsnavadsoscnvannsnntextnwsindansansaneeronsntteniacinasnwasndentodsaenthequxtunrncsuvestonapgaveersaveynwsian 230 Table 110 PID kVAR sharing lOOP 1 cccccseeeececsnnessecccaenseceecneseeceesseseeeeesseeeeeeaeeseeeeeaaeseesesaaenseeessaunsesessaanseessaaunsecssaaaaeeeseas 230 Table 111 PID cos py bn NT Narve 230 Table 112 Reset of maintenance Cycle Lavard aE 231 Tapie 113 Date ona UME Se NGS serren a EE O A r aR re aea 233 TADIO TAA Meers OSCE EEE ER EE 233 Tanedo Meer 6 EEE EE EE NE NE 234 Table ME EEE NE 235 A53 Z0 9 0020 N EN Technical documentation Chapter Overview 13 TENNE 235 ETEN 236 Table F199 Ethernet configura OM arosirrisienci kinine ortini tnin ienr sanaes bausucenbenstnesbaonepinveceesait ousoauenaescgusearteeeavesseectbesdarecbandanens 237 Table 120 Modbus configuration cccccseeecennsececssecccssescsunecscsuseseceusesesusecssuuseseseeesssusecsseuses
162. engines can accept the specified load for this heavy consumer then a heavy consumer authorization is issued by the unit on a digital output set up as authorize heavy consumer If the conditions are not met then another engine starts and connects on the bus bar to share the load before the authorization is issued by the unit If multiple heavy consumer requests are active at the same time then the first one will be processed When the authorization is issued or if the request is removed the unit will wait during the delay fixed by A53 Z0 9 0020 N EN Technical documentation Chapter Advanced marine functions 140 parameter E4127 before processing another heavy consumer request This is made to ensure that the first heavy consumer has been turned on after the authorization has been issued Note While an heavy consumer request is enabled the automatic load unload management is inhibited The heavy consumer request has priority over automatic load unloadmanagement Diagrams below represent heavy consumer sequences requests authorizations when the system is set up to check the available kW E1913 1 and when the system is set up to check the number of running engines E1913 2 Power Plant 2 GEs of 100 KW each Heavy Consumer demand Heavy Consumer 75 KW time KW of Power Plant 200 KW __ 100 KW A time KW available Start and Synchronisation of se
163. ent to write custom equations This can be done either 1 Byacomputer connection to the embedded Web site in System GENSYS 2 0 gt PC file menu See 19 4 6 for more details 1 By the front panel LCD using an SD card in System Communication ports config COM6 SD CARD menu See 17 7 3 for more details 16 3 2 RARAMETER DEFINITION BLOCK The starting point of this block is designated by a PARAMETERS statement Each parameter 1xxx or 4xxx variable can be found as an input in this block The structure of the input is as follows The variable parameter number preceded by the letter V Ex V1006 The value Ex 320 R W attribute for MODBUS and PLC equations Ex Y The label optional only for user information Ex Gen Nominal kW The minimal value optional only for user information Ex 00000 The maximal value optional only for user information Ex 65535 Ex A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 148 PARAMETERS V1006 ZORY VIOO 1 00N In the example above Genset nominal power is set to 320kW The Y attribute shows that this value can be changed by MODBUS or custom PLC equations whereas the N attribute in the second line sets Generator Gen nominal kW Gen PT ratio HONOM 165535 FONN 165535 PT ratio as read only for MODBUS and PLC equations Note This write attribute can only be changed when using access level 2
164. er 3 Power used by heavy consumer number 4 Minimum number of engines that should run in order E4126 to accept heavy consumer number 4 Minimal delay between the authorization to load a heavy consumer and the processing of another heavy consumer request Power level that should always be kept on the power plant i e running engines This way a consumer smaller than this power level can be loaded instantly without the need of a heavy consumer request Delay betw req E4127 Power reserve E4128 TABLE 43 SETTINGS HEAVY CONSUMER 1 Power reserve setting must be identical in all modules in order to work properly Some useful variables can be displayed in information page in order to understand the heavy consumer sequence Parameter var num kW available E2768 Help start E2769 Heavy proc GE E2937 Requested kW E2939 Requested qty GE E2940 Comment kW available on power plant Help request from another module GE number managing the heavy consumer request Expected kW before heavy consumer authorization Expected number of running engines before heavy consumer authorization TABLE 44 USEFUL VARIABLES ON HEAVY CONSUMER 15 13 RROCEDURE When a heavy consumer needs to be supplied a digital input setup as heavy consumer request must be activated on a GENSYS 2 0 unit If the conditions to accept this heavy consumer are met the required number of engines are running and or running
165. er factor regulation If the Mains are not connected both speed and voltage droop is applied Note If you need to disconnect a GENSYS 2 0 from the inter GENSYS 2 0 CAN bus you must change the number of generators parameter E1147 on all other GENSYS 2 0 units of the power plant When the power plant is set to load unload mode Parameter E1258 set to Hours run or GE number all generators will start using droop mode if a CAN bus error occurs 17 2 E0BROADCASTING DATA BETWEEN MULTIPLE UNITS I Custom data can be sent from one unit to the others using simple custom equations This K is very useful to create your own advanced features and adapt your modules to your very PG specific requirements It is possible to send up to 10 digital variables and 2 analogue oe variables from one CRE Technology unit to all other units connected to the same inter module CAN bus COM 1 FIGURE 80 BROADCASTING DATA BETWEEN MULTIPLE UNITS A53 Z0 9 0020 N EN Technical documentation Chapter Communication 163 Variables associated to custom broadcast data sent to other units are described in the table below Variables used to send data to other modules Variable Datatype o E2752 1 digital variable E2753 2 digital variable E2754 3 digital variable E2755 4 digital variable E2756 5 digital variable E2757 6 digital variable E2758 7 digital variable E2759 8 digital variable E2760 9 digital variable E2761 10 digital
166. er requests per GENSYS 2 0 Older versions only accept a single heavy consumer request e A power reserve can be fixed to ensure a permanent kW margin on running engines If running engines are so loaded that they can t ensure this power reserve then another generating set will start and share the load 15 12 SETTINGS Parameter Possible value Comment FERA Disable 0 Heavy consumer function is not used default kW 1 GENSYS 2 0 analyzes acceptable load on the Power CT Heavy plant Engines start if necessary Minimum number of engines necessary on the power plant for heavy consumer Analysis of both the power available and minimum number of engines E1913 MinNb 2 kW amp MinNb 3 Heavy consumer 1 E1911 Min number of genset 1 Minimum number of engines that should run in order E1912 to accept heavy consumer number 1 Power used by heavy consumer number 1 A53 Z0 9 0020 N EN Technical documentation Chapter Advanced marine functions 139 Parameter NET Heavy consumer 2 E4121 Min number of genset 2 E4122 Heavy consumer 3 E4123 Min number of genset 3 E4124 Heavy consumer 4 E4125 Min number of genset 4 Possible value Comment Power used by heavy consumer number 2 Minimum number of engines that should run in order to accept heavy consumer number 2 Power used by heavy consumer number 3 Minimum number of engines that should run in order to accept heavy consumer numb
167. erating modes to allow you to control your generator The first 3 are standard modes on industrial units These operating modes are gt Automatic mode Test mode Assisted manual mode also called semi automatic mode 100 manual mode This mode must be enabled by setting parameter E1621 to 0 SZS SZS SZS R On MARINE units standard modes are Ka e Automatic mode Ko e Semi automatic mode also called assisted manual mode E e 100 manual mode They are factory set and should not be changed 7 1 ASSISTED MANUAL MODE Assisted manual mode is a kind of automatic mode where main state transitions are manually v4 triggered by pressing the desired front panel button This mode is available from v4 00 software version User control D Use MANU button to activate this mode Corresponding LED will light on O Assisted manual mode is also called semi automatic mode On MARINE units press on s D A of gt front panel to activate this mode START button will launch the complete automatic start sequence of the generating set Once ready the engine will be let running without additional control of the GENSYS 2 0 If a speed governor is connected to GENSYS 2 0 it is possible to increase the speed with the key and decrease it with the key If a voltage regulator is connected to GENSYS 2 0 it is possible to increase and decrease the voltage with the SHIFT keys and S
168. ers 6 COM6 SD CARD Terminal for FLASH memory cards SD card format This menu allows to set the recording time in seconds of the SD card logger seer 17 7 1 for more details and download upload text file Parameter Comment var num SD log timer Recording time in seconds E4041 TABLE 121 SD CARD CONFIGURATION Module gt SD This menu allows downloading a text file from module to SD card See 17 7 3 for more details SD gt Module This menu allows uploading a text file from SD card to module See 17 7 3 for more details 19 4 6 GENSYS 2 0 gt PC FILE This menu is only available on web site It allows downloading text file from module to PC e Download Gensys File txt e Data logging e Alarms Faults summary WARNING File transfer is only possible when engine is stopped A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 238 1 Download Gensys File txt By selecting Download Gensys file txt the current configuration file will be displayed in your internet browser Use the File Save as menu of your browser to save this file WARNING If you use the text file to edit a new configuration it is strongly recommended that you use the text file uploaded from the module modify it and download this new text file to the module Always use a text file compatible with the installed firmware version 2 Data logging By selecting Data loggi
169. eseeesssusecsssesesesansss 51 Table 10 Typical no change over basic CONFIQUIATION cccccceeeeccceeecscssececcsecesuusescsusecesusesssunecsssusesessesesssusecsssusesesensss 54 Table 11 Typical basic multi Generator CONFIGUIATION cccccceeeeccceeecccssececesesesueecstsusececusesssenecsssusesesseesssusecsssesesenansss 55 Table 12 Typical basic configuration for GENSYS 2 0 with parallel line modules cccccseeecceeeeccceesececeeeccessecsesesesesenses 56 DEN NNN NN 58 Table 14 Typical basic mains paralleling Configuration ereire nin nE ieo e AA EEEE ANE O E TA 60 Table 15 Paralleling with mains configuration ccccceeecccsesececsesesccusescsusececuusesssueeesssusesesuusesssenecsssuseseseecstsueesstsusesesanses 64 Table 16 GENSYS 2 0 GCR configuration ccccccccccccccccccssusseeeeeeceecccecccscssscscuuuueuseeeesseseecessssssusuuuuucesseeseeessessssssssesusaueneesesss 65 Table 17 Power plant paralleling with several mains configuration ccccceeeeccnesececssececeesecesusecscseseseuseeesssusecsssuseseseesss 66 Table 18 Speed governor PALAINETELS 1 seecccesecceeececsccceseesusecceuscscesessesecseneessecsausesseneetenecsauesesesessenestenecteuseesesesseseesansees 78 Toe TO PN MANE eek EEE EEE ETNEN NEON E ENT 79 Table 20 Parameters speed and voltage control with Contacts PUlSses rrrrvrnnnnnnnnnnnnnnnnnnnnnnnnrvvnnnnnnnnnnnnnnnnnnnnnnnrvvvvvnnnn 80 TOE 2 PVG VG O EE NE EE E ee 83 Table 22 AVR paramet ets
170. esssaueeesssausecsssaueeessssaansees 161 Figure 79 Example CAN bus fault cccccccsseseeccccneseccscsuseeccssaessecessaunsecessueseeesaaunsessesauseeeessauseeesssauasecessauaseesssaunsessssaunsses 163 Figure 80 Broadcasting data between multiple UNITS csscccccssseseececsneeececcsuesecescauneecesaaueecsssaussecessaueecsssauneessssaeassss 163 Figure 81 Analogue and digital data broadcast CXAIMPLe cccssssecccnseseeccccneeecccccussecessuunsecssaaussecsssaueecsssaussecessaunsees 166 Figure 82 CAN bus inhibition schematic example seeccccccccenneeesecceccccnsussseecescscaueuseecesssscueusseecessessuaeseeeesessauaenseeees 168 Figure 83 Modular remote CANopen I O extension module ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeseeeeseeeseeeeeeeeeeeeeeeeeeeeeeeeees 170 Figure 84 CANopen coupler Wiring ssccccseecccnseseccnnesecsauseccsauseessaeeeesauseeesaueeesseneeesaueesaausessausecssausesssaasessausecssauseesauaeeses 170 Figure 85 MDEC GENSYS 2 0 CONNEXION srein anro ii eee NEE A ARES a ESEE EN ETE NS 183 FOUT oO IG IG ra a E E E O E E EE 185 ee 207 Figure 88 Modification by variable NUIMDEL ccccccsseesecccssessecccnnensecsssaussecessaueeecesaauueesessaunsecsssausseesssaunsecessausessssagasees 232 Figure 89 Modbus rights access screen sccccccsseeseecsnneseeeecsaeseeessaensecessaueeeessaauueeeesaaunsecsssauasecessausseesssaunsecessaunsessssaansees 237 Figure OE Ge 1 19111018 01 FOSUIES 9 EEE EE
171. esult in an overload or a reverse kW When the power measurement has been check the load sharing or constant kW setpoint can be adjusted by this way gt Fora GENSYS 2 0 in load sharing Inthe Configuration Control loops kW control kW sharing loop menu you can adjust the gain in order to improve the load balanced between GENSYS 2 0 Adjustment between 0 and 200 gt Fora GENSYS 2 0 in kW setpoint base load or peak shaving or in load ramp In the Configuration Control loops kW control Ramp Constant kW menu you can adjust the gain in order to improve the load ramp or the integral in order to improve the constant kW setpoint Adjustment between 0 and 200 Chapter Installing and commissioning a GENSYS 2 0 application 74 A53 Z0 9 0020 N EN Technical documentation Nn DEDICATED I O LINES Inputs outputs are associated with functions Some I Os are dedicated others are programmable using configuration parameters 1 1 SPEED GOVERNOR INTERFACE This interface is used to control engine speed The Speed governor control is used to manage Speed set points Synchronization kW Load sharing and kW set points The Speed governor interface can be Analogue output PWM 500Hz digital output CATERPILLAR PERKINS 2 Digital pulse output see 11 2 11 1 ANALOGUE SPEED GOVERNOR OUTPUT The following procedure must be used to match the interface with the speed governor Connect the spe
172. ever be disconnected The battery circuit should only be opened using a breaker placed between the battery s positive terminal and the K2 terminal Power supply 24 a oA FIGURE 39 POWER SUPPLY CIRCUIT BREAKER Note If terminalK3 OV is disconnected and the bus bar voltage is applied to the GENSYS 2 0 there is the risk of getting AC voltage on the CAN bus terminals Chapter Installing and commissioning a GENSYS 2 0 application 2 Interconnection of all battery negatives 70 A53 Z0 9 0020 N EN Technical documentation FIGURE 4O INTERCONNECTION OF ALL BATTERY NEGATIVES 3 Rental fleet amp Marine amp HV generating sets CAN bus isolators are fitted inside the GENSYS 2 0 unit so it is possible to use it safely in MARINE applications and on rental fleets 4 External power tank capacitor An external power tank capacitor can be connected between terminal K1 and K3 See Figure 35 to help the battery maintaining an adequate power supply when starting the engine low voltage or brownouts This Capacitor is optional GENSYS 2 0 is able to operate with a minimum power supply of 9V This capacitor can be used in case of a single 12V battery power supply Do not connect such power tank on 24V applications 10 3 4 VIBRATIONS In case of excessive vibrations the module must be mounted on suitable anti vibration mountings 10 3 5 REAL TIME CLOCK BATTERY If the battery is disconnected remove the rear panel and conne
173. filling 11 8 2 AUTOMATIC MODE 1 Description These filling functions are automatic and do not require any custom equation To configure the filling function you have to e Set the digital output as a fuel filling E2229 coolant filling E2242 or oil filling E2245 e Set the following parameters Filling Function EEE Fuel Coolant Oil Filling input E4085 E4088 E4091 Low level input E4086 E4089 E4092 High level input E4087 E4090 E4093 TABLE 25 FILLING PARAMETERS IN AUTOMATIC MODE A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines The parameters Filling input allow selecting the resistive sensor to use among e Analog input 1 F1 F2 set filling input parameter to 31 e Analog input 2 F3 F4 set filling input parameter to 32 e Analog input 3 F6 F7 set filling input parameter to 30 e Analog input 4 F8 F9 set filling input parameter to 29 Parameters Low level input and High level input allow defining the filling thresholds Alternatively two digital inputs can be set as low level and high level switches if no analog sensor is fitted 27 Example If we use the same example as the automatic mode with equation see 11 8 3 to fill the fuel tank then parameters would be set as shown below E4085 31 E4086 20 E4087 80 E1260 2229 Note E1260 is the function associated to digital output 1 1 8 3 AUTOMATIC MODE WITH EQUATIONS 1 Description
174. g on the CANopen module side Modular remote I O can also be added to GENSYS 2 0 using the CANOPENO protocol and DB9 connector For the remote I O wiring see the figure below AADW2 ae n i 1 i E Shield Drain GENSYS 120 Ohms CAN2 COM2 2 CAN L waco SNQ mu FIGURE 84 CANOPEN COUPLER WIRING e CANL must be connected to pin 2 of the DB9 e CAN H must be connected to pin 7 of the DB9 e CAN GND must be connected to pin 5 of the DB9 e Drain must be connected to the shield of the DB9 An end resistor of 120 Q must be connected to each end of the cable between CANH and CANL This resistor exists inside GENSYS 2 0 and can be activated with a switch accessible from the rear of the unit and located under the plug marked OFF 1200 COM port is marked on the rear You need to extract the plug A53 Z0 9 0020 N EN Technical documentation Chapter Communication 170 to change the switch When the switch is ON resistor is active on bus When switched the other way the resistor is not connected to the bus Contact your local dealer for a list of recommended CANopen extension modules 1 System configuration CANopen communication uses CANopen messages that can be set up in the Enhanced configuration CANopen menu GENSYS 2 0 can handle a total of 13 input messages and 19 output messages Three parameters must be set for each message to be used Each message is determined by 2 The
175. generators paralleled with mains Used as Mains power input measurement with G N G Ww Use parameter E1461 to switch between voltage current input Parallel 2 5 12 Isolated 5V 10kQ load sharing and power set shielded level kW only 25 12 compan with traditional analogue load share de Ke 252 lines often called Parallel lines Parallel 2 5 12 Compatibility with Wheatstone bridge shielded Mainly used in applications with mixed equipments e g GENSYS 2 0 with GCR or old ILS modules See details in 0 f lati k pickupa 25 12 Used for speed regulation crank drop out and over speed G N O O See Cautions in 21 If not wired engine speed can be measured using alternator voltage But pickup is recommended Also see details in speed settings 11 1 1 2 57 12 G9 10V analogue output to speed governor 11 10V ref i f Shield 25 12 one OV reference input from speed governor G11 Speed ref 2 5 12 Compatible with most speed governors See details in 11 1 1 2 55 12 Analogue output 5V isolated A53 Z0 9 0020 N EN Technical documentation Chapter Description 30 Terminal Terminal Description capacity mm AWG Shield 2 5 12 2 5 12 H2 H3 4 H Mains breaker in N o 2 5 12 3 Remote start stop Oil pressure 2 5 12 Spare input t UT Water temp 25 12 Spare input J6 to J15 2 5 12 Spare input 1to 10 AR y a a
176. gine meas 2 IO Shield 83 20mA 75 lt I 20mA wu N I OI Shield Ol Parallel V Parallel Eb lozz gt 22 53245 2256 AS og o unason i I EO re O 23 06g 28236 eo f OB eruonron 23 22z2000z00z og r226 lt gt 6 gt Z p 1 Spry 1018 Howa JWOD Pickup Pickup analo Speed outs BAA an g 23 2 aa 2 Pwm output ks AVR out 5 AVR out Shield 1 3 Ger L1 i 00 480 V Ger L2 3 Ger L3 2 Gen N 2 Gen 13 Jj A Gen 3 Gen 12 rd Gen 12 Gen 11 id Gen l1 Gen Open Breaker T Gen Close Breaker PN gt Gen Common _ By Mains Open Breaker g Mains Close Breaker Fy Mains Common L Bus Mains 17 Bus Mains 11 fn Bus Mains 12 Bus Mains 12 Bus Mains 13 Bus Mains 13 Bus Mains L1 Bus Mains L2 5 Bus Mains L3 9 suie Mains breaker IN Gen Breaker IN Remote start stop Ss Spare J4 Oil press a Spare J5 Nvater temp fn Spare inpul J6 Spare input J7 Spare input J8 Spare input J9 Spare input J10 Spare Input J11 E a i e Y O Q zs 3 e Spare input J12 Spare input J13 gt Spare input J14 H Spare input J15 H FIGURE 34 MINIMUM WIRING DIAGRAM A53 Z0 9 0020 N EN Technical documentation ion icat GENSYS 2 0 appl ISSIONINg a Installing and
177. hanging the equation E2219 EO IL AND E2920 EOT O0 rO E2015 EO OU AND E2927 EO M A53 ZO 9 0020 N EN Technical documentation Chapter Additional functions 122 14 7 SAFETY INHIBITIONS 14 7 OBJECTIVE Safety inhibitions are mandatory on certain types of application particularly in safety O generators used in public spaces norm NF E 37 312 by OS The aim is to inhibit the oil pressure and water temperature safeties on the GENSYS 2 0 VE Gy 7 i F o Thus in the case of a fault the generator remains in operation Other protections over speed overload etc are still active if set 194 7 2 CONFIGURATION 1 Hardware Contacts for oil pressure and water temperature are no longer connected to J4 and J5 but to spare configurable inputs In this example the oil pressure and water temperature contacts are on J13 and J14 2 Software The following equations must be downloaded to level 1 or 2 as described in 17 7 3 or 19 4 7 A53 ZO 9 0020 N EN Technical documentation Chapter Additional functions 123 BLOC De Oil pressure and water temp Inhibition COE ashe NT E2811 Logical Input J11 GENSYS 2 0 inhibit security E2812 spare input 8 J12 oil pressure E2813 spare input 9 J13 is water temperature E1273 fct spare input J12 E1274 fct spare input J13 EO033 speed i E1712 user param start speed E1714 user param stop speed E1456 Oil pressure sign
178. he other GENSYS 2 0 units before closing the bus breaker this depends on the validation of the dead bus management The load sharing is accomplished via the inter GENSYS CANO bus 17 2 or via the parallel lines 9 4 The generators stop with a remote stop signal 7 2 4 POWER PLANT WITH SEVERAL GENERATORS WITH AUTOMATIC LOAD UNLOAD The communication between GENSYS 2 0 units is via the inter GENSYS CAN bus 17 2 and determines which generators start or stop The number of generators used depends on load requirements all generators receive the remote start signal but only start if necessary Note The operating modes are described in the chapter 9 below 7 3 TEST MODE This mode allows testing automatic mode behaviour When TEST key is pressed the engine starts as if there was a remote start and GENSYS 2 0 will carry out the standard automatic mode sequence to take the load with synchronization in case of parallel mode To exit test mode press AUTO or MAN key on the front panel Note TEST mode should only be used to check the sequence of the generating set to go on load It cannot be used as a permanent working mode as some advanced features such as load dependent start stop or other functions may not respect the standard automatic mode behaviour A53 Z0 9 0020 N EN Technical documentation Chapter Operating mode 47 SN Test mode is not available on MARINE units It is replaced by semi automatic mod
179. he speed defined by the E1896 setting CAN bus synchronization There is a residual voltage of 80V All Cloutputs close simultaneously to activate excitation after dialogue between GENSYS 2 0 units The nominal voltage is reached immediately at the same time on all generators The plant is available to take up required load Breakers are closed when engine is stopped There is a residual voltage of 80V 9 5 2 ADVANTAGES 2 SG SG Full plant availability in less than 10 seconds Gradual magnetization of the step up transformer no transient short circuit 9 5 3 CONFIGURATION One GENSYS 2 0 per generating set CAN bus must be connected between GENSYS 2 0 units An Excitation output e g exit C1 must be configured on each GENSYS 2 0 unit Generator breaker must be powered by 24VDC so as to close without AC In the Setup menu General Central sync mode E1177 must be set as Static stop The value of the maximum excitation rpm is set with E1896 default 97 The alternators must be identical Each GENSYS 2 0 must be equipped with a speed sensor magnetic sensor Pick up Variable Variable label Variable value number 1179 My Number 1 to 32 this value must be different for each device on the same bus 1147 2 lt N lt 32 4006 1148 NoCh over 1153 X 1158 Bus CAN 1177 Static paralleling Yes 1515 X 1258 X 1078 TABLE 13 PARALLELING WITH MAINS A53 Z0 9 0020 N EN Techni
180. icswmiaesesonenaqasmnsainwiesaanetdeapedeomenasayasrensgawtsmansneceansearsaucenncss 128 14 10 SENG ACCESS BE EE EEE EE 129 14 11 E E ND EEE REE EEE ENE NE EE 129 14 12 HON TO ESP ID anda raei 130 14 13 LOAD DEPENDANT START STOP ssscccceecccceeccecesececcsucccccucecececcecnsececuecececsccecaucececaucesecuuceeeneuececautesecaececaunecess 131 14 14 PHASE OFFSET DYN11 AND OTHER Lunnan aayauiniie vichlaciowadianinanelasialunlanivuivaanaatias lesan aw tiabieanann betaatidewonsaanaldawsaniatieewaes 135 14 15 VOLTAGE SYSTEM 120 THREE PHASES 180 TWO PHASES SINGLE PHASE sssccceceessecceceeseecceseeeeeceeseeeeeseesanenses 136 14 16 MENNENE 137 14 17 FRONT PANEL INHIBITION 0scsscccsssscovscconscvsnscnssscnsevcassoensesvsseouscensncevsaeeuusecussensesvassouausovneeosnconsnsensaccnsscnsnsensss 138 15 ADVANCED MARINE FUNCTIONS sevice aecpencetwccactiorcarccoswatendavunesuep E suenuscervacaetaaseen cen reatentaruaereas nen 139 15 1 PEAVY CONSUMER ceciren nr ESEA eau AA aamsediatoauion eau EAE A E TA AE 139 15 2 NON ESSENTIAL CONSUMER TRIP ee 142 15 3 CONNECTING MULTIPLE UNITS TO THE SHORE ssscovsscosnscnssccosscvsnsctueccnsccvsuccenscosssovsnscnnsetesscnssssnucconssovsuccsnscnnssovens 146 16 TETHES PL NN 147 16 1 NNN 147 16 2 VENN NNN 147 16 3 EFE 148 16 4 WRITING CUSTOM PLC EQUATIONS arernevnrnrnnnnnnnnnnnnnnnnennnnnnnnnennnnennnnennnnennnnennnnnnnnnenennnnnnnnnennnnennnnennnnennnnennnnanennenennene 155 16 5 GENSYS 1 0 GENS
181. ied using configuration menu or equations Function can be modified using configuration menu or equations To modify a parameter through the menu go to the configuration menu Enhanced configuration Digital transistors output Choose the digital input to modify using the lt lt and gt gt soft keys to change page 2 inputs per page and and VW to choose the parameter The description of the function is given on the next line and can be modified with the and keys The following table shows all input associated parameters Not delayed Delayed Default label Label Validity Direction Delay Function value value 10 J11 J14 J15 TABLE 27 INPUT PARAMETERS 12 1 CONFIGURABLE INPUT LABEL This is the name you give to the input The name will be displayed in the info alarm and fault screens if so programmed You can change the label using the menu or you can download a text parameter file via the Internet connection or via the CRE Config software A53 Z0 9 0020 N EN Technical documentation Chapter I O lines 96 12 1 2 VALIDITY Validity input variable numbers can be set as Num Label Function 2330 Never active should be selected if you do not use the input 2329 Always active input will be monitored as long as GENSYS 2 0 has power 2192 Input will be monitored at the end of the safety on delay E1514 2331 Stabilized Input will be monitored when genset is
182. igure 344 FUNG CXONMIDIC rerni ian E SREE AE EREITEA SEEN E Din 94 Figure 55 Wiring parallel lines ccccccssecccseseccssnseccsuusecsasecesauseessaeeeesaeeeessaeeeessaueeesauueessaunecssauseessauseesauasessausesssueessaaaseees 95 Figure 56 Change over with one digital input setup as Mains electrical fault ccccccsssseccccsneseeccecanssecessasseceseaeasess 117 Figure 57 Permanent Mains paralleling with one digital input setup as Mains electrical fault ccccsseseeeeeeeeeees 118 A53 Z0 9 0020 N EN Technical documentation Chapter Overview Figure 58 Permanent Mains paralleling and generator electrical fAUIt ccccccccsseeeecccnseseecccsaussecsssausescessauesecssaaenees 119 Figure 59 Wiring GENSYS 2 0 and Auto Start Module scccccsssccccsnsecccsuscccsusecssausecsscsecsausecssasesssaesessausecssasessagaeeees 120 Figure OO Fe slart seguente SAG eee 121 PIQUE DL Winna GEINSVS 2 0 TO B3M I vr 125 Figure 62 gt Wiring GENSYS 2 0 TEM ssvsncsvintzsncsensenosvandvouetiechnustautnciwunaxsnes vec vane Vines vetbaste see NEVE AANE ENEAN AA 128 Figure 63 Typical GPID Controller siririn trar n T eT TOE nse canutasaveest devised tawv TOEA CartnaTiaweddantane sua taxes 130 Figure 64 Standard mode example with a Ax100kW power PION 1cccccseseccneseccseseccsseccsaseccseesessausecssasesssnseees 132 Figure 65 Optimised mode example with a 4x100kW power PIANt cccccssessecccceesecccsn
183. imply giving its variable number By doing so you can customize your information screen and display 10 parameters per page 5 pages available Please refer to the technical documentation for list of variable numbers A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 243 eo USEFUL INFORMATION This page gives access to useful information concerning different areas of the GENSYS 2 0 unit s functioning 20 11 SPEED REGULATION DETAILS soyeynBa peads jay las paadg jal jewau 11013 22013 18540 ueg YN IOYLNOJOYIIN soyesauab 82073 UOgeiNap aweuig 3159 MY p Buneys peo g doo1g Z UORESIUOJYJU Buiyjou p 88023 POW YUIUMS UOIJEWUOJU NJASN J31deu 62073 dwey 08003 Ti J NOd SUIE 5 03 67073 vopenag 18003 01073 ja suiew jasuab Dap oe mu 9 4 jamod Xid jurodjas MX 88073 puewwon 18073 uas jenuep Leoga uogeneg ogoza vopeneg 1013 asjnd peo 81003 uawanseaw Jamog OIYDU S sule pl 829 FIGURE 94 SPEED REGULATION DETAILS 244 A53 Z0 9 0020 N EN Technical documentation 20 12 VOLTAGE REGULATION DETAILS KUSLISJINSESU shepo Aas ai uoaa pum Agddns omy FoLLI 13 440 FTA 9 cokla NIV9 oroza uogenag SASN39 SJeMple UONEUIOJU NJASN J31deu ST073 vorenaq SEOTF VOKEINSG 1uIOGas 14d s4 atoza weodies amoy ecoza _ uopenag N 1
184. inistrator to configure router and module s according to your need Parameter Possible Comment var num value Use DHCP Disable 0 Enable the DHCP protocol dynamic IP address or disable fix IP E4065 Enable 1 address IP Address Configure fix IP address of the unit DHCP disable or in fault E4010 a E4013 IP GW address Configure gateway IP address DHCP disable E4026 a E4029 TCP TCP communication port E4081 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 236 Parameter Possible Comment var num value UDP UDP communication port E4082 Modbus TCP Modbus TCP communication port E4083 TABLE 119 ETHERNET CONFIGURATION 1 Only available if DHCP protocol is disabled Note modifications on these parameters are taken into account during power on sequence So it is necessary to restart your module in order to use the new configuration 5 COM5 RS485 MODBUS RTU This menu allows setting up Modbus RTU See 17 6 for more details Parameter Comment var num Modbus address Define the GENSYS 2 0 Modbus SLAVE RTU address E1634 Modbus speed The following speeds are available 4800 9600 19200bps E1441 Modbus rights Allows defining the Modbus access rights access to the parameters E4107 LCD menu gives access to the following predefined settings Factory Full access Standard TCP No RTU Standard RTU No TCP No access Web site menu give
185. inputs 8 15 This menu shows the status of 8 digital inputs connected on the J terminal E2808 to E2815 The name of each input is displayed with the status Input active 1 Input inactive 0 3 Relay outputs This menu shows the status of the 4 relay outputs e Generator breaker E2016 e Mains breaker E2017 e Relay A1 E2018 e Relay A2 E2019 The name of each input is displayed with the status Input active 1 Input inactive 0 Note By default relay A1 corresponds to crank relay and relay A2 corresponds to fuel relay 4 Digital outputs This menu shows the status of 5 digital outputs connected on the C terminal E2020 a E2024 The name of each output is displayed with the status Input active 1 Input inactive 0 19 2 7 ACTIVE TIMERS This menu shows the timer values running in real time on 2 pages To change timer values you should go to Configuration Timers See 19 3 9 Chapter Menu overview 1 Timers 1 2 Parameter comment var num E2060 E2061 taking the load E2062 stabilization before taking the load E2063 voltage stabilization of the engine before taking the load E2064 stopping the engine E2065 stop when this timer 208 A53 Z0 9 0020 N EN Technical documentation Parameter comment var num Stop rest time Shows the time the engine has been waiting since being put at E2066 rest E2067 Prelub timer Shows the pre lubrication time before c
186. ion between generators is activated only during a load or unload request i e in the next start stop on load request 14 13 5 START STOP BY E1617 PARAMETER In this mode E1258 3 available in level 2 the genset start stop sequence will follow the priority number set in each GENSYS 2 0 in the variable E1617 as described below GE number Value of E1617 parameter TABLE 40 USE OF E1617 PARAMETER Start sequence Stop sequence Chapter Additional functions FIGURE 67 AUTOMATIC LOAD UNLOAD SEQUENCE WITH CUSTOM E1617 MODE 134 A53 Z0 9 0020 N EN Technical documentation 14 14 PHASE OFFSET DYN AND OTHER 14 14 12 INTRODUCTION This advanced function available with option 8 provides a choice of phase offset E1929 between mains and generator voltage measurement That means that GENSYS 2 0 will command the breaker to close with the selected phase angle shift 20 000V Mains Bus Bar Transfo DYN 11 30 E1929 30 GENSYS Genset FIGURE 68 PHASE OFFSET EXAMPLE You must take care before choosing this function and modifying the phase offset parameter 14 14 22 SETTINGS The phase offset modification can be done via the configuration menu synchronization check relay 19 3 10 by using the E1929 parameter The Phase offset E1929 can be chosen from the following values 0 30 60 90 120 150 180 30 60 90 120 and 150 A modification of
187. is associated with each parameter V1013 V1017 V1149 V1476 V1504 V1517 V1596 V1633 V1852 V1853 V1854 V1855 V1856 V1857 V1858 V1859 V1860 V1861 V1862 V1863 V1864 V1865 V1866 V1867 0 60 125 e OF U U N DO N wW O WO O O O O 0 O O O O O O ee N 2 2 2 2 2 Z Z lt lt lt lt lt lt J1939 sc adres J1939err delay Fail to O C br Div D ILS Div DQ share RESET delay CAN Speed Fail to start Branch P oil Brnch T water Branch Speed COM2 protocol J1939 Address CT speed CT Oil Pres CT Cool Temp CT Oil Pres CT Cool Temp CT speed CT Malfonction CT Protection CT Orange CT Red Opt4Param12 A53 Z0 9 0020 N EN Technical documentation 00000 00000 0000 0 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 Logic inputs J4 to J15 65535 65535 6553 5 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 Chapter Text file amp PLC 157 V1868 V1869 V1870 V1871 V1916 V1925 V1928 V1929 GENSYS 2 0 parameters listed above are shown with their default settings for the GENSYS 2 0 If your configuration file or variables modify these parameters make sure their use is the same as in the GENSYS 2 0 2 Z2 2 lt
188. is only available in modules from the MARINE range This menu allows the setup of parameters used for the management of heavy consumers as described in chapter 14 13 Parameter Possible value Comment var num Min Hz trip 0 Disable Enable tripping of non essential consumers if the power E1905 1 Non essential plant frequency slows down Min Hz level 1 Frequency level below which non essential consumers will Pee Ed Min Hz level 2 Frequency level below which non essential consumers will Max kW trip Enable tripping of non essential consumers if the load of the E1908 1 Non essential power plant is too high Max kW level 1 Load level above which non essential consumers will be dekte en roerne fontener wl Pe Max kW level 2 Load level above which non essential consumers will be PJ __ eippe Should set gher tran evel 2 n Level 1 delay Delay associated to level 1 thresholds before tripping non EN before pong ron Level 2 delay Delay associated to level 2 thresholds before tripping non isto esel oads shoud be et shorter thn delay TABLE 83 NON ESSENTIAL CONSUMER TRIP MENU A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 214 19 3 3 GENERATOR 1 Generator Parameter comment var num E1006 E1015 Nominal Volt Voltage setpoint eo o E E1607 input or equations Nominal kVAR 2 Second nominal reactive power of the generator activated with Nominal Volt 2 Second voltage setpoint a
189. ive information if the engine is stop Start the engine to display engine data A53 Z0 9 0020 N EN Technical documentation Chapter SUPPORT Troubleshooting 201 kW load sharing is bad Check the wiring direction of the current transformers and the power measurements Display Generator electrical meter Global view generator menu The power by phase must be balanced and positive Check the speed control is correctly configured and performs the same action on all speed governors Check that all engines are stable If one or more engines oscillate in frequency even slightly this oscillation will affect the load sharing Adjust the kW load sharing gain Configuration Control loops kW control kW load sharing menu The breaker control doesn t work correctly Check that the breaker output correspond to the equipment used Configuration Outputs Breakers menu Check the breaker wiring Check the timers associate to the breaker control See 11 4 1 A53 Z0 9 0020 N EN Technical documentation Chapter SUPPORT Troubleshooting 202 19 MENU OVERVIEW 19 1 MENU INTRODUCTION Menu is entered when ESC key is pressed and once password has been verified The password will define which menu will be accessible Level 0 will give access to display menu only Without password only press Enter Enter Level 1 will give access to all menus and level 1 equation Level 2 will give access to all menus
190. ivesaccuscesdiscdensbesabneubiestveubdeeutuesdissdebubwsabneubibetueaboensnesdibsdebubweabnewbubetneuboesins 244 21 FREMONT 246 22 REFERENCES gre ar or oe Oe ON are re ore eT ar rer eee ree rT eee 248 22 1 PRODUCT REFERENCE seernes lege 248 22 2 OPTIONS SE EE 248 22 3 ME 249 23 CRETECHNOLOGY sssssssssssssssssssesessssssssssssscsssssosssssssssssssssssssssssssessssssssssssssssssssssssssssssssssosssssssssosssssssssssssooo 250 A53 ZO 9 0020 N EN Technical documentation Chapter Overview List of figures ET PN 16 Figure 2 GENSYS 2 0 CORE mouting GiMensSiOnss ccccsseccccssescccsneeccnassecssuseccaausecssuseessausecssauseesaaeessauseessausesssuesessaanseess 17 MUNN NNN 21 Figure 4 GENSYS 2 0 MARINE front DANE reader 21 Figures ke PONE EEE EEE EEE ENE 27 Foe gd 190 EEE NE NE EE EE EEE 34 Elk DS e GEL OE EE pence nt erent erie 34 Figure 8 Password input mode display cccccseecccsseeeccseseccsaseccsausecssuneessausecesaueecssueessaunecssauseessaueessauesessauseessueessaanseses 35 Fe NNN 36 Figure 10 Browser link CESCriIPtiON cccccseecccsseseccsesccnssecesausecssuuseesaseeesaueeessaeeesaaueessaunecsaaueessauueessauasessausesssuaesesaaaseses 36 Figure 11 Contextual keys for input mode cscscvecsessesvecncnsesvecncnvesccsncesessesncusessesccusessesccssessesccssessescessescesccsssssencesssseess 37 ETEN 38 Figure 13 Typical GENSYS NNN 39 Foue TENNE 43 Figure 15 Assisted manual mode without
191. l pulse output is detailed in chapter 11 2 AVR control is used to manage Voltage set points Voltage Synchronization U U kVAR load sharing and Power Factor regulation To set AVR control correctly e Start engine in Manu mode e Set Gain E1103 0 and Offset E1104 0 on GENSYS 2 0 e Set the AVR system to 400 Vac using its potentiometer e Enter maximum correction E2038 7000 with Shift buttons e From the following table choose the best values for Gain and Offset to obtain 430V ac 5V GAIN OFFSET 0 0 0 255 255 0 255 TABLE 21 AVR GAIN AND OFFSET If necessary modify Gain and then Offset to obtain 430Vac 5 e Enter minimum correction E2038 7000 with Shift buttons then check that you have 370Vac 5 e Set to no correction E2038 0 and check that you have 400Vac Gain and Offset adjustment if you cannot obtain 400Vac on the AVR adjust the maximum voltage with the AVR potentiometer which is normally below 400Vac Choose the best values for Gain and offset to obtain the maximum deviation Deviation AVR gain E1103 AVR out AVR offset E1104 AVR out FIGURE 47 VOLTAGE OUTPUT See table below for preset settings For specific settings contact your dealer A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 83 Model AVR gain E1103 AVR offset E1104 TerminalH2 Terminal H4 Comment Manufacturer MX341 Al TRIM pot of AV
192. le generator paralleled with the mains Some of the main paralleling functions are e Power management command mode peak shaving e Phase shift e ROCOF OPTS Disable paralleling function AMF Disabling this option will also disable option 2 Mains paralleling described above OPTS Transformer phase shift compensation HV Dyn111 Note on GENSYS 2 0 LT modules option 2 is always linked to option 5 They are both factory enabled Enabling Removing option 5 will automatically enable remove option 2 A watchdog option is also available using logic output C5 This option must be specified when ordering your unit so that CRE Technology can produce it in the factory A53 Z0 9 0020 N EN Technical documentation Chapter References 248 ZZ 3 ACCESSORIES CRE Technology provides a complete range of accessories to help you install and use your module Some examples are given below Please contact your local distributor to help you choose adequate equipment to fit your needs 1 Cables Reference Overview Description Crossover RJ45 Ethernet cable 3m Ip E DB9 female connector with 1200 IL E terminal resistor free wires DB9 connector accepting double cable connection To be used on multiple generators applications CAN RS485 communication cable without connectors Length on request DB9 1200 termination dongle g d a CAN cable for 2 GENSYS 2 0 on c O TABLE 123 CABLE REFERENCE
193. level 0 to the currently connected level Passwords are limited to 8 characters maximum 2 Options This part shows options that are enabled inside your module For more information on options or to lock unlock one of them please contact your local CRE Technology distributor OFF is an inactive option ON is an active option 2 Mains paralleling option For single generator paralleled with the mains Phase shift ROCOF power management display 5 Disable paralleling function AMF 6 MASTER 2 0 This is a factory only configurable option This option is set to OFF on GENSYS 2 0 and set to ON in the MASTER 2 0 7 Disable the internal start sequence 8 Phase offset option This option is generally used with HIGH VOLTAGE transformer applications A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 234 19 4 3 SCREEN SAVER 1 Introduction The screen displayed when user does not interact with GENSYS 2 0 keys not used is called SCREEN SAVER Information displayed on this screen is automatically chosen depending on GENSYS 2 0 status as described in table below Some parameters can also be used to customize this behaviour Screensaver Description Displayed in Displayed in AUTO mode MANUAL mode Synchronization Frequency difference bar graph In When the column Voltage difference bar graph synchronization generator is ready Phase difference column state and the generator Frequency m
194. m Information keys on the GENSYS 2 0 front panel A53 Z0 9 0020 N EN Technical documentation Chapter User interface 6 3 35 DOWNLOADING A TEXT FILE When you are connected with a computer a text file can be transferred between the GENSYS 2 0 and the PC This allows the following actions SG Upload new parameters to the GENSYS 2 0 Upload new equations to the GENSYS 2 0 Download parameters from the GENSYS 2 0 as a backup for you Download equations from the GENSYS 2 0 as a backup for you SG SZS SCS Data that can be transferred depends on your access level For more information concerning text files please refer to 16 3 6 5 FHETHERNET SETUP OF YOUR COMPUTER With Windows XP Open the control panel Click on network connections Click on local network General Support Graph Connection IP Host Name Incomming Bytes Per Second 2 144 kbps Outgoing Bytes Per Second O kbps Activity p Received he 0 A53 Z0 9 0020 N EN Technical documentation Chapter User interface 40 NSG NSG NSG we Click on Settings Network x Configuration Identification Access Control The following network components are installed X TCP IP gt Dial Up Adapter Add Remove Properties Primary Network Logon Novell Netware Client v File and Print Sharing Description TCP IP is the protocol you use
195. manual remote close button for genset manual breaker is programmed 3337 Gen breaker Open To be selected if manual remote open button for genset manual breaker is programmed To be selected if manual remote close button for Mains manual breaker is programmed To be selected if manual remote open button for Mains manual breaker is programmed 2260 Auto mode forced GENSYS 2 0 CORE will never switch to manual mode 2261 Manual mode forced Will switch GENSYS 2 0 CORE into manual mode TABLE I DIGITAL INPUT FUNCTIONS A53 Z0 9 0020 N EN Technical documentation Chapter GENSYS 2 0 CORE 18 3 GENSYS e O LT The GENSYS 2 0 LT is a GENSYS 2 0 that doesn t feature the following functionalities e Support of custom PLC equations e Support of remote CANopen inputs outputs extension modules This logo appears in various chapters of this document It indicates that the described function is not available on GENSYS 2 0 LT A53 Z0 9 0020 N EN Technical documentation Chapter GENSYS 2 0 LT 19 4 GENSYS 2 0 MARINE The MARINE family includes the following units e A5323 GENSYS 2 0 MARINE e A53Z4 GENSYS 2 0 CORE MARINE e A53Z5 GENSYS 2 0 LT MARINE The main features that distinguish MARINE units from standard industrial units are e ESI DNV type approval certificate available on MARINE units Visit CRE Technology Web site or contact your local distributor for more details e Advanced load management function
196. me is elapsed without any Web communication the password will be asked for again GENSYS 2 0 internal Web server is a very easy and efficient way of setting up your module Various menus can be accessed via a Web browser such as Firefox or Internet Explorer as shown in the screenshots below preron gt BSE http gensys l020 htm z I httpiffgensys s010 htm gt A HB 5 4 4 http ffgensys l020 htm gt amp gt A D http figensys s010 htm DEN Rae Power plant overview Power plant Start stop sequence My Number 1179 1 Quant it GENSYS 1147 1 Protections Quantit MASTER 4006 0 Mains parallel 1148 ChangeOver x Breaker settings EEG Mains regul 1153 Peak shav Gen Mains electric settings Speed control settings ILS compat ible 1158 Yes Synchro mode 1177 Dynamic v Excitation control settings DeadBus manag 1515 Yes lt lt gt gt Voltage Schema 4039 Triphase 120 Esc Faults Alarms Information Shift I Save vi FIGURE 13 TYPICAL GENSYS 2 0 WEB PAGES Left page shown above gives access to 6 subpages Protections for example Right page shows different kinds of parameters numerical values list of choice that can be modified and then sent back to the module using Save button Web links lt lt and gt gt give access to other pages of the current menu Esc link leads back to the upper level menu Bottom links are identical to the Fault Alar
197. mpatible with CAN inter GENSYS 2 0 with ILS analogue parallel lines A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 56 5 5 MULTIPLE GENERATORS WITH STATIC PARALLELING This mode is useful when you urgently need to start a full plant with multiple generators The generators will be ready to take load in the shortest possible time This mode is also very useful when your installation includes high voltage transformers Starting generators which are paralleled together gives a progressive magnetization without peaks no transient short circuit Note As long as there is a voltage on the bus bar the dynamic paralleling mode will be used even if static paralleling is configured The static paralleling mode is only usable if all of the power generators are stopped and bus bars are dead CANBUS inter Gensys abo eS DG1 DG DG3 DG4 bro i RPM Pic ku p tJ Excitation ON OFF TILE CB CB FIGURE 24 STATIC PARALLELING WITH 4 GENERATORS COUPLED TOGETHER IN EMERGENCY SITUATION 9 5 SEQUENCE Voltage 400V 80V FIGURE 25 EXAMPLE WITH 4 GENERATORS PARALLELED TOGETHER IN EMERGENCY SITUATION A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 5 Loss of voltage Each GENSYS 2 0 is ordered to start All breakers CB1 CB2 CB3 amp CB4 close as ordered by GENSYS 2 0 DG1 DG2 DG 3 amp DG4 start All generators reach t
198. n OV U amp l y N e ep ep ep e 00 00 to Ov 16 connected to OV y 3 5v 1 5 Hz not 26 20 to reach EMR over speed Ghana Control PWC 2000 75 5 25 SCANIA 16 Itr full 20 36 electronic engine A53 Z0 9 0020 N EN Technical documentation Shunt 26 com G11 connected Aux connected to OV 11 12 open 31 5v Programmable See 14 9 Chapter Dedicated 1 0 lines VA Terminal G11 ref Terminal G9 out Manufacturer Model offset 1077 Amplitude 1076 EMCPII 5 interface 13 10 ECU 38 23 80 34 TABLE 18 SPEED GOVERNOR PARAMETERS Connecting GENSYS 2 0 to a Cummins EFC CATERPILLAR JOHN DEERE LEVEL Ill G2 speed input line 915 D2 sensor return 914 5V ref speed 999 Remark 2Hz and 0 8Hz although the GENSYS 2 0 output still increase Two different wirings for the same governor Because of the very high sensitivity of Cummins EFC module input please use the schematic below to connect your GENSYS 2 0 to the EFC The resistors must be as close as possible of the speed governor terminal This way GENSYS 2 0 analogue speed output can be set higher parameter E1076 according to the resistors used i 15k speed P Speed out __ G9 Speed Out Speed 1 5k governor EFC Cummins G11 Speed Ref 9 speed ref K3 Ov 2 battery Gensys2 0 FIGURE 42 CONNECTION WITH EFC CUMMINS
199. n level 2 to menu Configuration Control loops kW control and set the following parameters kW sharing loop G 50 E1102 Hz loop G 25 E1902 4 Adjust genset speed to give 49Hz using the speed governor GENSYS 2 0 in manual mode without load 5 Switch to Test mode When the breaker is closed frequency should return to 50 00Hz within 5 seconds 6 Adjust the Hz central gain E1902 to adjust the time if needed Repeat step 5 for all gensets 8 Test the load sharing by changing the nominal frequency of one generator to 49Hz Bus frequency should remain at 50Hz and kW load sharing within 2 of that desired The stability of load sharing is adjusted with kW sharing GPI E1901 A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 114 Notes E1902 stability of de drooping only activated in the master GENSYS 2 0 Adjust to recover 1Hz within 5 Sec E1476 0 Inhibition of central frequency E1476 with a high value response time will be slower recommended default value 2 E1901 Load sharing integral is only active on the slave GENSYS 2 0 units E1102 Global gain of load sharing is obtained by multiplying the PI and the central Hz gain E2739 1 Iam the master I control the frequency E2739 0 Iam a slave I share load using the integral 14 13 GCR SYNCHRONIZATION amp MAINS PARALLELING When using the central frequency de droopi
200. nalogueinput38 Analogin38 0323 00 16384 analogueinput39 Analog in39 0324 00 16384 analogueinput40 Analogin40 0325 00 16384 analogueinput4l Analogin41 0326 00 16384 analogueinput42 Analogin42 0327 00 16384 analogueinput43 Analogin43 A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 152 Code Variable Default Default Description number unit code accuracy code 038 00 gt Analog in 44 2283 00 00000 VirtualinputSparet1 VirtualinO1 2284 00 00000 VirtualinputSpare2 Virtualino2 2285 00 00000 VirtualinputSpare3 Virtualin03 2286 00 00000 VirtualinputSpare4 Virtualin04 2287 00 00000 VirtualinputSpare5 Virtualin05 2288 00 00000 VirtualinputSpare6 Virtualin06 2289 00 00000 VirtualinputSpare7 Virtualin07 2290 00 00000 Virtual input Spare8 Virtualin08 2291 00 00000 VirtualinputSpare9 Virtualin09 2292 00 00000 Virtualinput Spare10 Virtualin10 2293 00 00000 Virtualinput Spare11 Virtualin11 2294 00 00000 Virtualinput Spare12 Virtualin12 2295 00 00000 Virtualinput Spare 13 Virtualin13 2296 00 00000 Virtualinput Spare14 Virtualin14 2297 00 00000 Virtualinput Spare15 Virtualin15 2298 00 00000 Virtualinput Spare16 Virtualin16 2299 00 00000 VirtualinputSpare17 Virtualin17 2300 00 00000 Virtualinput Spare1
201. ncecsaceceaceceaceceaceceaceseaceceaceceaceseaceneas 18 3 GEN POT o E E E A E E E E E E O E E A E A A E 19 4 GENSYS SONNE 20 5 DESCRIPTION seseroprrakrii trin yrsr br Enr EENE EEREN EEEE EEEREN ENEAN NENEN NEEN 21 5 1 FRON 21 5 2 REAR PANEL CONNECTORS ccsccsiccisscctcadsnacindcanaedanietnuniltalenaudeaatelawelndcanaad aammmseik doewnedbuotuauslnenudaed saaduacbitekwantiwaduseaecosmaetauns 27 6 USER INTERFACE ate rcececicncecnciovessasnercisnniciccyectavsesecievenvatuersiannietaceraisaseeualsvinsedisesiennisssaveetsuabecaisvensedusecieanieteaseateus 34 6 1 EFTER 35 6 2 VAN NNN 36 6 3 REMOTE CONTROL USING A PC ETHERNET CONNECTION emumeronnrrrnnvnnnrrnnnrnnnnrnnnnnnnernnnnnnnernnnrnnnernnnrnnnennnnrnnnnsennrnnneenenrnn 38 7 PERINGNODE jr 44 7 1 PENNE a caascersacsenieaceeracuciontaanstcaeascaucienanaesisonaie aes easaaeudaaananacianenantecuncebaeseneadaaanacecwannanien 44 7 2 PTE et eco se tests st Gensisctd cats dines eaves eereinre eslcc EEA AA EAE 47 7 3 ETIENNE 47 7 4 100 MANUAL MODE ccccciviscancinetaslecduterexsatacensadeiecesstesteaactusanenditeaucasdusenesntnatacladuiedeasivenaniaduiecsasbeesasecdwisaensaseenendivs 48 8 START EON coana E sie veisavaneeucenicrsusveaaseuis nia vedsauaneeucesseveisueuacauessraveisauaneeecesioreieueiins 49 9 PREDEFINED CONFIGURATION aanessssssssssssssssssssssssssssosesesssssssossossssssssossssssssssssssssssssssssssssssssssssssssssssssosessssssssoso 51 9 1 SINGLE GENERATOR IN CHANGE OVER MODE cccececc
202. nected to the busbar and not before GENSYS 2 0 will open the corresponding breaker and try to synchronize again The number of attempts can be configured 13 10 POTENTIAL ALARMS FAULTS LIST The potential alarms faults list is described in the table below e Variable field parameter number corresponding to the alarm fault If this variable is equal to 1 it means that the Alarm Fault is active e Potential Alarm Fault field corresponding to Alarm Fault label This text will be display in the Alarm fault pages e Alarm Fault control field this variable allows to define the protection type to associate to the Alarm Fault This list can also be download from the web site in the menu System GENSYS 2 0 gt PC file Alarms Faults summary Potential VELEI Description Alarm Fault control Alarm Fault P E0130 CAN bus tauli A communication problem occurs on the inter E1259 unit CAN bus Chapter Protections 110 A53 Z0 9 0020 N EN Technical documentation Potential es riot ET GE Alarm Fault escription E2546 MA min kW Mains reached a minimum of kW E2550 MA max kW Mains reached a minimum of kW E2172 Engine is in over speed E2176 Under speed Engine is in under speed pe The oil pressure reached the minimum threshold Analog input F8 F9 The water temperature reached the maximum AR threshold Analog input F6 F7 E2188 Battery is in under voltage E2274 Max batt volt Battery is in over voltage
203. ng a file containing all alarms faults as well as the parameters define in the FIFO data logger is displayed in your browser See 19 3 12 for more details on FIFO data logger Use the File Save as menu of your browser to save this file 3 Alarms Faults summary By selecting Alarms Faults summary a file containing all potential alarms faults and their use See 13 10 for more details Use the File Save as menu of your browser to save this file Example tsx Alarms Faults summary 0 Disable I Generator electrical fault 2 Mains electrical fault 3 Alarm 4 Fault Soft shut down 5 Security Hard shut down 6 Speed droop 7 Help Fault Soft shut down 8 Help Gen Electrical fault Potential alarm fault Actually setup as ANSI CST VO130 CAN bus fault lt V1259 6 V2347 Oil pres fault VO9Z2 5 V2004 Water Temp gt VU922 5 V2005 Emergency stop lt V092 5 V2097 Generator f lt V1024 81H V2Z101 Generator f lt V l2r BIL V2105 Generator U lt V1030 0 21 V2109 Generator U lt V1033 0 59 V2113 Min KVAR lt V1036 0 370 V2117 Max kVAR lt V1039 0 320 V2121 kW lt V1042 5 32ZRP V2125 KVAR lt V1045 0 32RQ V2129 Min kW lt V1048 0 37P V2133 Max kW lt V1051 3 2P V2137 Max I lt V1054 0 51 V2141 Max In lt V1057 0 50N V2145 Mains f lt V1060 0 81L V2149 Mains f lt V1063 0 81H V2153 M
204. ng function and paralleling with the mains using an analogue bus the central frequency has to be inhibited during synchronization The following equations should be added in level 1 or 2 if the synchronization bus is used terminal 42 of GCR terminals G1 amp G3 of GENSYS 2 0 BSI USS DE IS S WS VE DE DS TE WE IE S S VE DS DE ISOS US ISS ESI ISS US STS OS STS SIS OS TSS TS IS S WS YE ESAS TS ISI USS E DS O dage Nenne ME 006 me NS ENG aS See onnaa On mains breaker feedback is connected to terminal JI E Don forget Eo allow parameter FI TO and EI020 to be Oo mm modifiable by modbus and equations GAA RRR RRA ARK AREA RRR RRR RK RRR ARK RRR ARK RRR RAR RAK RRR S G TEST E2006 EO 1 AND E2000 mO 0 EO 1 THEN BTOC El476 0 E1020 20000 BEND ELSE BLOG BL4763 28 E1020 0 BEND TEND A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 115 14 14 INTEGRAL INHIBITION To disable this type of load sharing and return to the old type apply the Disable value from the table below The variables involved in the new type of load sharing are Variable Label Description Default Disable number value value V1102 Load sharing G Parameter to set the Global gain V1900 Load sharing P Parameter to set the Proportional gain V1901 Load sharing I Parameter to set the Integral gain 2 10 V1902 Hz centre gain Parameter to control the central frequency acting as a frequency
205. ng a GENSYS 2 0 application FIGURE 37 MOUNTING BRACKETS ON GENSYS 2 0 Use the tool which is provided to screw the bracket gently onto the panel just to hold the module in place Insert the second bracket into the two holes on the lower edge of the module and push it to the right Use the tool to screw the bracket gently onto the panel Tighten brackets gradually until the module is firmly secured 69 A53 Z0 9 0020 N EN Technical documentation Plug in the connectors 10 3 2 EARTH GROUNDING Earth grounding of the GENSYS 2 0 should be made with two M5 screws amp fan washers Use a short 4mm cable to connect the unit to earth see below FIGURE 38 EARTH GROUNDING 10 3 3 WIRING GUIDELINES The power cable must be kept separate from the communication cable The communication cable can be installed in the same conduit as the low level DC I O lines under 10 volts If power and communication cables have to cross they should do so at right angles Correct grounding is essential to minimise noise from electromagnetic interference EMI and is a safety measure in electrical installations To avoid EMI shield communication and ground cables appropriately If several GENSYS 2 0 units are used each of the OV power supplies pin K3 must be connected to each other with a 4mm cable use an adapter for the 2 5mm connection to the GENSYS 2 0 power connector itself 1 Power supply circuit breaker Terminal K3 OV should n
206. nged Mar 2009 July 2009 Sept 2009 Feb 2010 Enhanced semi automatic mode description New chapter concerning optional power tank capacitor New minimum wiring diagram Updated static paralleling diagram Updated maintenance cycles chapter Updated reference of digital input variables Updated custom logo size Updated CAN bus good practices Updated technical support contact Updated external automatic start module setup description Additional features starting from firmware v3 00 CRE Config software compatibility Assisted manual mode Front panel button inhibition Firmware upgrade using SD card Generating an empty file template Import Export Delete TXT files on SD card Resetting factory parameters New methods to permanently store parameters in memory April 2011 A53 Z0 9 0020 N EN Technical documentation Chapter Overview Date Version Comments b Additional features starting from firmware v4 00 v4 00 Power plant up to 32 modules using CAN bus Support of FAT32 SDHC cards Automatic backup of new parameter values ASSISTED MANUAL mode activated by default Option 7 Enable disable internal engine start sequence Interface with external start module without equation Fuel water oil filling without equation New menu organization Potential Alarm Fault list Download of a CUSTOM language file Enhancements and modifications Update of schematics and graphs Maximal CT ratio value Maxim
207. nguage instead of Easy PLC software Such equations require a high knowledge of GENSYS 2 0 functioning modes and internal PLC features To achieve this and help you adapt your GENSYS 2 0 to the most complex applications CRE technology can propose two solutions e Advanced training sessions on GENSYS 2 0 and its programming language e Development of equations according to your needs Engineering service Feel free to contact CRE technology or your local distributor for more details on training sessions A53 Z0 9 0020 N EN Technical documentation Chapter Text file amp PLC 156 16 5 GENSYS 1 0 GENSYS 2 0 COMPATIBILITY Using a GENSYS 1 0 configuration file into a GENSYS 2 0 unit is a risky operation and requires excellent knowledge of the parameters and equations transferred New functions have been added to the GENSYS 2 0 which uses new variables Certain GENSYS 1 0 variables have been redefined with new functions in the GENSYS 2 0 Gensys A40Z0 E2004 to E2015 The references for GENSYS 1 0 variables E2004 to E2015 must be replaced with variables E2804 to E2815 in all the equations which will be introduced to the GENSYS 2 0 Note that a timer may now be associated to E2804 to E2815 GENSYS 2 0 Description these variables by using variables E1998 E1999 and E1277 to E1286 Special care must be taken with the following parameters if used in the GENSYS 2 0 Also check the read write authorization Y N which
208. nrrrrnnnrrrnnenrennnsernnnsssennn 164 Table 56 Broadcast data received from inter module CAN DUS rrrrrvnnrrnnnnnrrnnnnnrrnnnnnrrnnnnvrnnnensnnnnnnrnnnnnsrnnnnnrnnnnesereneeeeeen 165 Table 57 Analogue and digital data broadcast example ccccseccccsseeeccsesececeesececeeecsesusececeusecesueecsssuseceseuseseseeecstsuseseeees 166 A53 Z0 9 0020 N EN Technical documentation Chapter Overview 12 Table 58 CAN bus inhibition variables 2 1 1 c ec ec ccc ccececcscscuceccecscecucececscscnenscenscseneaesssscseneaesssscncneeenscscnesnssecsensesessscscnsueaes 167 VEDI ENN 168 Table 60 CANopen input and output variables ccccceeccccseeecccceseccceusescsusececsusececueeesssusececeusesssueecsssusecsseseseseeecsssesesesees 171 Table 61 CANopen configuration example cccccsececcceeseecseececesececesesesuseceseusessseeeesssusececsusesssuecsssusecsseusessseecessesesesaes 172 Table 62 J1939 Analog measure OF J1939 cecccsoscrecsescnsususonssscscvensescnousssouesscsesensesencesssoustscsesencesencesssoustscecsensessnensssouss 173 140663 11959 Monu factutrel E CU ISl erer iarr En a E NENT ENO T OEE A OAOE 174 14016 64 J1939 Measurement ceisia niin rania NEE R ERARE ETE AREER EE EE AEE AET a 177 Table 65 Unknown SPN FMI vcisiscscasvessaiexvetincieciessncennecancouvenendavwedenevacossdedbadouenssnsixdon vader dubious sducoeduvcnendiandeoitertouvessaiavnedens 178 Table 66 J1939 Alarmis faults list aa cacrp pes cnt rs ririt sens
209. o 9 characters will appear along with 5 icons above the contextual keys The first four contextual keys allow the user to move the cursor up down left or right onto the desired character Key OK will validate the selected character and write it in the password line a appears for each character entered ENTER key validates the password If it is correct the main menu will appear on the LCD display Otherwise the password page will be displayed again You can now enter ESC ENTER and type in the level 1 password as described above so as to access the top level menu which contains three entries A53 Z0 9 0020 N EN Technical documentation Chapter User interface 35 Display Configuration System SG SG gt Display Configuration System FIGURE 9 MAIN MENU 6 2 LOCAL NAVIGATION The 5 icons above the contextual keys will change in appearance depending on the type of parameter to modify chosen list label numerical value password They are referred to as the navigation bar or soft keys User can navigate through the different menus with this navigation bar and the ESC ENTER keys Navigation bar has 5 contextual keys soft keys Depending on the menu displayed different icons may appear above these keys allowing the user to scroll up down the pages or to select a link to a new menu or parameter When a parameter is selected and the user presses ENTER key then the di
210. o be used to ensure reliable CAN communication These rules must be applied to all CAN communications including inter GENSYS 2 0 CAN bus COM1 and ECU remote I O CAN bus COM2 Table below lists the standard CAN DB9 wiring compared to GENSYS 2 0 DB9 Terminal GENSYS 2 0 Standard CAN ME El tola 1 NC Reserved 2 CAN L CAN L X 3 GROUND 1 CAN GND X 4 NC Reserved 5 GROUND 2 CAN SHLD optional 6 GROUND 1 GND optional 7 CAN H CAN H X 8 NC Reserved 9 NC CAN V optional SHIELD GROUND X TABLE 5 DBS PIN OUT 17 11 CAN BUS CABLE Cables used must be selected to respond to CAN bus specificities Always use 1200 shielded twisted wire pairs Shield should be connected to the metallic connectors of the cable CAN bus must be deployed in a single line way no star ring or mesh connection as shown below Network topologies FIGURE 77 NETWORK TOPOLOGIES Both ends of the CAN bus must be terminated with 1200 resistors Such resistors are fitted into GENSYS 2 0 COM1 and COM2 and can be activated using DIP switches at the rear of the module under the OFF 1200 plug Termination resistor is connected to the CAN bus when the switch is set to ON 1200 side When the switch is set to OFF resistor is disconnected from the CAN bus Figure below gives the example of 3 CRE Technology modules connected through CAN bus Terminal resistors must be activated as shown on the 2 modules located at both ends of the CAN bus
211. oad sharing lines FIGURE 33 POWER PLANT PARALLELING WITH SEVERAL MAINS This application requires additional modules to manage the mains power supply Additional modules can be MASTER 2 0 recommended or GCR not recommended for a new installation MASTER 2 0 uses all digital technology whereas GCR uses analogue load share lines sometimes called Parallel Lines This chapter is a basic overview Full MASTER 2 0 functions can be found in the MASTER 2 0 technical Variable number Variable label Variable value 1179 documentation 1177 Staticparal NO X TABLE 17 POWER PLANT PARALLELING WITH SEVERAL MAINS CONFIGURATION A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 66 10 INSTALLING AND COMMISSIONING A GENSYS e O APPLICATION 10 1 MINIMUM WIRING DIAGRAM sop FE 3 lero 33 g 4 g S53 o uap v E v a 30 Eg ag S Z Power Tank 25 Power supply fe Power supply Emergency stop Crank outpu 5 Fuel B relay out uopneaydde auope jasuek 1 COM 4 Isolated ETHERNET Ge Z Fr C Me N o b gt in io N output 7 Py Gute ro Output 2 t 9 KI Output 3 E ey Out t Wlly LO gf Shield on Oil pressure meas a Oil pressure meas E Water temp meas lt i Water temp meas gi Engine meas 1 I a Engine meas ca Engine meas 2 T En
212. ode Auto mode Test mode Nb ofrunning hours Eletric protedions Analog logical inputs _ gt V lt V gt f lt f gt Q Oil Pressure gt P 3L Water temp remote start Emergency stop Gens et breaker aux Mains breaker aux Pickup frequency Spares Logical outputs Crank Fuel solenoid Mains breaker Genset breaker Spares Analog output analog signal to speed regulator LY or HV 100 430v FIGURE 18 POWER PLANT IN CHANGE OVER MODE WITHOUT PARALLELING VEUEN Variable label Variable value number 4006 Nb ofMaster 0 gt 1177 Static paralleling No gt TABLE 9 TYPICAL BASIC CHANGE OVER CONFIGURATION A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration In Change over mode as shown in Table 9 the generator starts and takes the load when a mains electrical fault occurs When mains power returns the generator breaker is opened and the mains breaker is closed after a pre set delay For the generator to start when mains failure occurs either a protection mains or other or a digital input has to be configured as a Mains electrical fault See Figure 19 If remote start is on when mains are present the generator starts GENSYS 2 0 opens the mains breaker then closes the generator breaker and takes the load See Figure 20 E0022 Mains voltage E2201 Mains failure E2000 Mains breaker E0003 Genset
213. om the J1939 norm point of view this address corresponds to the source address Chapter Communication 181 A53 Z0 9 0020 N EN Technical documentation 17 3 3 COMe MDEC MTU COMMUNICATION The MDEC Engine Management System controls and monitors all the functions of MTU 2000 and 4000 Series genset engines This system includes an Engine Control Unit ECU an Engine Monitoring Unit EMU a Local Operating Panel LOP and engine wiring and sensors It incorporates a self diagnosis system complemented by a load profile recorder which stores the service life data of the engine in much the same way as a flight recorder MDEC also serves as the interface between the engine electronics and the overall generator including gearbox coupling and alternator Note Selecting MTU MDEC communication prevents you from using extension remote I O modules 1 MDEC configuration To correctly communicate with GENSYS 2 0 MDEC internal variables have to be configured The MDEC should be configured as follows to activate the CAN communication 200 set to 450 201 01 set to 32 201 05 set to 201 For more information on MDEC configuration contact your MTU dealer 2 GENSYS 2 0 configuration To activate the MTU CAN connection enter Configuration Engine J1939 MTU menu and select e Manufacturer MTU e ECU type MDEC Download the custom language MDEC has labels and codes or numbers which correspond to the MDEC variables
214. om v4 55 offset and amplitude values are working the same way as in CATERPILLAR usage If you send a TXT file from an old firmware i e from v1 00 to v4 04 into a newer unit with firmware v4 55 or later parameters will be automatically adapted and you will be informed by the compilation result Chapter Dedicated I O lines WARNING 001 PWM 500Hz settings updated E1076 E1077 See technical documentation A53 Z0 9 0020 N EN Technical documentation Caterpillar PEEC Caterpillar ADEM un MAY B F oe te PWM Signal o lip mney sex O 1 Converter lear DATA LIK 0 PSE Sn nan At oo 6 ginun surr I A mS RY lt 5 21 2 3 NOt D n l slim p O D gegen og mm e 8 7 LE oe 9 PWM r ola s som v ED EE ee a si mere PWM e ATT REF zs M lero E mar VA pep an a E peen o START amp ENGINE SHUTDOWN o opaa one olata pata unk iE ATOO laa ata Lo Gunma ER O er BATTERY FIGURE YG CATERPILLAR PEEC AND ADEM CONNECTIONS 1 2 SPEED AND VOLTAGE CONTROL WITH CONTACTS PULSES GENSYS 2 0 K1 K2 K3 K4 y s 3 vu oD vu vu Y YL 2 a 9 amp g FIGURE 45 SPEED AND VOLTAGE CONTROL WITH CONTACTS PULSES 1 2 PARAMETERS Param tre Valeur Description f E2341 OutputC1 Configuration Outputs Digital outputs f E2342 Output C2 Configuration Outputs Digital outputs U 2343 Output C3 Configuration Outputs Digital outputs U
215. ommon Gen open breaker Gen close breaker Gen common Engine meas 1 OFF 120 Q Engine meas 1 COM 2 Engine meas 2 COM 1 Engine meas 2 COM 5 CAN 2 J1939 RS485 MODBUS RTU COM 2 COM 5 Water temp meas Water temp meas Oil pressure meas i i Oil pressure meas 4 Oo 3 SF dzz i gt gt gt 2 DES 3 Memory slot gR FIGURE 5 REAR PANEL A53 ZO 9 0020 N EN Technical documentation Power tank Spare input Spare input Spare input Spare input Spare input Spare input Spare input Spare input Spare input Spare input Water temp Oil pressure Remote start stop Gen breaker in Mains breaker in NO HAV Chapter Description 27 On MARINE units e Logic inputs J4 and J5 are factory set as spare inputs like J6 to J15 K e Relay outputs A1 and A2 are factory set to spare outputs like transistor 3 outputs C1 to C5 A e G1 G3 analogue input is factory set to 10V input but can be used as 20mA using parameter E1461 5 2 2 INPUTS YOUTPUTS Terminal Terminal Description capacity Comment mm AWG Supplied via emergency stop input at battery positive voltage Can also be used as configurable relay output see 11 4 2 SA max Supplied via emergency stop input at battery positive voltage Can also be used as configurable relay output see 11 4 2 5A max gt He 2 5 12 Crank relay out Output 6 gt N Fuel relay out 2 5 12
216. on TABLE 64 11939 MEASUREMENT LIST 1 PGN Parameter Group Number 2 SPN Suspect Parameter Number Chapter Communication 177 A53 Z0 9 0020 N EN Technical documentation In addition of these measures the module display the last five 5 unknowns SPN FMI which have been received by the module with the diagnostic message DM1 The known SPN are described below in the 1939 Alarm Message chapter These SPN FMI are backup in the following parameters Parameter Description J1939 SPN LO 1 Last SPN FMI received by the module E0852 J1939 SPN HI 1 E0853 J1939 SPN FMI 1 E0854 J1939 SPN LO 2 SPN FMI n 2 received by the module E0855 J1939 SPN HI 2 E0856 J1939 SPN FMI 2 E0857 J1939 SPN LO 3 SPN FMI n 3 received by the module E0858 J1939 SPN HI 3 E0859 J1939 SPN FMI 3 E0860 J1939 SPN LO 4 SPN FMI n 4 received by the module E0861 J1939 SPN HI 4 E0862 J1939 SPN FMI 4 E0863 J1939 SPN LO 5 SPN FMI n 5 received by the module E0864 J1939 SPN HI 5 E0865 J1939 SPN FMI 5 E0866 Chapter Communication TABLE 65 UNKNOWN SPN FMI 1 SPN LO correspond to LSB of SPN SPN HI correspond to MSB of SPN 4 J1939 CAN bus fault The parameter E4080 controls the action to perform on a communication fault of the J1939 CAN bus This parameter is available in level 2 in the Configuration J1939 MDEC menu 178 A53 ZO 9 0020 N EN Technical documentation 5 J1939
217. one fault triggered by GENSYS 2 0 5202 Will activate an output when there is at least one alarm triggered by GENSYS 2 0 5204 Will activate an output when there is at least one serious summary fault securities triggered by GENSYS 2 0 Will activate an output when there is at least one minor fault summary triggered by GENSYS 2 0 5200 Will activate an output when there is at least one generator summary electrical fault triggered by GENSYS 2 0 2201 Mains elec faults Will activate an output when there is at least one mains summary electrical fault triggered by GENSYS 2 0 Output activated by the protection in the Non essential 2724 Trip out 1 consumer trip sequence See 15 2 This is the first trip Non essential consumer trip A53 Z0 9 0020 N EN Technical documentation 2017 Chapter I O lines N N O UJ 101 Function Description Output activated by the protection in the Non essential consumer trip sequence See 15 2 This is the 2nd trip activated E1894 seconds after the previous one Non essential consumer trip Output activated by the protection in the Non essential consumer trip sequence See 15 2 This is the 3rd trip activated E1894 sec after the previous one Non essential consumer trip Output activated by the protection in the Non essential consumer trip sequence See 15 2 This is the 4th trip activated E1894 sec after the previous one Non essential
218. ons faults alarms Refer to document Z0 90030 xIs to get the complete list of variables packed inside bitfields E0516 E0535 Fault 1 to 20 A negative value indicated that the fault is ON A positive value indicates that the fault is OFF A zero means no data E0516 is the most recent event listed Example E0516 2005 means that emergency stop is active E2005 emergency stop E0516 2005 means that emergency stop has been released E0821 E0850 Fault 21 to 50 A negative value indicated that the fault is ON A positive value indicates that the fault is OFF A zero means no data E0850 is the most ancient event listed Example E0842 2005 means that emergency stop is active E2005 emergency stop E0842 2005 means that emergency stop has been released TABLE 75 MODBUS PARAMETERS FOR ALERM FAULT MANAGEMENT 2 Sharing digital input and Modbus control over a single function If you need to control a specific function for example REMOTE START E2514 both using Modbus and logic inputs please follow instructions as described in the example below to avoid conflicts between logic inputs and Modbus write accesses In this example remote start E2514 is controlled both by input J8 and through Modbus access This means that both can start the generating set To do so a virtual input here Virtual input 1 E2283 is setup the same way as input J8 and is then controlled through Modbus e Set parameter E1269 DIJ8 fun
219. ont panel and operating modes e Specific I O factory settings e Specific configuration menus e Advanced power management system and menus e Uneven load sharing protection on kW and kVAR eHeavy consumer management accepts 4 independent requests with specific kW level and or number of engines eAbility to maintain a predefined kW margin on running engines Allows immediate management of heavy consumers Ability to stop a specific engine on request logic input if this doesn t overload the power plant Blinking Alarm Fault LED if a new event occurs December Logic output function Voltage synchronization in progress 2012 M External engine stop request with load dependent kW checking User defined labels on transistor and relay outputs C1 to C5 A1 and A2 PWM Caterpillar parameters conform to Caterpillar usage A maximum of 10 parameters E1xxx E4xxx can be changed per PLC cycle MARINE e Additional information on non essential consumers management e Paralleling a power plant with the shore using a Selco T4000 auto synchronizer Additional information on TEST mode usage Additional information on software options Additional information on load dependent start stop sequences PLC programming language removed users are advised to use Easy PLC software January M2 Add GENSYS 2 0 MARINE picture on front page 2013 Layout of the technical documentation Precision on the inductive aspect of parameter E1110 Power factor setpoint
220. ontrol settings Parameter Possible value Comment var num Speed measure Magnetic 0 Recommended if a magnetic pickup can be wired to G7 and E1078 G8 terminals of the GENSYS 2 0 Alternator 1 Speed measurement from generator frequency No of teeth E1106 Pole pair no E1109 Number of teeth on the fly wheel necessary if magnetic has been chosen as speed measurement source Number of pairs of poles on the generator necessary if alternator has been chosen as speed measurement source Idle speed Engine idle speed of the internal speed controller the E1079 engine will accelerate from crank disconnect value to idle speed then the speed will increase following a ramp from idle speed to nominal speed Nom speed 1 First speed set point default p amet Nom speed 2 Second speed set point activated with logical input or E1081 Speed droop TABLE 93 SPEED CONTROL SETTINGS CONFIGURATION E1075 1 Only available on level 2 2 Available according to Speed measure E1078 3 Idle speed hould be set to nominal speed 1 value E1080 if the internal speed controller is not used Speed governor control Parameter Comment var num ESG gain To be set between 100 for 10V to 10V output to external E1076 speed controller and 100 for 10V to 10V output This value must be set to have a GENSYS 2 0 control speed deviation of 3Hz on the engine See 11 1 1 for more details ESG off
221. opping itself To be selected to stop the external Horn Useful if one Remote stop horn output is set as Horn to be used in conjunction with digital outputs To be selected if manual remote close button for genset breaker is programmed T if f 2337 Gen breaker Open manual o be se ected if manual remote open button for genset breaker is programmed A53 ZO 9 0020 N EN Technical documentation 2655 2336 Gen breaker Close manual Chapter I O lines 98 Function Description To be selected if manual remote close button for mains Mains breaker Close manual breaker is programmed 2339 Mains breaker Open manual To be selected if manual remote open button for mains breaker is programmed T if iff i f h 2001 Generator breaker Aux O be se ected j di erent input for the generator breaker position is required i iff i for th i ker i 2000 vere er To be selected if a different input for the mains breaker is required 2002 ante ctarn To be selected if a different input for remote start is required 2003 Oil pressure fault To be selected if a different input for oil pressure fault is required 2004 Water temperature fault To be selected if a different input for water temperature fault is required To be selected if load unload features depend on a priority genset see Configuration gt load unload menu Will inhibit the Manu key on the GENSYS 2 0 front panel Auto mode forced GENSYS 2 0 will never be in Manu mod
222. or written permission THIS SOFTWARE IS PROVIDED BY THE AUTHOR AS IS AND ANY EXPRESS OR IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES 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 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 188 17 6 COMS MODBUS RTU ON SERIAL PORT RS485 All GENSYS 2 0 internal variables Measurements parameters PLC outputs can be monitored remotely through an RS485 communication bus using a MODBUS RTU protocol GENSYS 2 0 being a MODBUS slave It is also possible to enter parameters into the GENSYS 2 0 All digital and analogue input output values and all other parameters which appear in the GENSYS 2 0 menus can be obtained by the serial port RS485 DB9 male COM4 Parameters Einnn are in read only mode factory setting but can be individually switched to Read Write mode using the embedded Web site Measurements EOnnn are Read only variables E2nnn are in Read
223. otected against Chapter Description 31 Terminal Terminal Description Capacity Comment mm AWG Power supply 2 5 12 PWM output 2 5 12 500Hz PWM output Compatible with Caterpillar and Perkins PWM controlled units 0 5V protected against short circuits to OV Details in 11 1 2 Bus Mains 13 2 5 12 Bus Mains 13 25 12 Bus Mains current measurement 1 to 5A Maximum rating 15A during 10s Bus Mains 12 2 5 12 consumo Bus Mains 12 25712 External current transformer is normally used Bus M aa 25 12 Maximum ratio is 3250 meaning 3250 1 or Bealls 16250 5 Bus Mains I1 25 12 CAN1 Male DB9 Isolated CANO bus shielded polarity inversion Power supply must be wired from the speed governor via 4 mm wires See state of the art rules wiring diagram External 5A 40Vpc fuse recommended COM1 inter GENSYS 2 0 Proprietary protocol to communicate with other GENSYS 2 0 MASTER 2 0 units and share data information See details in 17 2 COM2 CAN2 options Male DB9 Isolated CAN bus 125kb s factory setting J1939 shielded See details in 17 3 CANopen Used to communicate with MTU MDEC e remote I O see 17 3 1 e J1939 ECU se 13 3 2 e MTU MDEC protocol see 17 3 3 A53 Z0 9 0020 N EN Technical documentation Chapter Description 32 Terminal Terminal Description Capacity Comment mm AWG COM3 USB USB GENSYS 2 0 with firmware
224. ovide specific trainings on our products and softwares 4 Technical support 33 0 4 92 38 86 86 office hours 8 30AM 12AM 2PM 6PM GMT 1 Email support cretechnology com O SKYPE support cretechnology com INFORMATION You can download the most up to date version of this documentation and different other documentations relating to CRE technology products on our Web site http www cretechnology com 1 A53 Z0 9 0020 N EN Technical documentation Chapter Overview Technical documentation history Date Version Comments Jan 2008 B Correction and full explanation of several features gt Feb 2008 Details added for the semi auto mode J1939 details added Modification of general wiring diagram Removal of USB connection Addition of Ethernet connection Firmware update using SD card added Chapter on GENSYS 1 0 GENSYS 2 0 compatibility added Extra information concerning analogue sensors Information concerning CEM compliance added Ethernet connection added and USB connection chapter updated Digital input parameter errors corrected Two phase three phase system management added SD card archiving added Breaker management info added SD card flashing removed Start sequence GENSYS 2 0 firmware v2 05 IP address can now be changed Support of Modbus TCP July 2010 H J1939 compatibility with Cummins QSX15G8 Automatic shutdown of the horn Corrections on PWM 500Hz documentation CANopen example cha
225. owing active alarms Pressing a second time on the same key will switch back to the menu displayed beforehand Alarm archive can be deleted in the System Date Time meter Data logging reset menu 1 Direct access to global monitoring page user configurable 2 Save parameters in flash storage when pressed with SHIFT this action is called SHIFT I Pressing this key will switch to the associated menu which is custom made and contains parameters the user wants to monitor easily Pressing a second time on the same key will switch back to the menu displayed beforehand LED test pressing this key will turn on all GENSYS 2 0 LEDs It is a simple test to check the LEDs and the keypad TABLE 4 SERVICE PANEL KEYS Starting from firmware v4 55 FAULT and ALARM LED blinks when a new fault alarm or embedded Web site associated LED stops blinking It is kept lit if a fault alarm is still ON otherwise it is switched off A53 Z0 9 0020 N EN Technical documentation FAULT occurs When the user displays active faults alarms using front panel buttons nur og ALARM Chapter Description 24 5 13 CONTROL PANEL The control panel allows the user to pilot and control the generator See chapter User interface for more details concerning the functions of front panel LED and keys K Function M lt This LED is illuminated when a key is pressed and is switched off when all keys are released This LED also sta
226. parameters are displayed e Generator active and reactive power P et Q e Engine speed e Generator voltage phase 1 e Frequency e Sum of the speed output en A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 229 Hz loop This menu is only available in level2 It allows to set the center frequency PID See 14 1 for more details Parameter Comment NETT G Global gain of the center frequency E1902 TABLE 109 PID HZ LOOP CONFIGURATION While you adjust the PID settings the following parameters are displayed e Generator active and reactive power P et Q e Engine speed e Generator voltage phase 1 e Frequency e Sum of the speed output en 2 kVAR control kVAR sharing loop When reactive load sharing is enabled this menu allows setting the kVAR sharing PID See 14 12 for more details on PID Parameter Comment var num G Global gain of the reactive load sharing E1123 TABLE 110 PID KVAR SHARING LOOP While you adjust the PID settings the following parameters are displayed e Generator active and reactive power P et Q e Engine speed e Generator voltage phase 1 e Reactive power set point e 3 phases reactive load Chapter Menu overview cos amp loop This menu allows to set the cos control when the generator is paralleled with mains See 14 12 for more details on PID Parameter Comment var num G Global gain of cos control E11
227. pgrade e Import Export a text file Table below details what kind of SD card can be used depending on firmware version installed into your module To check your firmware version go into menu System About or System Serial number Soft version Supported cards and file systems depending on firmware version Firmware versions 4 00 and above can accept SD and SDHC cards formatted using FAT16 or FAT32 file systems Firmwares older than v4 00 only accept SD cards up to 2 GB formatted using FAT16 file system High capacity SDHC cards cards above 2 GB and cards formatted using FAT32 file system are not supported Formater SD STORE E 21 gt Hub UG 2 x Capacit Capacit 1 28 Go 1 28 Go v Syst me de Fichiers Taille d unit Taille d allocation par d faut Taille d allocation par d faut Nom de volume Nom de volume SD_STORE SD_STORE 17 7 1 DATA LOGGER USING SD CARDS The SD card must contain a file named logger csv CSV Comma separated value is a computer file format which shows tables in the form of values separated by commas or semi colons This file can be created using Microsoft Excel or the notepad open the notepad then write the names of the variables you wish to save max 25 using the Exxxx format Separate each variable with a comma and save the file as logger csv A53 Z0 9 0020 N EN Technical documentation Chapter Communication 193 EJ Microsoft Excel logger
228. put A53 Z0 9 0020 N EN Technical documentation Chapter I O lines 107 V1210 O N Sparel calibl Se WALZ IL 1 N Sparel calib Sed en vakle IL N Sparel calips Oe eG TG vi T 1 N Sparel calib4 o Ailes ke WALZ La dl N Sparel calibs o Oe eS Gy Welle Is dl N Sparel calib6 leo red WAZ IS 1 N Spare Nea STG per VZ 1 N parel calib 2 WALZ eS l N Sparel calib9 Z32702 2 OF VZ 1 N Sparel caliplo SLT ORE o WIZZ 1 N parelel apl Z ere Foo Kl Ai O N Sparel resl TUCO 0000 WIZZ 2 LOO N Sparel res2 10 O000 9565565 YIS 2000 N Sparel res3 TO COCO Moa sc 5 V1224 S009 N Sparel res4 00000 WIZ 25 4000 N Sparel res5 OOOO 65555 va 5000 N Sparel res6 OOOO OCs 56 5 v22 6000 N Sparel res7 TO OOCO eea vi noe N Sparel res8 TOC O00 Coos gt WIZ 28 8000 N Sparel res9 TO O00 0 oases WALZ SO 9000 N Sparel resl0 OOOO Oso o 6 5 WAZ Sb 10000 N Sparel resll POCO O 0000 For Normally closed or normally opened inputs wiring will be similar only the software requires modification Then enter these equations to switch to virtual input PENN analog input to DI spare 1 GAARA NE KN SKE RRR ARK ERK KA KK A Ks GCHOOSI analog input Spare I OE oar a apea O S S IS D P S IS DS S DS TS RAR S DS IS E DA DS NNN E2203 6 Calibration rable bs Imi l ar or En sel opered Input ROO egu uat ions PN AS S DE DS A S DE DS AS DS DE D AS DS DS D AS DS DS DS S OS DS S S DS O Analog input in numeric opare A gt GAA S S A
229. r Mains breaker Bus voltage Genset breaker PREFERENCE mode NSYS 2 0 MARIN G Bus voltage LED Green LED lit when generator voltage Alternator is present Function Green LED lit when engine is running Green LED lit when generator breaker is closed Green LED lit when mains breaker is closed Green LED lit when voltage is present on Mains Bus voltage inputs CB CLOSED S _ PREFERENCE Green LED lit when generator breaker is closed O Green LED lit when the generator is running in PREFERENCE mode also called PRIORITY mode BUSBAR SUPPLY Green LED lit when voltage is present on Bus voltage inputs TABLE 6 CONTROL PANEL LED A53 Z0 9 0020 N EN Technical documentation Chapter Description 26 5 2 REAR PANEL CONNECTORS 5 2 1 OVERVIEW EEE s2eeeee FP 2 2 8 2 8 S88 88 S 5 b 8 Enpa EE ER amp a amp KR E 2 w Voltage 100 V to 500 V Generator I1 Generator I1 Generator 2 3 9 35 i Generator 12 A Generator I3 orn 0 memes G NSYS 2 0 1A to 5A z yno ejau jen4 9 ndino ino Aejas yuen doys A2uabsowz3 Bus Mains I1 Bus Mains I1 Bus Mains I2 Bus Mains 12 Bus Mains I3 Bus Mains I3 PWM output Power supply 9 to 40 VDC Power supply Mains open breaker CAN 1 inter Gensys USB Ethernet Mains close breaker COM 1 COM 3 COM 4 Mains c
230. rameter reduces the difference between the set point and the actual value By increasing I the rise time will decrease However overshoot will increase and may also render the system unstable slow hunting The D parameter increases the stability and minimizes the overshoot phenomena By increasing D overshoot will decrease but the system may still be unstable particularly if the measured signal is disturbed sensor signal not filtered 14 12 2 EMPIRICAL SETTING METHOD First set G to 50 Set the parameters P and D to zero Increase the value of P until the system becomes unstable From this position decrease the value of P to 60 of the previous value Set in the same way Increase D if the system is unstable upon fast load variation If stability cannot be achieved restart the settings and reduce system unstable or increase system too slow G A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 130 14 13 LOAD DEPENDANT START STOP IY 13 INTRODUCTION This function automatically controls the starting and stopping of generators of a power plant depending on the current load whether paralleling with the mains or not Coordination with the other GENSYS 2 0 units is done via the CAN bus COM1 Required configuration to allow automatic load unload is e Remote start input must be active on each GENSYS 2 0 connected to OV If remote start is off the generator never starts e Atlea
231. ranking E2084 Preglow timer Shows the preheating time before cranking TABLE 78 ACTIVE TIMERS 2 2 Timers 2 2 Parameter comment FEAA aa E2256 excitation after a generator electrical fault E2073 any action on mains breaker E2074 any action on generating set breaker Fail to synchr When synchronizing in auto mode this timer defines the time to E2075 determine if synchronization has failed E2081 E2082 E2239 reached See 14 13 E2240 is reached See 14 13 MA back timer In changeover configuration shows the time to wait when mains E2091 returns Chapter Menu overview TABLE 79 ACTIVE TIMERS 2 2 19 2 8 MAINTENANCE CYCLE MONITORING This menu display the maintenance cycle monitoring that has been configured see 14 16 19 2 9 ABOUT This screen is only display with the level 0 password It s the same menu than System About available with the level 1 password See 19 4 11 19 2 10 DATA LOGGING This menu is only available on web site 5 pages will show the FIFO event data logger selected in the data logger configuration page See 19 3 12 You can download the summary file with a computer connection See 19 4 6 209 A53 Z0 9 0020 N EN Technical documentation 19 3 CONFIGURATION MENU This menu allows configuring the unit You can access to this menu with the level 1 or 2 password The submenus are the followings e Power plant e Power management sys
232. rator menu 13 4 ALARM This action triggers an Alarm 13 5 FAULT SOFT SHUT DOWN This action triggers a Soft shutdown Genset breaker will open allowing the engine to cool down off load for the duration of the cool down timer The engine is then stopped 13 6 SECURITY HARD SHUTDOWN This action triggers a Hard shutdown Genset breaker will open and engine will be stopped immediately without cooling down 13 7 DROOP The kW load sharing is not done by the CAN bus but in droop This protection is used when a default on inter units CAN bus is detected See 17 2 1 for more details 13 8 HELP FAULT SOFT SHUT DOWN This action triggers a Soft shutdown with Help call Before the soft shutdown sequence GENSYS 2 0 will call another genset onto load via the inter GENSYS CAN bus When the helping set is connected to the busbar and not before GENSYS 2 0 will open the genset breaker allowing the engine to cool down off load for the duration of the cool down timer The engine is then stopped A53 Z0 9 0020 N EN Technical documentation Chapter Protections 109 13 9 HELP GEN ELECTRICAL FAULT This action triggers a Generator electrical fault with Help call Breaker s to be opened can be configured genset breaker or mains breaker Before opening the corresponding breaker GENSYS 2 0 will call another genset onto load via the inter GENSYS CAN bus When the helping set is con
233. rator electrical fault Mains electrical fault Alarm Soft shutdown with cool down sequence Hard shutdown no cool down sequence Droop mode generates an alarm TABLE 54 CAN BUS FAULT Note that you may go to Display Power plant overview pages to try to understand your wiring problem For example on a 4 generating sets power plant if module 3 is disconnected from CAN bus you will only see its data in its Display Power plant overview pages whereas you would see data from modules 1 2 and 4 on the 3 other modules This is shown on the drawing below A53 Z0 9 0020 N EN Technical documentation Chapter Communication 162 1200 kW 1200 kw 01 1200 kw 1000 kW 1000 kW a ie 1000 kW 1200 kW 1200 kW _ 1200 kW FIGURE 79 EXAMPLE CAN BUS FAULT If a remote start occurs on a GENSYS 2 0 working in automatic mode and set up to manage Deadbus situations E1515 0 and a CAN bus fault has already been triggered GENSYS 2 0 will start its engine and close its breaker if there is no voltage on the bus bar after a delay that depends on the generator number E1179 If there is a voltage on the bus bar GENSYS 2 0 will synchronize the generator before connecting to the bus bar If the generator is paralleled to the Mains when a CAN bus fault occurs and error control variable E1259 is set to 6 Droop mode Alarm speed control will be switched to droop and volt control will be switched to pow
234. ready for use 2332 Input will be monitored as defined in equations TABLE 28 INPUT VALIDITY DOMAIN 1 Safety ON time configuration is accessible via Enhanced configuration Start stop sequence menu on the Timers page Parameter is configured in E2192 and counter value is in E1514 12 1 3 DIRECTION For each of the inputs two options are available Num Label Function 0 Norm open Should be selected in normal cases unless the input is used for protection 1 Norm close Normally closed should be selected if the input is normally connected to OV and is opened when active TABLE 29 INPUT DIRECTION DOMAIN 12 1 4 DELAY For each input delay can be defined in 100ms steps between 0 and 6553s 12 1 5 INPUT FUNCTIONS Function input variable numbers can be set as indicated in the following table Function Description Should be selected if you do not use the input If the function associated to the input is Used by equations not listed below choose used by equations Can be chosen if a coolant pre heating system is installed can be used in conjunction with digital transistor output Will only work in manual mode Can be chosen if a pre lubrication pump is installed on the Manual oil prelub request engine can be used in conjunction with digital transistor output Will only work in manual mode Can be chosen if pre heating plugs are installed on the Manual preglow request engine can be used in
235. red 5 E2831 downstream on the compressor discharge side of the turbocharger E2875 E E2874 E2830 induction system O E2834 E2835 E2836 E2837 COOL LEVEL OxFEEF Ratio of volume of liquid found in engine E2873 cooling system to total cooling system volume E2874 cooling system 175 A53 Z0 9 0020 N EN Technical documentation Measure PGN CRANK CASE PRESS OxFEEF OIL LEVEL OxFEEF E2871 FUEL DEL PRESS OxFEEF E2870 E2869 E2868 amp E2867 TRIP_ FUEL OxFEE9 E2866 amp E2865 TOTAL FUEL GASEOUS E2864 amp E2863 OxFEAF TRIP FUEL GASEOUS E2862 amp E2861 OxFEAF BATTERY POTENTIAL E2860 OxFEF7 OIL FILTER DIFF PRESS E2859 E2858 amp E2857 E2856 E2829 FUEL TEMPERATURE OxFEEE E2855 LOAD C SPEED E2854 OxFEFC OxFO04 ACC PEDAL POS OxF003 E2853 A53 Z0 9 0020 N EN Technical documentation 1218 Number of fault DM5 Accumulated amount of fuel used during vehicle operation 1040 1039 SPN Description Gage pressure inside engine crankcase Ratio of current volume of engine sump oil to maximum required volume Gage pressure of fuel in system as delivered from supply pump to the injection pump Fuel consumed during all or part of a journey Total fuel consumed trip drive fuel trip PTO moving fuel trip PTO nonmoving fuel trip idle fuel over the life of the engine Total fuel
236. rotection control for high charge air temperature from V4034 1 Manufacturer selection MTU MDEC E0407 Protection control for high oil temperature from MDEC E0414 Protection control for low charge air temperature from MDEC E0422 Chapter Communication 31 1 ge V4068 ECU type ECU selection MDEC TABLE 70 IMPORTANT PARAMETERS 1 The standard sensors required for oil pressure water temperature and engine speed don t need to be connected to GENSYS 2 0 The value of these 3 analogue inputs E0029 E0030 E0033 will be taken from the MTU CAN bus 2 Control can take the following values O disable 1 Generator electrical fault 2 Mains electrical fault 3 Alarm 4 Fault soft shut down 5 Security hard shut down 184 A53 Z0 9 0020 N EN Technical documentation 4 MDEC variables The following variables are used to communicate with MTU MDEC devices E0330 to E0484 as input variables MDEC to GENSYS 2 0 E2662 to E2677 as output variables GENSYS 2 0 to MDEC The variables from MDEC can be seen from E0330 to E0484 The variables than can be written in MDEC are available from E2662 to E2677 The table in the annexes lists all the variables with correspondences between MDEC and GENSYS 2 0 5 Specific screens for MDEC dedicated pages Engine monitoring can be done via the Display Engine meters menu 3 http gensys d010_htm Microsoft Internet Explorer
237. rrrrrrrnnrrnrrrnnnnrnnnrrrnrsrsrsssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssseee 220 Table 96 J1939 protection configuration rrrrnnrrrrrrnnnnnrrrrnnnnnrrrrnnnenrrrrnnnenrrrrnnnensrrrnneesrnrnnneserersnnessrrnsnnesssrnnnnesrnnnnnenssee 220 Table 97 Generator protections configuration esessersseseeresereerseereresesrerereseereserecresereresssreressseeresererrssereresssrereseseererese 221 Table 98 Mains protections CONFIGUIATION scccccsessessecsoovessecncossssecncosesscenccessscncossessencesssseencoveessencessessencosssssencesssseens 222 Table 99 Engine battery protections configurations ssscccccccccccccccccccccssuceececsececececcsscssseusuuueuseesseeeeesssssssssussuuannessesss 222 Table 100 Digital outputs configuration 0 cccccccsssesecccnssnsscccnsuseseeccsuuseeeessuuseeeessaueesesauenseesssaenseesssaunseeessaunseessaaaaeeeseas 224 Table 101 Relay outputs configuration cccesseccecsensesvecconeesecucnsesvecueaeesccncesesscoucevsescencesssscencessescencevesscencesesscencesesseess 224 Table 102 Breakers NTN 224 Table 103 Engine timers configuration ssessssereresesreressseeresereresssreresesreroreseeressreeresereresssreressseeresereressereresserereseseereesse 226 Table 104 Mains mers ON OUT NON adsense EEEN EAER EEOAE AAEE EEA 227 Table 105 Synchro check relay configuration cccseccecseeseevectonsesvecunseesecueausesccucuesscenceseescencevessc
238. rt The start sequence is managed by an external module module 1 See 14 5 for more details TABLE 90 EXTERNAL INTERNAL START SEQUENCE CONFIGURATION Crank settings This menu is showed only if an internal start sequence has been selected It allows setting the following parameters Parameter comment var num E1134 E1138 E1325 started for crank 1 E1325 started for crank 2 E1325 started for crank 3 TABLE 9 CRANK CONFIGURATION PARAMETERS 1 Only available on level 2 Checking before starting This menu is showed only if an internal start sequence has been selected Parameter comment var num Water temp Pre heat is activated if J5 is closed and if temperature is under the E1154 preset threshold E0030 lt E1154 Oil prelube Prelube will be activated when engine state is pre start and if Chapter Menu overview E1155 pressure is under the threshold E0029 lt E1155 If the threshold E1155 is 0 then prelube is active while the engine state is pre start In this case an oil pressure sensor isn t required Cooling thresh Air fan is activated when temperature is over the preset threshold E1178 E1178 and deactivated when water temperature is lower than 80 of the threshold Air fan is not active when engine is stopped TABLE 92 CHECKING BEFORE STARTING CONFIGURATION 1 Only available on level 2 218 A53 Z0 9 0020 N EN Technical documentation Speed c
239. rter 3 B gt y P and programmed in Configuration gt Start sequence menu Output will be active when the measurement of analogue input 1 oil pressure is under the set value it will not de activate Ana1 threshold until measurement is over set value hysteresis value To be programmed and used with the following parameters Oil threshold E1175 Oil hysteresis E1176 Chapter I O lines 2269 Output will be active when the measurement of analogue input 2 water temperature is over the set value it will not de activate until measurement is under set value minus hysteresis value To be programmed and used with the following parameters Wat temp thresh E1426 Wat temp hyst E1427 2270 Ana2 threshold 103 A53 Z0 9 0020 N EN Technical documentation Value Function Ana3 threshold 2271 2272 Ana4 threshold 2525 GE available 2767 Heavy Eon authorization 1 2931 Heavy KODET authorization 2 9933 Heavy ge authorization 3 Heavy consumer fue authorization 4 Inverted of the Fuel output E2019 This function allows to use 2838 Fuel inverted the Fuel relay output A2 with an inverted polarity k 1 if th 5000 Unload brkeri Order output to close generator breaker n 1 upon start if the nominal power lt E4001 5001 Unload brker 2 Order output to close generator breaker n 1 upon start if the nominal power lt E4002 5002 Unload brker 3 Order output to close generator
240. s heavy consumers non essential load tripping e Uneven load sharing protection e No paralleling with mains K This logo applies to all MARINE units It is used in this documentation to highlight features that are specific to marine units or applications This logo applies to all LT units this includes GENSYS 2 0 LT MARINE and indicates that the function described is not included in LT units A53 Z0 9 0020 N EN Technical documentation Chapter GENSYS 2 0 MARINE 20 5 DESCRIPTION 5 FRONT PANEL G NSYS DA FAULT ALARM 1 START STOP gt E FIGURE 3 GENSYS 2 0 FRONT PANEL GaNsys 2 0 MARINE PA ENGINE GENERATOR cB PREFERENCE BUSBAR RUNNING SUPPLY SUPPLY O O FIGURE 4 GENSYS 2 0 MARINE FRONT PANEL A53 ZO 9 0020 N EN Technical documentation Chapter Description 21 The display panel allows setting up and monitoring of the GENSYS 2 0 configuration and the power plant it controls It provides a large LCD display and a keypad See chapter below for more details about the functions of LEDs amp Keys 240x128 14x64 4 492 52 30x16 large font 19 45x9 45 037x037 Backlight 160 cm tCDmode STN S S TABLE Z LCD SCREEN CHARACTERISTICS A53 ZO 9 0020 N EN Technical documentation Chapter Description 22 5 1 DISPLAY PANEL The five dedicated keys of the display panel allow direct access to special menus or functions See chapter
241. s access to fully customizable settings as described below TABLE 120 MODBUS CONFIGURATION 1 Only available with password level 2 2 Onthe computer you will have access to check boxes in order to create your own configuration Starting from firmware v4 03 advanced access rights are available e Activate Inhibit Read Write access individually on Modbus RTU or Modbus TCP communication ports e Write access to date time counters e Global write access to all configuration parameters Modbus address 163 ap Modbus speed 1441 9600 Writing to Date Time Writing to Engine meters Writing to all parameters Reading using Modbus TCP Writing using Modbus TCP Reading using Modbus ETU EEE EIOOO Writing using Modbus RTU Save Esc Faults Alarms Information Sare modified parameters FIGURE 89 MODBUS RIGHTS ACCESS SCREEN A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 237 Starting from firmware v4 03 Writing to all parameters enables access right to all configuration parameters independently from individual Modbus PLC access right that can be set on each parameter using Modification by variable number menu or TXT file with password level 2 When writing to all parameters is set individual access right is not taken into account when writing to all parameters is inactive then individual access right can be used to enable write access to one or more specific paramet
242. sariren irite raer EET EEN EIEEE EE EEO EEEN EEEE ARA EEEE 85 Table 23 Used variables for breakers Setting sseeeccccseeseccccsseecessaussecessaussecessauesecssssuseessaauasecsssaunseessaaunsessssauaseesssaees 86 T ble 24 Breaker control ON GT AN ON asked 87 Table 25 Filling parameters in automatic mode 1 00 ccccseeeceeseccenecccsesceseccenecsausescsesseseesenecssecssesessesessenecsesessesessesessaneees 92 Table 26 Filling parameters in automatic mode with equations cccccsecececeeeeccceecsccusececeucesecueececsusesesseecsssusecsseeeesesaesss 93 oe NNN 96 oe 97 Table 29 Inpul GIFECH ON GOMGIN suckicswncowsncncassdoncassedndasasteaxasansdvatacavanhioanedntensalaoswadovGnvanse hoxeanuvdnseassaltat msasdnedani iaiesanetaceacabar 97 DENN NN 100 Table 31 Digital outputs Junction aadnk aE NEEE ANONS NENE EENEN EEEE Na 104 Table 32 Oil pressure calibration POINTS ssccccsescccssescccsesccssseccsausecsauneeesausecssaueeesaunecesaueessauseesauaecssaueesaueessaunsessges 106 Table 33 Water Temp calibration POINTS ccccccsescccssesccnsesecsausecssaeeessuuecssausecssaueeesausecssauecssaueessauaecssausecsaueessaunsessges 106 Table 34 Potential Alarm Fault list cccccccceseccccseccccsscccccsececaeccccsseeecnssececnseeeensusesenseececaseseaseseseausesecaeeesensesseeaueesenaes 113 ENN NNN 116 Table 36 Mains electrical FONE resres ireririenini ieni tnt annen enn EE EEEN EENEN EUNATE NEEE EPEAREN AEE ERRATEA 117
243. set Voltage on output to external speed controller without correction E1077 between 100 for 10V and 100 for 10V E0020 E0033 E2058 TABLE 94 SPEED GOVERNOR CONTROL CONFIGURATION Chapter Menu overview 219 A53 ZO 9 0020 N EN Technical documentation J1939 MDEC Parameter Comment var num Manufacturer Manufacturer selection to communicate on COM2 by J1939 See E4034 17 3 2 for more details E4068 more details E4080 TABLE 95 J1IS39 MDEC CONFIGURATION 1 Only available on level 2 If an ECU has been selected it s possible to configure the engine protections according to the information received by J1939 Parameter Comment KET aa CT speed Protection associated to a high speed en Omer CT speed Protection associated to a very high speed de emenaocsedtonveyehope CT Cool Temp Protection associated to a high water temperature dess eneretten CT Cool Temp Protection associated to a very high water temperature deigen memories nerver CT Oil Press Protection associated to a low oil pressure PE CT Oil Press Protection associated to a very low oil pressure lesne E1863 CT Protection Protection associated to a problem with an engine system that is E1864 most probably not electronic subsystem related For instance engine coolant temperature is exceeding its prescribed temperature range E1865 the engine need not be immediately stopped E1
244. set ready Speed stabilization E1140 Voltage stabilization E1141 Normal running Start request Stop request FIGURE 60 EXTERNAL START SEQUENCE IY 5 2 CONFIGURATION 1 It is first needed to inhibit GENSYS 2 0 internal start sequence by selecting External Auto start module E1608 1 in menu configuration Engine 2 Case 1 external start module features a Generating set ready logic output Configure a GENSYS 2 0 logic input as External GE OK Menu Configuration Inputs Digital inputs Input J15 in this example Case 2 external start module doesn t feature any Generating set ready logic output GENSYS 2 0 will have to wait for the lower voltage E1028 and the lower engine speed E1163 are reached to go in speed stabilization E1140 then in voltage stabilization E1141 to consider the generating set is ready The Fuel relay output is directly connected to the start request input of the ASM 4 Set up a GENSYS 2 0 logic input as External alarm using menu Configuration Inputs Digital inputs Logic input J7 in this example and connect it to the Engine alarm signal of the external start module 5 Set up a GENSYS 2 0 logic input as Ext security hard shutdown immediate engine stop or Ext fault soft shutdown stop after cool down sequence using menu Configuration Inputs Digital inputs Logic input J6 in this example and connect i
245. splay switches to Input mode In this mode ENTER key will validate the new parameter value and return to Navigation mode while ESC key will discard parameter changes before switching back to Navigation mode The internal browser displays a white pointer in front of each link or parameter of a menu A black pointer indicates the current active link or parameter Figure 10 shows these two pointers Active link H Display Inactive b gt Configuration links FIGURE 10 BROWSER LINK DESCRIPTION A53 Z0 9 0020 N EN Technical documentation Chapter User interface 36 6 2 INPUT MODE To change a parameter first select it with the contextual keys and then press ENTER to switch to Input mode New icons will appear above the contextual keys depending on the kind of parameter selected Label modification Digital value modification Option modification FIGURE 1 CONTEXTUAL KEYS FOR INPUT MODE When the new parameter value is set press ENTER to store and confirm the new value 6 2 2 SA VING ACTUAL CONFIGURATION Starting from firmware version v4 00 the module executes an automatic backup of the v4 00 parameters in a non volatile memory except for parameters modified through Modbus So manual backup methods described below are not necessary but are still working In GENSYS 2 0 using firmware versions older than v4 00 parameters used in configuration are stored in a FLASH memory When a parameter is
246. ssecessaessecsssaussecessaeseecsssaensees 132 Figure bo Au l matic IGA OOG EEE EEE EE EEE NE 133 Figure 67 Automatic load unload sequence with Custom E1617 MOC ccccccccceeeeeeeeseseeceeseeesessececeseseeeceeeceeeceeeeeeceeeeeees 134 Figure GB Phase offset example urene ideas Gasdadswniatiassdeseadabioetadeos 135 EEE NN 136 Figure 70 Heavy Consumer Control with active power analysis sssccccsseecccsnseccssuseccseusecsausecesaseessuusessausecesausesssaneeeas 141 Figure 71 Heavy Consumer Control with number of gensets analysis rr rrrrrrnnnrrrrrrnnnnnvrrnnnnnrrrrrnnenrrrrnnnenrrrrrnnensrrrsnneee 141 Figure 72 Heavy consumer typical Ne 142 Figure 73 Non essential consumer tip Output SETNING ccccacasccedjsavicncsrsercevecsdadescanseniaceebunnssevadeecietedesbiasevacjenteaseansseseuses 143 Figure 74 Non essential consumer trip on KW ccccccccccssseeseecesccccsueseccesstcnsusseecessceauunseeeessescueueseecessesaauesseeeessssaaagseeeess 144 Figure 75 Non essential consumer trip on HZ ssccccccccssesssecescccnseeeseeceseeccuuueseecessesauuuseecesessauuneseecesstsaaunsseeeesessauannseeees 145 Figure 76 Shore connection using Selco T4OOO scccccseecccnescccsseccsauseccssseessseeesauseessausecsausecssauseessueessausesssaseesageeeeas 146 Figure Z7 NetWork TOD CIOQICS irre enni e r E A lu saul EE O E AET EEE E E 160 Figure 78 Example of CAN connection between 3 MOMUIES ssecccccssseeseccsnneeeecescaueecessausee
247. ssueeesssuecsssusesesuecsssusesesees 237 Table 121 SD card con igur al OD rrii a aae a a NE E ATN AUNE OE OTONO E OEA 238 Table 122 GENSYS 2 0 product reference cscccecsessessecuonseesecuonsesvecueavessccncesessccucevesscencesssscencesesscencesssscencessescencesesseess 248 TOO EG OTIC CC EEE EE EE EE EA E ET 249 Table 124 CRE Technology product reference scciitinsabiscsuvassicavacdeevensacnvisadedeavaneesesdouvabandavancesdendecawdeavousidacteius eavensedaveecces 249 A53 Z0 9 0020 N EN Technical documentation Chapter Overview 14 1 OVERVIEW 1 EUROPEAN UNION DIRECTIVE COMPLIANCE CE The EMC Directive 89 336 EEC deals with electromagnetic emissions and immunity This product is tested by applying the standards in whole or in part which are documented in technical construction file CEM 2004 108 EC which replaces directive CEM 89 336 EEC relative to electromagnetic emissions as from July 20th 2009 This product is developed to respect harmonized norms EN 55099 2009 EN55099 2010 EN 55088 2008 2006 95 EC replaced directive 73 23 EEC since January 16th 2007 SAE J1939 71 73 31 Other standards EN 61326 1 2006 Industrial location EN55011 EN 61000 3 2 EN 61000 3 3 Note This is a class A product In a domestic environment this product may cause radio interference The user is responsible for taking the necessary precautions LZ ENVIRONMENT Temperature Operating
248. st 2 generators must be equipped with GENSYS 2 0 units e Units must be in AUTO mode The useful variables to manage the load dependant start stop function are available via the Configuration Power management system Load dependant start stop menu IY 13 2 PRINCIPLE The automatic load unload can be configured in 2 different ways e Standard mode e Optimised mode allowing to avoid that a large number of parallel generators run just above the unload threshold E1914 parameter selects which mode will be used In standard mode GENSYS 2 0 are configured e To start a generating set if the power plant load threshold E1256 has been reach during a determined time E1257 e To stop a generating set if the power plant load is below the threshold E1254 during a determined time E1255 In optimised mode GENSYS 2 0 are configured e To start a generating set if the power plant load threshold E1256 has been reached during a determined time E1257 same as in the standard mode e To stop a generating set if the power that will remain on the bus bar after the generating set stops is below threshold E1915 during a determined time E1255 A Since firmware version 4 55 it is also possible to setup a digital input that will stop a generating v set after having checked that this will not overload the power plant according to the load dependant start stop configuration See chapter about digital inputs for more details Example
249. steGPID configuration in the Active Power Regulation menu If the genset goes into reverse power or stays at low load during the ramp time E1151 increase P CsteGain in the Active Power Regulation menu At the end of the ramp time the GENSYS 2 0 will swap to kW Sharing Gain You can now set your load sharing gain and check the settings which depend on load impact test with load bench for example Chapter Installing and commissioning a GENSYS 2 0 application NSG SG SG For this point it s important to check the wiring of the power lines current transformer After paralleling the GENSYS 2 0 start a power regulation according to his configuration SG o Load sharing if paralleling between generators o Constant kW setpoint on generator if GENSYS 2 0 is set as Permanent with base load o Constant kW setpoint on mains if GENSYS 2 0 is set as Permanent with Peak shaving o Droop 73 A53 Z0 9 0020 N EN Technical documentation Whatever the power regulation it s important to have power on bus in order to check the currents voltages cos measurements The menu Display Generator electrical meter Global view generator will allow to check that the consumed power by phase is positive and balanced If it s not the case check your wiring WARNING A wrong wiring affecting the power measurements e g reverse of current terminals will cause a bad GENSYS 2 0 control that can r
250. t This will be displayed in the info alarm and fault screens if so programmed Validity Virtual input validity variable numbers E1348 to E1357 E1388 to E1397 E1640 to E1659 can be set as e Never E2329 never active should be selected if you do not use the input e Always E2330 always active input will be monitored as long as GENSYS 2 0 has power supply e Post Starting E2192 the input will be monitored at the end of the safety on timer e Stabilized E2331 The input will be monitored when generating set frequency and voltage are stable e Spare scenario E2332 input will be monitored as programmed in equations Direction Virtual input direction variable numbers E1358 to E1367 E1398 to E1407 E1659 to E1679 Can be set as e NO O normally open should be selected unless the input is used for protection e NC 1 normally closed This should be selected if the input is normally connected to OV and opens when active Accuracy This parameter sets accuracy number of digits after decimal point Possible values are e 1 e 0 1 e 0 01 e 0 001 Functions Virtual input function variable numbers E1328 to E1337 E1368 to E1377 E1680 to E1699 can be set as described in chapter 12 1 5 Note Both virtual and real inputs use the same functions A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 223 I9 3 8 OUTPUTS 1 Digital outputs This menu allows configuring the
251. t to the Engine fault signal of the external start module Note if GENSYS 2 0 doesn t receive any External GE OK signal then parameter E1633 will be used as delay before triggering a no start fault Chapter Additional functions 121 A53 Z0 9 0020 N EN Technical documentation 14 6 REMOTE START UPON EXTERNAL PULSE IN To set the GENSYS 2 0 to start upon an external pulse input 2 solutions can be used e Usea relay L OS e Set an external input vig This variable E2514 Virtual Start must be maintained at 1 after the first rising edge 4 and go to 0 after the second rising edge Example is for the J15 input O WARNING 1f section empty or miscing exi Cing egu tions will De lost PROG 1 BLOG PULSE ON REMOTE START FROM EXTERNAL CUOU Q E2585 Value of the E2015 with one cycle less to detect a pulse OR E oils ho SAND ESS FOM Perec on or aa ea jule CEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEE peers E2391l4 E2914 OR E281 gt EO 1 AND E2505 FO NNDS ANDES SEO AND 2805 HO ON HON BEND Do not forget to set the input GENSYS 2 0 must be informed that J15 in this example is used by a custom equation V1276 1 N PULLS TUN TION 00000 02 999 Here the variable E2585 detects a rising edge on E2815 The cycle or the variable E2815 goes from 0 to 1 The variable E2585 stays at 0 a cycle longer in order to see E2815 1 and detect the rising edge You can also detect the falling edge by c
252. tacisecacs nasieawtatnsaneeave a ceacinbnoedeaeseanetenatadace a 109 VE NNN 109 15 PT FT 109 Bo NNN 109 13 7 0 VF 109 13 8 HELP FAULT SOFT SHUT DOWN cccccccsccccceecceceececsceecscceuecsceuceseueueeseeuuecscuuucssueuecseeuueeseeueeseueuecssuuueseeeueeseeeneeds 109 13 9 HELP GEN ELECTRICAL FAULT sananevnennvnsnnvnennvnennanennnennsnnvnsnnsnsnnvnennnnenssnennnevnsnennsnnvnsnnvnennvnennenennnevnvannnsnnvnsenenennvnennen 110 13 10 POTENTIAL ALARMS FAULTS UIST ssicsvavnnnayecaponvidasadatelisenaads tesnaasnlddnnnnaseainn ndyt elena stasnmadeldamauistainadeanvconsedsdewanadabennnes 110 1A ADUITION AG PUN CIOS crvictcectires teieacanauinyesetwin vite trea ren cbaien eeu eie bi enna eeswaeteeuliea a aai 114 14 1 LOAD SHARING USING INTEGRAL DE DROOPING cccccsssecccccesecccccesecceeeesecceseusseceeseueeecceseueeecesseueecesseuneesessagneeeeees 114 14 2 OPERATOR CONTROLLED RET URN TO MAINS cssscsasssnnraawestapeaonteasbametincabsndantaawedtepaian ESTESE EEN REE EA 116 14 3 MAINS ELECTRICAL FAULT cscsccccsssccovsccnsscnsussnssovsusosnsevensensnccnsscnsusonssocnusosnsesussensnscnsscnstsonssecnssoonseovssensnccnsscasnsonses 117 14 4 GENERATOR ELECTRICAL FAULT ae 119 14 5 GENSYS 2 0 WITH EXTERNAL AUTOMATIC START MODULE ccececcececcecuccecncceteceeeuseeeeceeeesseeesseusseeeseseuseseueeseueeeeueeees 120 14 6 REMOTE START UPON EXTERNAL Even 122 14 7 TNT 123 14 8 FRE NNN 125 149 GENSYS2 OVWTHTEM COMPACT si scccsiianevenssnwesnaneanssoassu
253. tem e Generator e Mains Bus e Engine e Protections e Inputs e Outputs e Timers e Synchronization e Control loops e FIFO data logger e Modification by variable n Chapter Menu overview 210 A53 Z0 9 0020 N EN Technical documentation 19 3 1IPPOWEPR PLANT Parameter Possible value Comment var num E1179 plant E1147 E4006 installed on the power plant Mains parallel ChangeOver 0 On Mains failure engine starts and takes the load by E1148 opening mains breaker and closing generating set breaker with interlocking On mains return unload generating set by opening generating set breaker and closing mains breaker with interlocking and stop engine NoBreak CO 1 Only available with mains paralleling option Same as na changeover mode but loading unloading is made without black with ramps after synchronization with mains Permanent 2 Only available with mains paralleling option aftera start cll demand GENSYS 2 0 will synchronize generating set to mains and keep both breakers closed GENSYS 2 0 must receive a start demand and will not manage mains breaker output There will be no synchronization with the bus bar or the mains Load sharing Analog 0 Load sharing will be done via analog bus pins G4 and G6 E1158 COM 2 port E1153 maintain constant power supply from mains set power E1177 amp engine speed and generator voltage excitation Deadbus manag
254. tinuous default setting contact to open Contactor E1 Mains E4 Genset Continuous contact to close E2 Mains E5 Genset CLOSED OPEN Undervoltage coil opening E1 Mains E4 Genset Pulse to close E2 Mains E5 Genset CLOSED OPEN Undervoltage coil opening E1 Mains E4 Genset Continuous contact to close E2 Mains E5 Genset CLOSED OPEN Breakers E1 Mains E4 Genset without Pulse to close undervoltage coils SP E2 Mains E5 Genset CLOSED OPEN 5 Pulse to open E1 Mains E4 Genset Continuous contact to close E2 Mains E5 Genset CLOSED OPEN TABLE 24 BREAKER CONTROL CONFIGURATION A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 2 Working of pulse or an undervoltage coil For control using a pulse or an undervoltage coil the necessary parameters are E1893 pulse length E1994 Undervoltage coil delay This sets the time between the opening of the breaker and the closing of the undervoltage coil control contact E1995 Undervoltage coil pause time Sets the time between the closing of the undervoltage trip coil control contact E1 or E4 and another breaker close request by the other contact E2 or E5 This must be longer than the breaker reset time These values can be modified in the Configuration Modification by variable n menu Undervoltage coil E1994 Output close E1
255. tion Technical support 33 0 4 92 38 86 86 office hours 8 30AM 12AM 2PM 6PM GMT 1 Chapter CRE TECHNOLOGY 250 Check our entire distributors list around the world on www cretechnology com tab DISTRIBUTORS H Head Office FRANCE Nu E Official Distributors 1 Agents vi wid od y Y r FIGURE 99 CRE TECHNOLOGY DISTRIBUTORS CRE Technology retains all copyrights in any text graphic images and software owned by CRE Technology and hereby authorizes you to electronically copy documents published herein solely for the purpose of transmitting or viewing the information copyright all rights reserved Chapter CRE TECHNOLOGY 251 A53 Z0 9 0020 N EN Technical documentation
256. to connect to the Internet and wide area networks Select Ethernet TCP IP Internet Protocol TCP IP Properties General Tou 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 f Use the following IP address IP address 192 768 11 100 Subnet mask 255 255 255 Default gateway f Obtain DMS server address automatically f Use the following DNS server addresses Preferred ONS server Alternate DNS server l Advanced Cancel Enter the addresses as shown above Note IP address 192 168 11 100 shown above can be used if GENSYS 2 0 IP address is 192 168 11 1 factory setting Otherwise computer and GENSYS 2 0 IP addresses should match the same subnet mask as shown below A53 Z0 9 0020 N EN Technical documentation Chapter User interface 41 Example Subnet mask 255 255 255 0 Computer IP address AAA BBB CCC XXX GENSYS 2 0 IP address AAA BBB CCC YYY Click on OK Close the networking windows Create Modify Windows hosts file as explained below Windows hosts file can be found in C WINDOWS system32 drivers etc It can contain lines to link GENSYS 2 0 IP addresses to hostnames For example Factory IP address of GENSYS 2 0 192 168 11 1 gensys generic IP address and
257. ture and sending commands start stop speed control 1 Setting In order to use the J1939 communication on the COM2 port e Enter in Configuration Engine J1939 MDEC menu e Inthe list select the manufacturer E4034 e Select the ECU type E4068 according to the manufacturer e Set the Alarm fault See below e Connect the CAN bus between the engine ECU and the COM2 port of the GENSYS 2 0 see 17 1 for more details The internal configuration of the module will be directly set according to the manufacturer ECU pair e GENSYS 2 0 address E1856 e ECU address E1013 e Oil pressure measure by J1939 or by analogue sensor E1852 e Water temperature measure by J1939 or by analogue sensor E1853 e Engine speed measure by J1939 or by analogue sensor E1854 e Speed control by J1939 or by analogue output e Start stop control by J1939 or by the Fuel Cranck relays Note The speed command by J1939 or by analogue sensor depends on ECU See below to know the speed control used by default After selecting Manufacturer ECU pair these parameters can be modified according to your need Measure Value Description Oil pressure 331 Measure from J1939 E1852 Measure from analogue sensor F8 F9 Water temperature 333 18558 Engine speed 330 Lind TABLE 62 11939 ANALOG MEASURE OR 11939 Notes GENSYS 2 0 can communicate with a large number of J1939 engines The list is steadily increasing please cont
258. um size of text file Available data space for SD card and internal FIFO loggers External power tank to be used only with a 12V battery Compatibility with RDM 2 0 remote display module GENSYS 2 0 CORE and GENSYS 2 0 LT dedicated chapters Chapter 10 3 table 22 AVR Leroy Somer R450 and Stamford MX341 Chapter 13 8 BSM II cable reference removed not useful August 2012 K Chapter 15 3 2 Add J1939 display page of unknown SPN FMI Chapter 17 3 12 Add the reset maintenance cycle page Chapter 15 7 1 Safely remove your SD card Chapter 17 4 3 2 LCD backlight adjustment through System Display properties menu Chapter 20 2 Accessories Add A40W2 cable Chapter 20 1 Add reference of all GENSYS 2 0 family modules February 2012 New features supported by v4 03 v4 04 Q Additional Modbus support including Multiple TCP connections New function support 01 02 05 OF Advanced rights management read write access e Support of Modbus RTU over TCP in addition to standard Modbus TCP protocol Chapter 19 3 10 configurable synchronization dwell timer E4108 September 2012 Updated wiring of standard CAN DB9 connectors Table 7 Added frequency range of voltage measurements Chapter 15 3 2 Note on Cummins CPG G Drive ECU firmwares A53 ZO 9 0020 N EN Technical documentation Chapter Overview Date Version Comments New features supported by v4 55 MARINE product range F e Specific fr
259. unning hours timers 5 cycles are on a day basis To configure the maintenance cycle uses the CRE Config software or the parameters file When the cycle duration is elapsed the corresponding alarm is raised Name alarm name that will be displayed when cycle duration is elapsed Cycle timer E1442 to E1451 Duration of the maintenance cycle expressed in running hours or in days Counter E2304 to E2313 Counter that will run for the desired duration Reset E4097 to E4106 Resets corresponding counter to zero A menu is dedicated to reset the maintenance cycle 19 3 13 These timers are displayed in the Display Maintenance cycle monitoring Note Variables E2304 to E2313 are automatically managed by the module and saved into non volatile memory These values are kept in memory even in case of power supply failure A53 Z0 9 0020 N EN Technical documentation Chapter Additional functions 137 14 17 FRONT PANEL INHIBITION Specific parameters can be setup and monitored to control each front panel button individually Parameters E0892 to E0913 contain the status of the front panel button a value of 1 means that the key is pressed while O means the key is released Variables E4043 to E4064 are set to 1 to inhibit the use of selected front panel buttons N Key Status Inhib Key Status Inhib Key Status E0893 E4044 E0894 E4045 E0900 TX E0895 E4046 E4047 E0901 FAULT E0897 E4
260. ure 25 Example with 4 generators paralleled together in emergency SITUATION ccccsseecccsseseccsessccsaesecsseeseesaeseeees 57 Figure 26 Paralleling With MAINS sccccccsssesecccnnesecccsseseccseaeeseeesssenseeessaeeseeeesaueeeeeeeaeaseeessauaseeessaansecsssaunsecessaunsesesaaaaseeeaas 59 Figure 27 Typical sequence in No Break CO mode on start request rrrrrrrrrrrnnnnnnnrrrrrrrnnnnnrrrrrrrrnnnnenrrrrrnrrnnneenerrrrnrnnnnenee 60 Figure 28 Typical sequence in No Break CO mode on MAINS failure rrrrnnrrrrrrnnnnnrrrnnnnnnrrrrnnnnrrrrrnnenrrrrrnnennrrrrnnenrrrrnnneneeee 61 Figure 29 Typical sequence in permanent mode ON MAINS FAIULEC sseccccccnsseccccneescccccaeeeecsscaussecsssaueecsssaunsecsssaaeseeseas 62 Figure 30 Typical sequence in permanent mode on start FEQUEST cssecccccnsssccccnasseccesassscessaussecessaassesssaussesssaaeseseas 63 Figure 31 Power plant paralleling With MAINS rrrronnrrrnnnnrrnnnnnrrrnnnnrrrnnnrrrrnnnrrrnnenrrnnnnrrnnnnsrrrnnensrnnnssrnnnnssrnnnerennnesrnnnnseee 64 Figure 32 GCR GENSYS 2 0 wiring diagram rarrrrrnnnrrrnnnnrrrnnnnvrnnnnnrrnnnnrrnnnenrrrnnenrrnnnnrrrrnenrrrnnenrrrnnnrrrnnessennnerennnerennnseee 65 Figure 33 Power plant paralleling with several MAINS cccsscccccssececssusecccausecesssecsausecssausecssauseessuueessaussessausesssuesessagaseeas 66 FiGure 34 MiniMuUnt VING ANINE kerirenkd kind 67 ES MN a i EEE E cae nective ET E vated cene ise O A ate 68 ENN 69
261. ust first be corrected before resetting the alarm failing to do this will trigger the protection again The alarms archive can be deleted in the System Date Time meter Meters reset menu by selecting the Event logger parameter E1988 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 242 19 5 3 INFORMATION At any time and any level you can click the Information link on your browser or press the i key on the front panel Choose BACK on your internet browser or press the button a second time to return to your previous screen This will automatically change the display and show the information screen Information 1 5 Power gt serious fault gt Engine Fault Generator kw 18 0 kw Valid mains kW 60 0 kw Gen cos phi 21 0 001 Mains cos phi 58 1 001 Test mode 2096 1 kW GEO9 50 0 05 kW GEO1 42 0 05 kW GEO2 43 0 0 500 Hz ACT 11639 1 Generator f 151 f 0 05 E amp FIGURE 93 INFORMATION SCREEN Power E2071 This will display the current status of the module regarding power management It will also display a state code which is dedicated to the technical support team of your local distributor Engine E2057 This will display the current status of the module regarding the engine It will also display a state code which is dedicated to the technical support team of your local distributor Parameter information You can display any parameter by s
262. ut To be selected for a min level sensor or a calculation can 2243 Coolant low level be used in conjunction with digital transistor output To be selected for a max level sensor or a calculation can 2247 Oil high level l Ka be used in conjunction with digital transistor output Manual stop request To be selected for a min level sensor or a calculation can 2246 Oil low level be used in conjunction with digital transistor output BBB GUELILIGEE ere Will inhibit all protections These alarms and faults remain 2197 Securities inhibition listed in the faults and alarm logging 2198 To be selected to prevent engine from starting 2210 Ext secu Hard shut down If external protections are installed for immediate stop of the engine If external protections are installed for immediate opening 2209 Ext fault Soft shut down of genset breaker and stopping of the engine after cooling down timer has expired 2 genset breaker and try to synchronize again 2718 Wains electrical fault If external protections are installed protection will open mains breaker and try to synchronize again 2681 To be selected to stop the engine after cool down The GENSYS 2 0 will ask another engine to start before stopping itself To be selected to activate the gen electrical fault action N 00 Help Fault Soft shut 27 oe down 2737 Help Gen Electrical Fault The GENSYS 2 0 will ask another engine to start before st
263. utput is activated if engine speed is other than 0 17 2 AUTOMATIC MODE AIR FAN is activated if temperature is over the pre set threshold E1178 and de activated when water temperature is lower than 80 of the threshold AIR FAN is not activated if engine is stopped A53 Z0 9 0020 N EN Technical documentation Chapter Dedicated I O lines 91 1 8 FUEL FILLING COOLANT FILLING OIL FILLING J6 Input 1 Fuel low level 2230 J7 Input 2 Fuel high level 2231 J8 Input 3 Manu fuel fill 2252 J9 Input 4 Coolant low level 2243 J10 Input 5 Coolant high level 2244 Output 1 C1 Fuel fill relay J11 Input 6 Man cool fill 2253 Output 2 C2 J12 Input 7 oil low level 2246 Output 3 C3 J13 Input 8 oil high level 2247 J14 Input 9 Manu oil fill 2254 Coolant fill relay Oil fill relay L Lt Output 1 function E1260 Fuel filling 2229 Output 2 function E1261 Coolant filling 2242 Output 3 function E1262 Oil filling 2245 FIGURE 52 CONNECTIONS FOR FILLING Fuel Oil Coolant filling can be managed using one analog level sensor or two switches one high level and one low level switch Starting from firmware v4 00 analog sensors can be used directly without requiring any additional equation while modules with older firmware will require custom equations 11 8 1 MANUAL MODE In the example above fuel filling output is only activated if J8 input is closed J11 J14 for coolant or oil
264. v2 00 or later Type B This port is replaced by Ethernet communication High Quality GENSYS 2 0 with firmware v1 xx Isolated type B standard USB connector Use a standard USB A to B cable to connect with PC Used for configuration parameters file downloading and uploading Uses TCP IP protocol to communicate with modem emulation Not to be used while engine is running COM4 Ethernet RJ45 CATS Standard RJ45 ETHERNET connector Use a 1000 cable Isolated Uses TCP IP protocol to communicate with external world Details in 17 5 COMS5 RS485 Male DB9 4800 9600 or 19200 bps MODBUS RTU shielded Used to communicate with SCADA Modbus RTU slave Read and write functions 2 wires Isolated See details in 17 6 COM6 Memory slot Memory slot used for extensions See details in 17 7 TABLE 7 INPUTS OUTPUTS DESCRIPTION A53 Z0 9 0020 N EN Technical documentation Chapter Description 33 6 USER INTERFACE G NSYS b i FAULT ALARM START STOP gt a FIGURE 6 USER INTERFACE The user interface can be controlled using different ways Directly on local browser using front panel LCD screen and keyboard 2 Remotely using dedicated CRE Config software or your favourite Internet Web browser vu O ei When GENSYS 2 0 is powered up it displays a welcome screen during a short time and then switches to the g display of the generating set s status if emergency stop is
265. vering 20 mA to the power input of GENSYS 2 0 G1 and G3 terminals Current to the power input of GENSYS 2 0 G1 and G3 terminals delivered by an external transducer measuring 0 kW PT ratio Ratio of your voltage transformer on the mains bus side Ex E1016 20 kV to 100V so enter 200 20mA setting E1020 OkW setting E1021 ng E4008 E4009 E1606 during load ramp before to open the mains breaker E1620 mains after a mains back timer E1085 to re synchronize to mains see 14 2 for more details TABLE 88 MAINS BUS CONFIGURATION 1 Only available on level 2 2 Available according to the value of kW measure E1464 3 Ex a4 20mA transducer is used 20ma corresponds to 500KW it means E1020 500 E1021 4 Mains electrical fault Parameter Possible value Comment var num Open breaker Mains 1 Select the breaker that will be opened upon a Mains E1846 Generator 2 electrical fault Chapter Menu overview Both 3 Start on fault Yes 0 Allow the engine to start on a Mains electrical fault E1841 No 1 Don t allow the engine to start on a Mains electrical fault TABLE 89 MAINS ELECTRICAL FAULT CONFIGURATION 217 A53 Z0 9 0020 N EN Technical documentation 19 3 5 ENGINE Parameter Possible value Comment var num Start sequence Internal start sequence The start sequence is managed by the GENSYS 2 0 See 88 E1608 0 for more details External Auto sta
266. voltage T3 E2001 Genset breaker lt lt lt gt First Black Second Black FIGURE 19 TYPICAL SEQUENCE IN CHANGE OVER MODE ON MAINS FAILURE T1 Fastest mains failure T2 Switch over delay E1459 T3 Genset ready T4 Mains back delay E1085 T5 Switch over delay E1459 A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 52 E0022 Mains voltage E2201 Start request on J3 E2000 Mains breaker E0003 Genset voltage E2001 Genset breaker lt gt lt gt First Black Second Black FIGURE 20 TYPICAL SEQUENCE IN CHANGE OVER MODE ON START REQUEST T1 Genset ready T2 Switch over delay E1459 T3 Switch over delay E1459 A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 53 9 2 SINGLE GENERATOR IN NO CHANGE OVER MODE FIGURE 2 POWER PLANT IN CHANGE OVER WITHOUT PARALLELING VET gro Variable label Variable value number 4006 Nb ofMaster 0 gt 1177 Static paralleling No gt TABLE 10 TYRICAL NO CHANGE OVER BASIC CONFIGURATION In No change over mode E1148 GENSYS 2 0 only starts on receiving a remote start signal and doesn t manage the mains breaker A53 Z0 9 0020 N EN Technical documentation Chapter Predefined configuration 54 5 3 GENERATOR PARALLELING WITH DIGITAL BUS KW KVAR COS f CAN Bus i FIGURE 22 PO
267. voltage for each phase E0000 E0001 E0002 e Current for each phase E0006 E0007 E0008 e Active power for each phase E0009 E0010 E0011 e Reactive power for each phase E0012 E0013 E0014 e Power factor for each phase E0015 E0016 E0017 e Average active and reactive power frequency and power factor E0018 E0019 E0020 E0021 2 Generator phase phase volt This screen displays the three phase to phase voltage measurements 3 Generator phase neutral volt This screen displays the three phase to neutral voltage measurements 4 Generator currents This screen displays the three current measurements 5 Generator kW This screen displays the three kW measurements 6 Generator kVAR This screen displays the three kVAR measurements 7 Generator PF This screen displays the three power factor measurements 8 Generator parameters This screen displays generator average active and reactive power frequency and power factor measurements 9 Generator energy meters This screen displays KWh and kVARh calculation Note These display pages fit according to the voltage system selected see 14 15 A53 Z0 9 0020 N EN Technical documentation Chapter Menu overview 205 19 2 3 MAINS BUS BARS ELECTRICAL METERS 1 Global view Mains Bus This screen displays all Mains Bus electrical meter in real time e Phase to phase voltage for each phase E0796 E0797 E0798 e Phase to neutral voltage for each phase E079
268. ware v4 03 N e GENSYS 2 0 handles up to 4 Modbus TCP connections with external equipments A e GENSYS 2 0 handles Modbus RTU over TCP protocol in addition to the more standard Modbus TCP protocol It is not necessary to select the protocol you want to use GENSYS 2 0 will detect it automatically and adapt its response to the detected protocol For more details on the Ethernet configuration refer to 6 3 For more details about supported Modbus functions refer to 17 6 A53 Z0 9 0020 N EN Technical documentation Chapter Communication 187 17 5 COPYRIGHT GENSYS 2 0 Ethernet communication uses the open source IwIP TCP IP stack Please see the copyright disclaimer below More details can be found on IwIP Web site http savannah nongnu org projects Iwi Copyright c 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 pri
269. wiodss f YETI uopepag N 0 KE Nike p eae Mand 2 073 uonennag 18 041U020J2IN FIGURE 95 VOLTAGE REGULATION DETAILS 245 A53 Z0 9 0020 N EN Technical documentation el PRECAUTIONS Change over and paralleling with mains For safety reasons breakers must be equipped with an independent paralleling safety relay to prevent failure of the automatic sequence as shown in Figure 96 Several generators warning and Figure 97 One generator with mains warning GENSYS 3 GENSYS E5 E6 E5 E6 FIGURE 96 SEVERAL GENERATORS WARNING GENSYS SENSE E2 E3 ie C2S product is the good solution as SYNC CHECK RELAY see accessories below Generator Mains breaker breaker NC A feedback NC feedback FIGURE 97 ONE GENERATOR WITH MAINS WARNING A53 ZO 9 0020 N EN Technical documentation Chapter Precautions 246 Manual breaker opening When an external security device opens the breaker the order has to be latched GENSYS 2 0 needs the feedback When a power plant has several generators even if only one generator has a GENSYS 2 0 the number of generators E1147 must be equal or above 2 If it is 1 you may seriously damage your generator The engine turbine or other type of prime mover should be equipped with an over speed over temperature or overpressure where applicable shutdown device that oper
270. with slave address set to 0 Stop bit N A 1 bit de stop fixed Response time Timeout N A Communication timeout should be set to at least 75ms on the MODBUS master TABLE 73 MODBUS CONFIGURATION PARAMETERS Chapter Communication Table below lists the different signals available on COMS connector Terminal Description 5 B signal 6 A signal 3 4 9 MODBUS isolated OV 1 2 7 8 Not connected TABLE 74 COMS TERMINALS 1 Useful Modbus registers for easy Alarms Faults management In order to lower communication bus load useful variables exist inside GENSYS 2 0 2 Bitfields variables pack up 16 logic variables inside a single register This way a single MODBUS request can be used to read useful information 190 A53 Z0 9 0020 N EN Technical documentation 2 Fault page data These variables will help you create your own FAULT page in your HMI just the way they appear in your GENSYS 2 0 module This way you don t have to scan all faults protections handled by your CRE Technology module Note Data available concerns only faults that appeared after the last power up sequence Events appeared before GENSYS 2 0 was switched OFF and ON again will be listed in the FAULT pages but not inside those variables Table below lists those two kinds of variables ETE JER Description E2640 E2649 Bitfields variables Each variable contains the current value of 16 logic variables such as circuit breaker positi
271. ys on during a save parameters command see SHIFT I above It is also used to indicate SD card accesses Switches the system to automatic mode Associated LED is ON when this mode is activated Switches the system to test mode Associated LED is ON when this mode is activated Switches the system to manual mode Associated LED is ON when this mode is activated This mode can be set as 100 manual mode or assisted manual mode see corresponding chapters for more details Starts the generator only available in manual mode Stops the generator only in manual mode O I Closes opens the generator breaker only in manual mode O I Closes opens the mains breaker if available only in manual mode Switches the system to semi automatic mode also called assisted manual mode see corresponding chapter for more details Associated LED is ON when this mode is activated Switches the system to 100 manual mode see corresponding chapter for more details Associated LED is ON when this mode is activated NSYS 2 0 MARIN PREFERENCE mode also called PRIORITY mode will start the engine if proper conditions are met and keep it running on load even if load dependent start stop conditions would stop it Associated LED is ON when this mode is activated G K AILIOKSIKL X KOORS TABLE 5 CONTROL PANEL KEYS A53 Z0 9 0020 N EN Technical documentation Chapter Description 25 5 1 4 CONTROL PANEL LED Genset breake

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