automatic microprocessor control panel for stand-by
Contents
1. 25 jlinputbatterychargergenerator 0 32V Cis CT 26 j lnputgensetcontactmakersignal ON 1 1 o 27 FILE REV DATE LANGUAGE GCMO1 MU GB 12 2 doc 18 01 2007 22 of 33 3 7 2 CONNECTION ON THE SIDE There are 3 terminal boards on extractable connector with two way receptacle with a capacity of 16A cross section 2 5 mm2 These three terminals are the inputs of the three phase mains sensor N TERMINAL DESCRIPTION INPUT OUTPUT 8 Phase input 0 500V strength 500 between phase and neutral oo 0 o 1 Phase input S 0 500V strength 500 KO between phase and neutral EE 32 Phase input T 0 500V strength 500 KO between phase and neutral On the higher part is foreseen the output of the connector 9 poles of serial interfacing 5232 3 9 TECHNICAL FEATURES PROTECTION DEGREE OF FRONT PANEL IP55 FRONT PANEL ANTISCRATCH WITH SINOTIC GRAPHIC LEXAN GE VOLTAGE AC 0 500V ac MAX ABSORBED CURRENT MIN ABSORBED CURRENT INVERTED POLARITY PROTECTION Built in WORKING TEMPERATURE RELATIVE HUMIDITY POLLUTION PROTECTION RELAY CAPACITY AVV ARR 15 54 30A 30V cc CONTACT MAKERS RELAY CAPACITY CG CR READING OF RUNNING ENGINE THROUGH ac GEN SET 1 READING OF RUNNING ENGINE THROUGH OIL PRESSURE BUILT IN BATTERY CHARGER BATTERY PROTECTION FUNCTIONS gt 27 and V 9 OVERLOAD PROTECTION 50 GEN SET VOLTAGE READING THREE PHASE MAINS SENSOR WITH DISSYMMET2. To using the generator in lock mode use the manual commands The lock Input 7 can be managed manually through a switch or an external timer PME REV DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 EN O 16 of 33 ALARM REPORT Memorizes all parameters measures and alarms at the moment of a failure and enables to visualize the last 5 alarms It is active only with the programming switch in lock position To visualize the alarm report press at the same for 8 St1 appears select the report from 511 to 515 with and enter with ENTER ST1 last report ST2 the last but one Ecc The following measures are memorized at the moment of the alarm 1 Mains voltage Generator voltage Generator frequency Current Working hours Battery voltage Start attempts Oil pressure low 9 Engine temperature high 10 Fuel reserve 11 Water level 12 Alarm 1 or theft 13 Emergency 14 Overload 15 Failed start Selecting the measures after the bat led you pass to led for failed start The number of start attempts is displayed PX IW QT ew ST 1 2 3 4 5 the active reports are active Selected the report press and select with to change report To go back to menu switch back to AUT the programming switch 2 8 OPTIONAL EXPANSIONS For the module GCMO 1 are foreseen two expansions 1 Serial module RS232 interfacing with PC GSM or Modem for remote control enables to moni
3. P gt gt gt Batterypresent S GENERATOR 13 Overvoltage 5D 1 1 1 V CL A YES w JJ 14 UndevodtageQ7 J Ct A J SR 15 Overload 5 S V LL A SR 16 Maxfrequeny 81 YES 18 Generator contactor closed ON 19 p 19 20 7 lt lt lt lt lt lt gt gt gt Wr MAINS o Mainspresence Z V ooo o Undervoltage 27 dissymmetry 60 LV EL e e Mains contactor closed G F 22 VARIOUS S Eoo Eoo Eo J ___ ait Prog G L F 23 Acousicalarm A 24 Emergency button active R F YES 25 Legend G Yellow 1 L Flashing A Acoustic alarm ON SI Immediate stop SR Delayed stop 27 Min voltage 5 9 Max voltage 51 Overload 81 Min max frequency H What happens in case of alarm with immediate stop e immediate opening of the generator contactor Activation of immediate stop Activation of acoustic alarm Memorization of alarm cause Recording of all parameters and signalisations Block status up to re establishment An alarm with a delayed stop brings about Immediate opening of the generator contactor Activation of immediate stop e Memorization of alarm cause Only after engine s cooling phase stop and block status up to
4. and pull the emergency push button enabled then reset 5 Led 8 alarm due to failed starting h try starting with manual control and inform the supplier FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 5 of 33 6 Led 13 The generator overload protection switch has tripped It is to be reset manually by a qualified engineer see maintenance section SECURITY PROCEDURES FOR THE USER A WARNING It is strictly prohibited for anyone to touch powered parts 1 5 1 ELECTRICAL MAINTENANCE Skilled personnel must perform all jobs The control unit is equipped externally with all the possible command control and reset functions Proceed as follows to access the equipment within the control panel 1 Setthe programming switch on LOCKED mode 2 Checkifthe unit has stopped completely 3 Disconnect the mains line that powers the control panel and switch the main switch ON OFF of the mains off 4 Check if the mains has been effectively disconnected which can be seen by the mains OK LED switched off and by the display switched to the mains that must indicate zero 1 Open the control panel and check for any anomalies in the e Fuses e Automatic switches e Thermal relays Once maintenance has been completed repeat the procedure in reverse order to reset the unit 1 5 2 MECHANICAL MAINTENANCE If the generator should fail to start due to an anomaly in the fuel circuit and also in an emergency status the following tips may pro
5. electronic rpm regulators etc If the switch were in this position with the generator stopped the starting battery would run flat very quickly STOP This is enabled whatever the situation enabling even only in manual mode It is to be held down until the motor stops completely EMERGENCY STOP If pressed the red mushroom push button in the middle of the door stops the generator immediately instantaneously opening the contact maker of the generator CG thus locking it To release the emergency status set the programming switch in Lock position and then turn the emergency push button and pull up A newly conceived and remarkably useful LED has been fitted on the GCMO1 module to assist the operator namely the WAIT PROG LED This LED flashes each time the timer is triggered informing the operator what is happening even over a lengthy timer period All leds are provided with a general description that makes the control panel easily comprehensible LED TEST To verify the functioning of all the leds bring the programming hand grip to lock Hold the push buttons down together for 2 seconds gt gt ALARM SILENCING Hold the RESET key down for 2 seconds to silence the buzzer alarm FUNCTIONS RESET Hold the RESET key down for 2 seconds to reset the alarm status and to restore the functions SUMMERY In normal running the generator unit is programmed in AUTOMATIC mode During maintenance on the generator unit put it on LOCKED
6. that s because the motor is not running yet but the utility supply 15 54 is active 4 Once the alarms have been checked in the case of anomalies see the input output section briefly press the START push buttons and then the STOP push button and check if the motor stops there is no need to start the generator 5 Check if the fuel reserve low oil pressure and high motor temperature probes match the indications respectively by disconnecting the wire on these and by temporarily connecting it to earth and checking the exactness of the indication on the control panel display 6 Visually check the power connections between generator and control panel as the board detects the motor started status via the voltage of the generator and if it is impossible to detect the voltage as the power connection is missing or a knife switch along the line is open the starting motor will continue to run with the motor started for three seconds 7 With the programming switch on ENABLE STARTING press the start push button until the motor starts 8 Wait 20 30 seconds and switch to POWER SUPPLY FROM GENERATOR 9 Check the rotation direction of the motors in use invert two phases if incorrect 10 Set the programming switch back to Enable Starting the CG contact maker will open and the load will be disconnected 11 Command manual stoppage 12 Close the remaining fuses 13 Set the programming switch on POWER SUPPLY FROM MAINS 14 After at least 1
7. ENGINE With no intervention need even in case of mains failure set the programming switch in MANUAL MAINS Thus the supply by mains would be assured CLC SIGNAL With the setting of the automatic TEST or AUTOMATIC LOCK in case of disconnection of the battery the timer has to be reprogrammed To indicate the loss of the programming on the display appears CLC for 0 5 every 1 5 It does not have any influence on emergency functioning it is only a call up for the re programming of the timer FLASHING HOUR LED Indicates maintenance requirement when programmed hours are up HOW TO PROCEED IF THE GENERATOR SHOULD FAIL TO WORK A possible alarm status will be shown on the display Whatever the anomaly the cause is to be found first and foremost then press the RESET push button twice The causes and the solutions differ depending on the type of anomaly involved 1 Flashing led 7 electrical anomalies due to min max voltage and frequency If the anomaly should persist after the RESET push button has been pressed then request technical assistance 2 Led 8 anomaly due to low oil pressure b high motor temperature c low water or oil level d fuel reserve e Check the relative levels water oil fuel and top up if necessary then reset 3 Led 8 anomaly of the battery dynamo a In this case request technical assistance 4 Led 8 alarm f due to local or remote emergency stop status Set the programming switch on LOCKED mode turn
8. FIELD Number of starting attempts TOO This establishes how many starting attempts the failed start function is to be enabled Starting time and pause 01 This establishes the duration time of the starting and pausing between one starting and another Mains enabling delay TO2 When the mains return within the established limits following the set time the output 30 0 255 is switched from generator to mains Generator enabling delay T03 The load output is enabled following a set time that is triggered by the motor started signal minimum 5 sec Stopping delay 04 This establishes the timing required between GE MAINS switching and stopping to enable the motor to cool down Starting delay 05 This gives a pre alarm for the starting procedure and makes the generator insensitive TOG Glow plug pre heating time This is the time setting of the sparkplug pre heating prior to starting 1 function Overload delay T28 When the threshold t27 is overload the led wait starts flashing and at the end of the T EJP Delay T12 This is the starting delay the relative input has to be programmed with the EJP 27 time in 128 intervenes the overload alarm FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 18 of 33 3 3 ALARM THRESHOLDS Ref DESCRIPTION B Engine working hours for maintenance It establishes after how many working hours the engine maintenance has 70 x10 to be done The GCMO1 module s
9. If the engine is running it stops automatically POWER SUPPLY FROM MAINS Forces the utility supply through mains exclusion of all automatic circuits Exclusion of automatic intervention of the generator unit MANUAL START Enables the push button START that starts the generator Enables the supply of the auxiliary circuits through 15 54 START Engine start push button for the start up cycle POWER SUPPLY FROM GENERATOR After a few seconds break to allow the oil lubrification to all parts moving bring the commutator of programmation to enables the power supply of the utility from the generator STOP The stop push button is enabled at all times Press it until the motor stops completely RESET SILENT Press ones the push button RESET to deactivate the acoustic alarm press twice to deactivate the alarm status and bring back to use the normal functions of the electronic module LED TEST To verify the functioning of all signal leds select with the programming switch LOCKED ENGINE And press for 2 lt p 2 2 HOW IT WORKS TEST A Does all automatic functions commutation excluded B Allows verifying the whole system without cut off the output C During the running all protections are operating D Incase of mains failure the generator starts immediately E The test running stops in case of coming back in automatic mode or with a programmed external command AUTOMATIC FUNCTIONING A The DIP SWITCH 1 select
10. in CRANK cn IL Il T01 Functioning in manual mode selecting MANUAL START you have only one glow plug signal In the case more cycles are required it is necessary go back to MAN MAINS MOTOR STARTER STR for petrol motor In this case at the same time of any start the output will be enabled for the 6 programmed time in 106 For the programming put 707 in STR and the starter time in TO6 o This function is independent from T01 START but blocked by MOTOR RUNNING CRANK When the START fails STARTER cuts off when the START is successful the STARTER goes on up to the end of cycle even in manual mode FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 12 of 33 GAS ELECTROVALVE At the start command the gas electrovalve opens after the setted time in t06 and the start proceeds for the time in 101 Enables to eliminate the unburnt mixture before every starting In stoppage phase is enabled first the gas electrovalve and then the start advices Programming t07 GAS 106 0 20 motor prewashing time COMMAND STOP FL 1 95 1 EVGAS ono 3 4 MOTOR CRANK i MOTOR RUN STOP The timing is just an electronic command in automatic mode RESET Rst In remote controlled plants it s necessary to have a command that re establishes the circuits or closes the switches The output 11 is active for the time programmed in t06 Programming t07 RST 106 0 20
11. output time active ANTITHEFT DEVICE Only for GCMO1 with serial output RS232C Only in remote controlled plants installed In case of disconnection of the generator the alarm status is given by remote control with GSM or MODEM The conditions are memorized in the alarm report FUNCTIONING With the circuit cut above the generator in relation to the relay R1 of 30A that insulates the battery wiring and the cable 14 which enables the antitheft device the module GCMO1 is anyway supplied by battery2 which supplies the remote control system Functioning Programming 40 fur With 40 at the input 14 FREE remains available for normal alarms GEN SET FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 13 of 33 2 6 EXTERNAL COMMANDS It is possible to program five different modalities of functioning on the inputs 7 and 8 1 Remote block command BLC so to cut off the start even in case of mains failure Night block and week end block for offices etc Test starting command TST without interfering with commutation Command with EJP function special for France Remote start command with forced output even with mains presence SCR Gen set reserve command RES for two alternate GE po oo Do TEST FUNCTION By configuring input 7 for the automatic test functioning TEST which enables through remote control to put the generator in automatic mode without cutting off mains power supply If during the test run
12. than 27V for generators with 24V batteries With the generator in locked mode disconnect the electromagnet the safety solenoid valve or the actuator or anything else necessary to prevent the generator from starting The power supply to the injection pump must be prevented so that upon starting the motor turns without starting Set the programming switch on TEST count 4 starting attempts at a rotation speed that is more or less the same from the first to the fourth The same procedure can be performed by setting the programming switch on ENABLE START mode and manually commanding the starting attempts for 5 seconds with pauses of 10 seconds for at least 5 times one after the other If starting fails after these 5 attempts minimum 4 the batteries are to be replaced 6 7 SWITCHING SCALING TEST If the utility system is modified check the scaling of the mains generator line switching The maximum load current must not exceed the switching limit values indicated on the internal nameplate FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 32 of 33 6 8 TROUBLE SHOOTING All control panels are marked with a work order number written on the test nameplate inside the panel All the technical and constructional data of the control panel are associated with the work order number therefore you must refer to this when requesting technical assistance or spare parts The following details must be indicated in any event 5 Type of elect
13. vane The control panel is powered by the mains and by the generator Before accessing it for maintenance purposes disconnect the mains and stop the generator by setting the programming switch on LOCKED 6 2 EFFICIENCY TEST Efficiency tests of the various automatic functions to be executed with the AUTOMATIC or TEST programs The safety devices against min voltage min frequency low oil pressure and dynamo are enabled when the generator is running at a steady state and following the programmed tripping of the generator delay that enables the load output Therefore all simulations are to be performed following this timing 6 3 MOTOR SAFETY DEVICES Disconnect the wire on the motor from the relative reading probe and connect it to earth for roughly 3 seconds A buzzer alarm will be triggered the motor will stop and the relative will be displayed The functions of each alarm are indicated in the AUTOMATIC RUN MODE section 6 4 GENERATOR SAFETY DEVICES Manually operate the lever of the accelerator or actuator to modify the revs in or Consequently the variation of the Hz frequency will be displayed Continue until the safety threshold is triggered with consequent alarm status and locking Minimum and maximum voltage Manually turn the VOLT trimmer on the electronic voltage regulator inside the generator First turn or then vice versa altering the voltage output until the safety devices are tripped Upon completion set th
14. visualization of gen set current on the display This allows correcting the differences between the real current and the displayed current Gen set voltage reading regulation Enables a fine regulation of the visualization of gen set voltage on the display This allows correcting the differences between the real voltage and the displayed value Battery voltage reading regulation Enables a fine regulation of the visualization of battery voltage on the display This allows correcting the differences between the real voltage and the displayed value Battery current reading regulation Enables a fine regulation of the visualization of battery current on the display This allows correcting the differences between the real current and the displayed value N DESCRIPTION T29 LOCK days selection T30 It selects the day of the week and establishes if the lock is overall or partial for the single day It T31 establishes if the functions lock is ON or OFF T30 T29 LOCK beginning time T31 It establishes the lock beginning time in hours and a dozen minutes for all the partial programming days in t29 T31 t29 LOCK stopping time It establishes the lock stopping time in hours and a dozen minutes for all the partial programming hours days in t29 Automatic test test days selection T32 t33 It selects the test day on 4 weeks and starts or stops OFF all the functions of automatic test Automatic test beginning time te
15. 5 20 seconds power the control panel with the mains and check the rotation direction of the motors in use again invert two phases if incorrect 15 Set the programming switch in AUTOMATIC mode check if by disconnecting the mains all the starting functions are enabled power output and generator protection When the mains restored there will be a delay before the lines are switched then a further delay to allow the motor to cool down 5 2 SERVICING PROCEDURES WHEN MAINS SUPPLYING ENABLED GEN SET In cases in which the electrical system is started but not the generator therefore its circuits and battery are practically not powered the powering of the electronics by the mains is to be avoided as this does not offer the control and safety devices provided by the battery Therefore all fuses have to be disconnected except F4 that supplies only the mains contact maker By starting the generator follow the servicing procedures FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 29 of 33 5 3 BATTERY REPLACEMENT PROCEDURE Setthe programming switch in position Manual mains gt Disconnect the fuses F1 and F8 Replace the battery and re connect the fuses and program A WARNING considering that the battery charger generators output a voltage of between 50 and 150 Volts when disconnected from the battery while the generator is running which is very destructive for the electronics the connections must strictly not be tou
16. AUTOMATIC MICROPROCESSOR CONTROL PANEL FOR STAND BY GENERATOR e INSTALLATION e USE e MAINTENANCE gt m DESCRIPTION 7 22 Howitworks 2 6 External commands 17 3 PROGRAMMING S4 Setings 0 0 000000000 3 5 Measures regulation 20 4 INSTALLATION 25 44Stopingg 2 a 9 SERVICE PROCEDURES 5 1 Servicing procedures 5 2 Servicing procedures with mains supplying disabled generator 5 4 GCM01 Board replacement procedure 5 3 Battery replacement procedure FILE DATE LANGUAGE GCMO1 MU GB 12 2 doc 18 01 2007 2 of 33 GENERAL FEATURES We congratulate you for having purchased the GCMO1 control panel for handling your generator unit As you read through this manual you will realise the outstanding performance and variety of applications offered by this supremely technological unit This electronic microprocessor module not only completely controls the generator and its switching but is also pre arranged for the direct serial communication with a PC Moreover using a GSM unit your generator can be completely remote controlled from miles away The GC MO2 unit is equipped with a complete set of digital testers that are required to monitor all mains generator and motor parameters To make the control of the unit absolutely comprehensible the manual is split up into two parts namely 1 The first USER MANUAL part has been prepared to provide a c
17. GCMO1 includes all power parts programming switch mains sensors battery charter power supply status commando etc PROGRAMMING SWITCH SW1 4 switches enable to select eight different working modalities SWi POSITION ON 1 BATTERY VOLTAGE 12V 2 MAINS SENSOR SINGLE PHASE 3 MOTOR PROTECTION BPO ATM POSITIVE 4 PROGRAMMING OPERATING SUPPLY CIRCUITS CC The GCMO1 is fitted with the first level safety device against excessive power supply voltages the module is able to operate constantly up to 40V and it can also withstand transitory voltages above 250V A second level safety device is also fitted against inverted polarity of the power supply which prevents the circuits in which it is encountered from being powered Any anomalies cause the F1 fuse to trip 16A that cuts out all the electronic circuits AN WARNING If after having powered the control panel the battery LED should fail to light up check the POLARITY OF THE BATTERY before operating any commands Possible connection errors could cause electronic anomalies in the MP01 module if commands are operated with the poles inverted FILE REV GCM01 MU GB 12 2 doc 12 2 DATE LANGUAGE PAGE 18 01 2007 10 of 33 COMMAND RELAYS Three relays 16A command the starting stopping and utilities 15 54 These are safeguarded by one single fuse F1 16A considering that only one relay is enabled at a time Two relays are free contact 10Aand command t
18. OP STOP ALARM RES FREE LOP HET LEV NO NC 421 20 25 2 0 e e e oo Ro N 20 P o co 9 N S 9 NN FUEL RESERVE START ALARM FREE EMERGENCY LOW OIL PRESSURE HIGH ENGINE TEMP WATER LEVEL EJP2 BLOCK TEST PREHEATING STARTER F RS EV Bom OX OU A WL EPB 20 PRODUCTION EJP1 STAND BY GEN SET UNIT BATTERY Ia mmm 7 mm MOTOR GROUND Wo nee Drilling template GCM01 216 200 117 105 127 4HOLES 4 7 FILE REV DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 24 of 33 4 INSTALLATION 4 1 POSITIONING The control panel must have a protection rating IP suitable for the area in which it will be installed IP 42 normal supply for closed areas IP 55 in the case of possible splashing of water or for control panels exposed to rain A WARNING It is advisable not to install the control panel further away than 20 meters form the generator CONTROL GENERATING SET PANEL MAX 20mt gt This requirement is due to the excessive currents caused by lightening that hits the public mains causing the voltage inside the control panel to rise excessively if the connectio
19. RY SINGLE PHASE MAINS SENSOR prearranged survey from the battery charge trans INSULATED MAINS SENSOR MAINS LINE PROTECTION AGAINST MIN AND MAX VOLTAGE V27and V59 DIMENSIONS OF THE MODULE 1 395 x 218 x 40 mm N B The technical characteristics are subject to modifications without notice following technical improvements FUNCTIONS 27 Min voltage 59 Max voltage 60 Dissymmetry 81 Protection for min max frequency 50 Instant current or short circuit 51 Max current with programmable delay FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 23 of 33 Pd gt Pi Vac Vac LS og MANS S BCT CG CR BATTERY 0 CG 5 IG E 8 06 CR 5 120 1 2 3 44 9 10 3 9M 12 7 5 27 R T OL CG CR KEYS RG GEN CURRENT THREE PHASE n CG GENERATOR CONTACTOR 5 VOLTAGE MEASURES SENSOR 2 X CR CONTACTOR RR MAINS RELAY i RG GENERATOR RELAY T BATTERY IG GENERATOR CIRCUIT BREAKER G C M 0 1 ELECTROVALVE p EPB EMERGENCY PUSH BUTTON SERIAL CONNECTOR RS232C BCT BATTERY CHARGER TRANSFORMER TH gt 16A 16A 16A HERR NG gt gt gt gt gt EMG EJP2 1 X N 15 54 CANDLES gt IA x TOP BATT BATTIEDYN fenm 2 j EE ie rr Sex RE yi STARTER 100mA SN wx wx Sox Sox TST RES START ST
20. ameters entered in the programming phase 6 Alphanumerical display that shows all the parameters together with the literal description of the type of alarm 7 Leds which show the visualized measure and indicate parameter s anomaly if flashing 8 Led for engine alarm a battery charter dynamo failure b oil pressure low c engine temperature high d water oil level low e fuel reserve f remote and local safety stop button ON g reserve alarm 1 to define h start failure alarm 9 Led indicates mains presence within normal limits 10 Led indicates mains contact maker closed and use supplied by mains 11 Led indicates generator unit contact maker closed and use supplied by generator unit 12 Intervention led of generator overload protection has to be reset manually 13 Generator unit ON 14 Supplied module 15 Led PROG WAIT fixed programming mode flashing timing phases or automatic running delay 1 4 CONTROLS The operational modes that can be selected with the programming switch are six namely 1 Automatic test This starts to test the generator without disconnecting the mains power supply from the utility When the switch is turned back to automatic mode the generator stops following a delay of roughly one minute it is used for periodic tests or to check the running efficiency following maintenance 2 Automatic mode if there should be a failure in the mains the circuit board responds by opening th
21. apacity of 16A and cross section 2 5 mm The wiring diagram of the strip board the same as on the carter follows the succeeding numeration INPUT 8 OUTPUT Command contact NC 10A Command contact NC 10 1 38 voltage sensor input 0 260V 60HZ Gen set neutral 4 Gen set voltage sensor input 0 260V 60HZ Gen set phase 5 Battery charger input 0 16 29V 5A 6 JBatteycharerinput0 16 20V5A 0 0 1 Zs Functions input LOCK TEST EJP2 programmable CC CBs Functions input EJP SCR RES programmable CC 9 JmptTA 5A paseX 2 J 10 J inputTA 5A common 1 j Pp 11 O 12 JjAlmmouput 00mAmax 0 0 0 0 0 0 0 0 0 1 _ O 13s Inputfuelreserve Alarm 10 14 jinputavallable arm o P d 15 jInpioilpresuelowAlam 16 gJlhnputwatertemperatuehigh Alarm o o 17 inputovercharge Alarm P d 18 jinputwaterlevelAarm P d 19 Input Emergency 0 0 o o j 20 Module power supply 0 32V16A CO 1 21 jModulepowersupply0 32V30A 1 1 1 86 22 command tB30Amax 1 1 1 1 1 1 1 1 O 23 Output stop command B 30 A max 1 1 1 1 O 24 jOutputauxiliary devices command 15 54 30Amax 1 1 O
22. ched while the generator is running or the loose cables 5 4 GCM01 BOARD REPLACEMENT PROCEDURE Disconnect the mains line Connect all fuses Replace the module Copy the programming of the SW1 situated on the strip board Close the fuse F1 battery VV VV ON WV Programming if different of standard 400V 50Hz the working voltage and the frequency e Ratio of the TA 5A e Working voltage e Working frequency e Alarm percentage max voltage e Alarm percentage min voltage e Threshold hysteresis max voltage e Threshold hysteresis min voltage e Compare the remaining values with the test board gt settings of the type of test TA the overload and short circuit current are crucial lt Re connect all fuses and check the efficiency FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 30 of 33 6 MAINTENANCE The control panel has been designed to operate without the need for maintenance The following is to be kept under control nevertheless Every 30 60 days check the electrolytic level of the battery Every 30 days check the water oil and fuel levels Every 30 days check the motor pre heating temperature if installed Every 30 days run the unit automatic test Every 6 months check the battery efficiency 6 1 ELECTRICAL MAINTENANCE See the relative manual for the maintenance of the GENERATOR The information provided herewith simply relates to the electrical command and control parts of the generator N
23. d down The following functions are possible 1 Forced power supply from the mains CR 2 Manual starting the generator CG contact maker is opened 3 The mains CR contact maker is opened and the power supply is forced from the generator 4 Manual stoppage POWER SUPPLY FROM MAINS This enables the mains power supply permanently and disables all the electronic functions with the exception of the battery charger and the EMERGENCY stop function MANUAL STARTING This provides the 15 54 commands that power all the generator utilities It enables the start push button and once the generator is running at a steady state the programming switch is set on the following function that enables the generator With the generator running all the safety devices are enabled As these are however controlled entirely by the electronics its failure could disable them POWER SUPPLY FROM GENERATOR This enables the power supply of the utility from the generator in case of intervention of the engine protections the generator stops with inserted load this solution is not technically correct but it s the only way to have the 99 of the working GE with the electronic failures MANUAL STOPPAGE The stop push button is enabled at all times By moving the jumper located on the right side of the module on the pin 1 and 2 instead 2 and 3 the stop push button is enabled only in MANUAL START mode 2 4 VARIOUS FUNCTIONS AND STANDARD UTILITIES The module
24. e mains contact maker Once the mains is re connected after a certain time the utility is switched back to the mains and the generator is stopped this is the normal operational situation 3 Lock this sets the generator in a locked status It completely disables every possibility of starting while the mains powers the utility This mode is used to work on the system in complete safety being certain that the FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 12 2 18 01 2007 OO EN O 4 of 33 generator will not start even if the mains should be disconnected it is used during maintenance The mains voltage control it s not active 4 Manual mains this enables power supply output from the mains even if the command and control electronics are faulty it is used when the generator is left inoperative 5 Manual starting this enables the generator to be started manually using the start push button The control is direct without the involvement of electronic components It ensures the operation of the generator even when the electronics are faulty it is used for the manual emergency controls or for maintenance purposes 6 Manual generator this enables the forced power supply from the generator it is available for manual procedures or in the case of problems with the automatic functions N warnine When the programming switch is in this position all the utility circuits of the generator are powered such as the solenoid valves
25. e voltage back to the normal value 6 5 OVERLOAD PROTECTION 51 Supposing that a load sufficient to exceed the maximum current that may be output is not available it is advisable to modify the calibration of the overload to a value lower than the load current available see setting section With the generator in automatic mode disconnect the MAINS and when the CG generator contact maker has closed enable the load When the set current is exceeded following the delay timing the CG contact maker is opened and the relative LED flashes the alarm is triggered and the generator stops following the motor delay timing Reset the current calibration maximum current of generator in ALARM THRESHOLDS section after the test has been completed FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 31 of 33 6 6 BATTERY EFFICIENCY The battery is kept efficient by the automatic battery charger which controls its charge avoiding oxidation and sulphating lt controls possible rising in voltage caused by the disconnection of internal components and also voltage sagging causes by anomalies in the battery charger The storage capacity or rather the capacity of facing up to the number of starting times sufficient to ensure the running efficiency of the generator is to be checked every six months in the following manner Check with the battery fully charged with a voltage greater than 13 5V for generators with 12V batteries and a voltage greater
26. ency selection Establishes the working frequency Engine voltage selection Selection working voltage It determines the nominal operating 110 220 230 voltage It is possible to select the value of mains voltage and the 400 Volts 260 380 400 mains 3 phase or 1 phase The alarm thresholds parameters 440 460 Volts T14 and T15 are calculated in function of this value 25 40 50 60 100 AT selection 100 5 150 200 250 This is the AT you use on your plant 400 500 600 1000 5 FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 19 of 33 Function selection EJP SCR or RES This are the functions of the input EJP SCR or RES input 7 EJP SCR RES Alarm or antitheft device This establishes the function of the available connection 14 free alarm Function selection BLC or TST Establishes the function of BLC or AVV Input 8 BLC TST 3 5 MESURES REGULATION DESCRIPTION Gen set frequency reading regulation Enables a fine regulation of the visualization of the gen set frequency on the display This allows correcting the differences between the real frequency and the displayed frequency Mains voltage reading regulation Enables a fine regulation of the visualization of mains voltage on the display This allows correcting the differences between the real mains voltage and the displayed voltage Gen set current reading regulation Enables a fine regulation of the
27. engine This probes command alarms low oil pression high motor temperature low gas level Etc OIL PRESSURE SWITCH ZEROOHM 0588 OIL THERMOSTAT NA VDO OHM INFINITE 120 C AIR FUEL LEVEL NC ZEROOHM VAR 10 20 Fig 5 THERMOSTAT PRESSURE SWITCH FUEL LEVEL BATTERY THE PARAMETERS INDICATED ARE NOT BINDING BUT SUBJECT TO TECHNICAL IMPROVEMENTS WITHOUT PRIOR NOTICE 4 6 ELECTRICAL STRENGTH TEST The control panels that are subject to the electrical strength test are to be prepared baring in mind that the only connection point with the electronic logic is established by the MAINS sensor inputs 21R 225 23T to which a divider is connected that is made up of 3 500 ohm resistors for high voltage for phase and connected to earth Therefore the R S T inputs are to be disconnected FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 28 of 33 5 SERVICE PROCEDURES 5 1 SERVICING PROCEDURES Before proceeding with the functional test 1 Isolate all fuses 2 Check the connection of the oil pressure switch If the connection to earth is not present B by means of the oil pressure switch the motor will not start Once installation is complete check its correctness by performing the procedures advised below 1 Connect the fuses 1 and 2 2 Set the programming switch on ENABLE STARTING 3 The leds oil pressure low and battery charger generator are operative
28. erational limits the output is switched over to the mains and the motor is stopped following a cooling delay The EJP and RES functions are disabled M 01 EJP FRANCE SCR forced starting with 1 2 output RES two GE alternated T FST test running m RES FUNCTION FOR TWO GENERATORS THAT RUN ALTERNATELY By configuring input 8 for the RES function used in plants composed by two generators one in reserve to the other Two applications are foreseen 1 Two gen sets one in reserve to the other and in stand by to mains 2 Two gen sets one in reserve to the other as production central without mains The EJP and SCR are disabled 1 STAND BY TO MAINS In case of mains anomaly the pilot generator replaces the mains If there would be an anomaly during the functioning or if the start attempt fails the reserve generator is activated and reached the speed it will supply the users Programming t11 Res t34 255 ore FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 14 of 33 2 CENTRAL STATION WITH TWO GEN SETS ONE IN RESERVE TO THE OTHER The pilot generator GE starts after the disconnection of the lock command BLC input 7 The running time is adjusted in t34 When the time in t34 is expired the reserve generator starts and when it reaches the speed it sends a signal to the pilot GE that stops the power output and switches to the reserve GE with a power interruption to the users of 1 At the end of time t34 of the rese
29. etween panel board and generator FUS 30A START BATTERY 16A max 8 RELAY 30A ee 5075 D STARTING MOTOR BATTERY Fig 3 FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 26 of 33 4 4 STOPPING The GCMO1 module is arranged to command any stopping system Stoppage with ELECTROVALVE normally energised while the generator is running and while the utilities of the unit are powered Connection 7 is defined 15 54 it emits the B with a maximum current of 16A as the GE starting is commanded to stop when the stoppage command is received OTHER MOTOR UTILITIES ELECTRONIC RPM REGULATOR Stopping with ELECTROMAGNET energised only during the stopping phase Connect to the input N 4 STOP NA max 16A and install a servo relay of 30A because the absorption of the electromagnets usually exceeds 16A FUS 30A BATT pesosooceeeesccecececcesceccesesccosececeo RELAY 30A p Ll 2 INJECTION PUMP Operation with the stopping command the electromagnet is energised and stops the motor To establish the stoppage of the motor the closure of the oil pressure switch is controlled which after 20 seconds from when it closed automatically disables the electromagnet thus avoiding settings and adjustments FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 27 of 33 4 5 MOTOR CONTROLLING PROBES It reveals the function of the engine from them we have the complete safety of the same
30. he contact maker of the commutation and generator CG CR THREE PHASE MAINS SENSOR To activate the three phase sensor set up the SW1 DIP2 in OFF position As it is not possible to work with the two types of mains sensors at the same time please be sure before connecting the three phase mains sensor that the SW1 DIP2 is in OFF position The connection of the three phase sensor without setting the relative DIP SWITCH in the right way could cause a wrong reading of the mains voltage therefore the module would not work rightly The three phase mains sensor is made with three 500 K OHM resistance dividers with high insulation voltage capable of withstanding any excessive voltages of up to 8KV for 1 second Itis sensitive to the minimum and maximum voltage on the single phase and to the phase displacement angle of the three phases SINGLE PHASE MAINS SENSOR To activate the single phase mains sensor set up the SW1 DIP2 in ON position For the single phase mains sensor you use the output voltage on the secondary of the battery charger transformer In this configuration the insulation is the same as in the battery charger transformer It is sensitive to Min and Max voltage SINGLE PHASE GENERATOR SENSOR Volt A single phase transformer of separation supplies the sensor It is sensitive to Min Generatore and Max voltage On the right side of the module are available two trimmers not indicated to avoid wrong use which enable the adjustment of mains vo
31. hich when the established operating conditions are reached the GCMO1 module closes the CG contact maker that then powers the utility from the generator unit G When running the engine M and the generator G are safeguarded against possible anomalies which if encountered cause to stop the generator immediately 4 When the R mains is restored within the normal limits the GCMO1 module after an adjustable delay opens the contact maker of the CG generator and one second later closes the CR contact maker thus powering the utility from the mains again D The generator continues to run for at least another minute to cool down after which it stops automatically 6 Only reserve and overload To ensure the perfect efficiency of the generator a battery charger automatically holds the battery perfectly efficient An automatic fuel filling system constantly keeps the correct level in the daily tank A pre heating system maintains the motor FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 3 of 33 at the ideal temperature so that it is ready to start whenever necessary 1 3 VIEW OF THE GCMO1 UNIT 8 15 1 10 12 3 2 11 4 Description of the components 1 Programming switch 2 Start button only with 1 manual start mode 3 Stop button gt LI 4 Display reading selection push buttons display 6 5 Reset Enter push button used to reset the functions and to eliminate an alarm status and also to confirm par
32. ignals with an acoustic and with 700 working lighting alarm The defined value must be multiplied by 10 hours Max Mains voltage The generator is started The value is in relation to the programmed 10 Vn 440 V normal working voltage TO9 Min mains voltage The generator is started The value is in relation to the programmed 20 Vn 320 V normal working voltage T09 Max Generator voltage Alarm triggered and stoppage The value is in relation to the programmed 10 Vn 440 V normal working voltage T09 Min generator voltage Alarm triggered and stoppage The value is in relation to the programmed 2094 Vn 320 V normal working voltage T09 Hysteresis alarm threshold Min V T17 It establishes the value of minimum voltage 30 Volts 0 40 Volts Hysteresis alarm threshold Max V It establishes the value of maximum voltage 10 Volts 0 20 Volts Max battery charge voltage 13 5v 13 14 5v 25 It establishes the max voltage of the charge battery 27 26 29v Max battery charge current T26 It establishes the maximum current of charge to adjust to the CB 5A 1 5A transformator s power Overload current After the delay in t26 starts the cycle alarming and stopping for overload With 0 Amper the protection from overload is excluded t26 3 4 OPERATING FUNCTIONS rm DESCRIPTION VALUE FIELD Preheating or starter function STR CND o STR Establishes the preheating or starter function input 11 GAS Working frequ
33. ing 10 x 38 fuses with not fixed fuse boxes Battery charger transformer of adequate capacity Automatic generator protection switch if provided Switch with tetrapolar contact makers of adequate capacity for the power of the unit interlocked mechanically and electrically and scaled in AC1 in compliance with standard ISO DIS 8528 4 6 Three amperometric transformers for measuring the generator and mains current 7 Terminal for the mains and generator inputs the utility output and any auxiliary connections 8 Safety fuse gauges and connection terminals nameplate Switching is controlled directly by CG and CR relays built in the MP GCM01 module which directly command switching via not powered contacts a aS IMPORTANT The CG and CR command contacts are normally closed to allow the command circuits in the case of certain anomalies to force the mains contact maker to close For example by disconnecting the battery and also the power supply to the battery charger transformer the mains contact maker is forced to close FUNCTIONING MEASURES All parameters are visualized on three displays of seven sections All the reading pages are controlled using the lt and gt push buttons which run in both directions The reading pages available are the following e Mains voltage Generator voltage Generator frequency Generator current Hour counter Battery tension Battery charter current If an alarm is triggered it will be shown on the disp
34. ing conditions Programming T35 7 seconds T36 minutes T37 hours T38 actual day of the week In case of disconnection of the battery the timer loses the programming On the display will appear CLC for 0 5 every 1 5 therefore it s absolutely necessary to program again the timer AUTOMATIC TEST RUNNING The automatic running can be programmed for 1 to 4 weeks The automatic test starts the generator for 5 A mains failure determines immediately the switching from mains to the generator When mains come back or the forced test running time expires the generator stops T32 7 disables OFF or enables the programming week day of the generator in automatic test DISPLAY WEEK DAY WEEK2 WEEK3 WEEK4 1 1 1 1 2 1 3 1 4 1 O 1 2 1 2 2 2 23 2 4 2 6 As ss T33 Establishes the starting time of the generator programmable from to 23 50 hours AUTOMATIC LOCK Enables to program time and days of the lock device active even with mains failure Select t29 to program the day then chose tot for the total lock and par for the partial lock With par you enable the lock start time in 130 and the lock stop time in 131 After d7 Sunday you will find the function press ENTER for the option between ON to enable the lock function or OFF to disable the lock function Programming When the internal timer locks the generator on the display appears BLC
35. lay For example a low oil pressure fuel reserve high battery voltage alarm etc CONTROLS The GCMO1 control panel equipped with a programming switch to select the following functions controls all operational modes TEST It performs all the automatic functions with the exception of the switching function It tests the efficiency of the whole system without disconnecting the mains power supply to the utility All safety devices are enabled while the test is running If the mains should be disconnected while the test is running the generator starts immediately The test ends automatically when the mains power supply is restored or following a programmed external command FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 7 of 33 AUTOMATIC MODE It s the normal working condition In case of mains anomaly the generator unit starts automatically after few seconds with the delivery for utility closing CG During running the generator is protected against all anomalies which if encountered would cause the stop of the generator and the visualisation of the cause on the relative When the main is restored within the normal limits after cc 1 min the commutation GEN CG MAINS CR takes place and after few minutes the generator stops automatically LOCKED STATUS It is the safety condition for simple maintenance operation on the generator Guarantees utility supply through mains blocks any start possibilities of the generator
36. lear and simple guide to help you use the generator rapidly completely and safely 2 The second TECHNICAL MANUAL part has been prepared to provide complete and detailed instructions for skilled personnel to start up the generator correctly 1 1 PURPOSE The manual has been prepared specifically for the user of the generator unit Information required for the following is provided 1 Tolearn the operational principle of the unit 2 Tointerpret the indications given on the electronic control panel 3 To control it for the various operational requirements 4 To perform the basic checks required ensuring the efficiency of the generator itself Technical or adjustment matters are not dealt with as these involve the installation engineer when setting up the system 1 2 OPERATIONAL PRINCIPLE HOW DOES A STAND BY GENERATOR UNIT WORKS Fig 1 shows the system components that consist of a public mains R a generator unit G M and a command and control panel QGE with a built in mains contact maker CR a generator unit contact maker CG and the GCM01 module USERS Supposing that the mains is within the normal limits the CR mains contact maker is closed therefore the utility is powered from the mains The GCMO01 module controls the mains and if there should be a drop in voltage a phase should be missing or the phases should be dissymmetrical the control panel 1 Opens the CR mains contact maker 2 Starts the G M generator unit w
37. libration generator frequency reading Calibration generator three phase voltage reading Calibration generator current reading 100A Calibration of battery voltage reading 12 24V Calibration of battery current reading LOCK days selection OES LOCK beginning time 20 O Automatic test test days selection OFF O Automatic test beginning time 8 Working hours of alternated gen sets PA ALL Alarm or antitheft function ALL FILE REV DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 21 of 33 3 8 CONNECTIONS AND RELATIVE DESCRIPTION The connection of the module GCMO1 happens through an extractable strip board two way receptacle this terminal board allows a fast disconnection of the module without intervention need on the single cables ajeje S n c 4 Q BOLOGNA ITALY SERIAL CONNECTOR TEL 39 051 73 90 99 FAX 73 90 94 RS232C TYPE GC M01 DATE SERIES SW1 SELECTIONS 0 OFF 24Vdc N SINGLE PHASE OFF THREE PHASE N 15 16 POSITIVE INPUT OFF 15 16 NEGATIVE INPUT N PROGRAM MODE OFF FUNCTION MODE rol AGE 62 D 63 D START CG CR SW1 5 5 7 5 popups papse pspapspep TESTING 1 2 3 Vcc 12 24V Vac 4 PROGRAM CONNECTOR TEST EJP STARTER PREHEATING CONNECTION ON THE LOWER PART There are 29 terminal boards on extractable connector with two way receptacle with a c
38. ltage and generator measures MOTOR PRE HEATING A single phase power supply is foreseen that is safeguarded by fuses for the motor pre heating system The heater on it must be fitted with built in thermostat If required specific plants to pre heating system on the motor or generator are possible AUTOMATIC BATTERY CHARGER The automatic battery charger is the double semi wave type with phase choker totally controlled by the micro controller It keeps the starting battery charged with a max Load of 5A and the charge is self adjusted to compensate for consumption and for when the battery automatically runs flat The voltage of the battery and the charging current can be displayed on the GCMO1 unit The electronics are built in the GCMO1 unit whereas the battery charger transformer is fitted externally It is equipped with Automatic cut out of the charge during the starting phase Electronic restriction of the current to prevent excessive loads Electronic restriction of the voltage to limit the maximum load levels 2 3 V E 13 5 27V Protection against short circuits Protection against inverted polarity Protection against excessive input voltage Protection with low battery voltage for an excessive discharge VVVVVV V POSITIVE MOTOR PROTECTION INPUTS Some modern motors are equipped with positive outputs to indicate the Low Oil Pressure and High Motor Temperature anomalies The GCMO 1 is pre arranged to communicate with these moto
39. n line exceeds 20 meters If there is no other choice than installing the control panel further away than 20 meters our engineering department can provide you with various technical solutions N WARNING To ensure the reliability of the system all of its components must be connected to earth Daily gas oil tank FUEL TANK GENERATING SET EARTH OTHER COMPONENTS FILE REV DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 12 2 18 01 2007 25 of 33 4 2 POWER CONNECTION To facilitate the set up are furnished schemes of linking and indicative charts for the sizing of the pipelines of the line and auxiliaries It must be reminded that all the equipments and lines must be protected from short circuit and overloaded Moreover for safety all the prevention measures must be adopted against the accidental direct contacts see normes CEI 64 8 4 for which at the beginning of the wire of arrival mains must be sets an automatic switch of suitable value and selectivity on the line of utility on a differential switch EN 60439 1 TABEL A1 VALUE FOR ONE SINGLE WIRE SWITCHING IN NUMBER OF THE MIN CROSS SECTION MAX CROSS SECTION AMPERE Ith For further information contact a reliable installation engineer or our engineering department It is advisable for the start command to install a servo relay above the motor so as to avoid that frequent voltage drops can prevent the starting Even with few wiring meters b
40. ning the mains fails the generator immediately supplies the users Cutting off the command TEST the generator stops automatically Programming 13 TST The BLC function is disabled LOCK FUNCTION By configuring input 7 for the block function BLC which enables through external command to put the module in a state of forced lock mode this function is very useful to put the module in night lock or weekend lock Programming T 13 BLC The TEST function is disabled FUNCTION EJP When JP1 is enabled after the programmed time T12 the generator starts with the command EJP2 the commutation from mains to gen set is immediate When these inputs are disabled with connected mains and within normal operating limits the output is switched to the mains and the motor is stopped following a cooling delay 1 The functions SCR and RES are disabled Programming 4 0 T11 EJP enables the function T12 starting delay of 0 28 FUNCTIONING Command EJP1 the gen set starts without commutation after t12 delay Command EJP2 immediate commutation EJP1 EJP2 30 min COMM SCR FUNCTION OR FORCED STARTING WITH OUTPUT The input 8 is suitable for the SCR function By configuring input T11 in SCR when this is enabled it starts the motor with the forced output from the generator As soon as this input is disabled if the mains is connected and is within normal op
41. r control Not earth reference on mains sensor panel and accessories Defect in stopping system Clean from dirt lubricate or replace Emergency stop push button pressed Turn and pull up to release push button Motor too cold Repair or replace pre heating system gt E D C 0 e C o 5 2 72 CO x FL oed esee C Q Q O 60 O 0 LL C 5 2 ga 5 pem tls 9 C 0 o oO c 35 gt 0 Jp c 0 m D 0 LL lt ea LL FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 33 of 33
42. re establishment we we 5 oe In case of alarm the display will automatically show the relative page and light the relative led Press ones the push button RESET to deactivate the acoustic alarm pushing twice to deactivate the alarm status and re establish the normal functions of the electronic module l When the voltage is restored within normal limits the mains re enter delay timer t2 is active and enables mains stabilization before sending load on it L After commutation which has a pause of 1 the cooling phase of the engine starts cc 20 t4 and to which ends the stop is activated and kept for about 10 M Ready for a new cycle N With mains presence the fuel reserve water level and overload protections are operating LOCK STATUS A Ifthe generator is working the block status actives immediately it s stop B Supply of all starting circuits is deactivated C Guarantees safe maintenance FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 9 of 33 2 3 MANUAL CONTROL FUNCTIONS The manual operational mode is considered as an emergency back up mode for the automatic functions It also ensures the operating efficiency with the micro controller in an abnormal condition The programming switch ensures the direct commands that are not backed up by electronic logics This means that when the START push button is pressed for example the starting motor will be operated for as long as the push button is hel
43. refore if the contact maker is to be opened the command relay must be powered FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 11 of 33 HOUR COUNTER AND MAINTENANCE REQUIREMENT 114 From 0 to 9999 after the first 999 hours the visualisation changes in 100 which means 1000 hours and the recording happens every 10 hours Anyway minutes and seconds are memorized for example 1250 1 25 It s forseen the hours reprogrammation in t39 When the relative led is flashing and the acoustic alarm is on the intervention hours for maintenance programmed in t14 are up Do not program when the function RES of two horizontally pivoted Gen sets is active CONFIGURATION OUTPUT11 STARTER The output 11 can be programmed for four different functions 1 Starter GC M01 2 Glow plug preheating 3 Gas electrovalve 4 Reset i eenen enn A transistor with max current 200mA manages the output 11 and it is foreseen to drive STR CND an interfacing relay GAS RST GLOW PLUG PRE HEATING CND A transistorised output is provided that may be programmed to command a pre heating system of the glow plugs The software controls this output and if programmed COMANDSTART to pre heat the glow plugs each time it is triggered the pre heating cycle is enabled before each starting cycle PREH GLOW PLUG 106 Program T07 in CND and the glow plug pre heating time
44. ronic board indicated on front panel 6 Battery voltage 12 or 24V T Mains voltage 230 or 400V 8 Generator capacity KVA 9 Frequency 50 60 Hz 10 Indications displayed on GCM02 module when the problem occurs 11 Operational mode AUT or MAN PROBABLE CAUSE SOLUTION Flat battery Fuse 8 4A of battery charger Flat battery Battery charger Battery with inverted polarity Check and invert cables Loose or oxidised battery connections Clean tighten and lubricate battery terminals 16 A battery fuse blown Replace the fuse 10x38 16 A e 0 ESSI mE E dicha Replace pinion or whole starting motor TO Connect and check the connection to No connection with oil pressure switch earth of the pressure switch Excessive speed upon starting Calibrate the electronic revs regulator Fill up with fuel or disconnect level Immediate alarm due to fuel reserve device Immediate alarm due to excessive Replace the voltage regulator voltage Low oil pressure Replace pressure switch High motor temperature Replace thermostat EN Fuse2 blown Replace 10x38 fuse with identical fuse Remote switch coil burnt Replace coil No voltage output by generator Request assistance Fuse4 blown Replace fuse with identical fuse Remote switch coil burnt Replace coil Fuses 5 blown Replace 10x38 fuses with identical fuse EN E Check earthing of generato
45. rs by modifying the SW1 3 from OFF to ON MOTOR STARTED READING This requires no external signal The control is achieved on two parameters the first and most important one is the voltage delivered by the three phase generator produced only with the presence of the remaining magnetism of the generator The first signal of STARTED MOTOR is given when during the start cycle are reached 400 500 rpm with a voltage between 7 and 8 Volt If due to an anomaly the generator is not powered the starting phase is stopped once and for all by the second safety control established when the oil is pressured which triggers a delay of 3 seconds that stops the starting phase EMERGENCY Pre arrangement for the external emergency command enabled in all operational modes with immediate stoppage of the motor opening of the generator contact maker and triggering of the alarm The emergency device not only controls the control software of the circuit board but is also equipped with an electro mechanical circuit that totally ensures the stoppage of the unit and the opening of the generator contact maker WARNING The command is double the NO contact of the emergency push button is required to ensure the immediate opening of the generator contact maker even in the case of an anomaly in the electronics In fact to ensure the emergency power supply even in extreme cases the contact that commands the mains and generator contact makers CG CR is normally closed NC the
46. rve GE the pilot generator is called with the same procedure If there would be an anomaly during the functioning of the generator the other one will start automatically Programming t11 RES 134 1 255 working hours t13 BLC To establish the PILOT generator put the programming switch in a position different from AUT test or lock for 3 and then switch it back AUT The FAILED START led begins flash to indicate that the PILOT generator and with fix light it indicates failed start It is possible to use the internal timer to program the automatic intervention of the power station composed by to gen sets Programming the lock function with the internal timer it is possible to lock each generator for the programmed time Given that in case of disconnection of the module GCMO1 the timer loses the programming it is advisable to supply the plant of two gen sets with two diods D1 and D2 of 40 A If you do not use the internal timer the diods are not necessary This circuit with diods on the battery is suitable only for plants without battery supplied by mains WIRING DIAGRAM ON STOP OFF START FILE DATE LANGUAGE GCMO1 MU GB 12 2 doc 18 01 2007 15 of 33 2 7 SPECIAL FUNCTIONS The GCMO1 is arranged with an internal timer to start and stop the generator even with mains failure TIMER FOR TEST RUNNING OR AUTOMATIC LOCK 4 programmed fields establish Day and month It is possible to lose monthly 5 in extreme work
47. s a three phase or two phase sensor to monitoring the mains In case RIF MONO use don t use the three phase reading even if available The mains sensor guarantees the following controls e Drop from 5 up to 30 of nominal voltage t16adjustable even of a single phase e Rising from 5 up to 2096 of nominal voltage t15 adjustable even of a single phase e Phase lack e Wrong angle between phases dissymmetry B Encountering one of the above named anomalies the mains contactor opens immediately as to assure the running of the generator even in case of high voltage drops C In case of mains failure the start delay timer is activated t5 it makes the system insensitive to short mains interruptions D The 5 start cycles begin after the START DELAY t0 and last 5 t1 with pauses 5 E In case of start failure after the start cycles 5 the signal FAILED START appears F Delivered voltage and frequency of the generator are measured when the speed is reached when they restore within the normal parameters of functioning the generator delay will be activated t3 after this time the generator contactor will be closed CG G During the functioning the following functions and signalisations are active which are displayed at their intervention FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 8 of 33 YES DESCRIPTION COLOR STATUS ACOUSTIC pula STOP GESTIONE FUNZIONALE LED LED ALARM DELAY O F
48. st 0 0 23 5 T33 t32 It establishes the beginning time test in hours and a dozen minutes for all the partial programming hours days in t29 Working hours of alternated gen sets T34 It establishes the working hours of alternated gen sets with a stand by group At the end of the time is asked the attendance of the stand by group When this is on speed the load is transferred to clock seconds O T35 clock days of the week It s a weekly clock for the correct functioning it must be programmed the day of the week at the moment of the programmation REPROGRAMMING TOTAL HOURS T39 It permits the reprogramming of the total hours FILE REV DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 20 of 33 3 7 SELF PROGRAMMING The module GCM01 is arranged for a self programming function This function is very useful in case of wrong functioning of the module due to mistaken configuration The self programming function enables to re establish all setting fields with a pre established standard valu le To carry out the self programming function press at the same time the push buttons and for 8 seconds after this time on the display appears PRG and the module configures itself with the below mentioned parameters Statingattempts S5 Starting time 5560 Mains enabling delay Glow plug pre heating time or starter Function selection PRC or STR Hysteresis alarm threshold Max V Ca
49. system powered by the generator request technical assistance to check the suitability of the CG CG mains generator switching to the new load SUMMERY On a periodic basis check the electrolytic level of the clear batteries Touch the motor to feel if it is warm if equipped with pre heating system and execute an automatic test FILE DATE LANGUAGE PAGE GCMO1 MU GB 12 2 doc 18 01 2007 6 of 33 2 TECHNICAL MANUAL 2 1 CONSTRUCTIONAL DESCRIPTION OF THE CONTROL PANEL The control panel is entirely manufactured in compliance with the following European standards ANS low voltage electrical control panels EN 60439 1 EMC electromagnetic compatibility directive 89 336 EEC Each control panel or device is completely tested and supplied with test certificate declaration of conformity and EC marking in compliance with 626 safety standards The control panel is manufactured in a steel sheet cabinet 15 20 10 that is skilfully treated and painted with standard grey silicon epoxy powder Ral 7032 and has a standard protection rating of IP 42 EXTERNAL COMPOSITION The control panel consists of the following 1 GCMO1 electronic circuit board that houses the control logic control and reading of the operational parameters of the generator 2 Emergency stop mushroom push button optional 3 Nameplate with operational standards 4 Nameplate with safety instructions INTERNAL COMPOSITION Numbered cables placed within PVC sheath
50. toring the commutation status all parameters voltage frequency current ecc and all alarms It is possible to command the functions AUTOMATIC automatic TEST LOCK FORCED START with gen set output and RESET Every communication is registered in a report 2 Module for the in circuit programming enables to transfer or modify the program with PC The software is supplied only to module with serial output FILE DATE LANGUAGE PAGE GCM01 MU GB 12 2 doc 18 01 2007 17 of 33 3 PROGRAMMING The programming defines the kind of functioning that be normal or articulated on need To simplify the use is given with a standard configuration for a Disel generator group in emergency to the mains To reach the function programming bring the switch N 4 in ON position All displayed measures can be modified Ex 380V into 395 or 378 or in other values The first displayed setting field is 100 To enter press located on the frontal of the module by entering in the field the display shows the actual setting To increase or decrease the adjusted value use and To confirm the chosen value and pass to the following field press The setting fields 46 from to T45 To move on through the fields use 2 gt The following features the minimum for the management of a stand by generating set The fields in written round brackets are related fields to the same function N DESCRIPTION VALUE
51. ve useful How restore the fuel circuit 1 Set the programming switch on Manual Start mode without starting the generator In this way the 15 54 that powers the fuel interception solenoid valve is activated 2 Once you have filled up with fuel operate the hand pump situated on the motor until the circuit is restored which can be seen by the pump becoming harder to move 3 Start in manual mode It is advisable to restrict the starting attempts to 10 seconds each with a pause of 15 seconds in between to allow the battery to recover efficiently Once the unit has started and is running regularly reset the automatic functions 1 5 3 PERIODIC CHECKS To keep the unit efficient some periodic checks must be made together with those scheduled by the manufacturer of the motor and by the installation engineer 1 Check the electrolytic level of the battery every 15 days following installation and request the assistance of an engineer if an excessive consumption is noticed Following the initial period check every 90 days 2 generators complete with motor pre heating system check if the motor is warm each time a check is made otherwise request technical assistance WARNING a cold motor at low temperatures could have difficulty in starting or outputting once started Ifthe generator is rarely triggered due to the lack of mains power supply execute an automatic test for at least 2 minutes 4 f new electrical machines are installed in the
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