GENSYS CORE. Technical Documentation. Core unit for all-in-one. Genset control and paralleling unit. with integrated plc. Chapter : Overview

Transcription

1 Chapter : Overview GENSYS CORE Technical Documentation Core unit for all-in-one Genset control and paralleling unit with integrated plc Part Number: A53Z1 B-EN Last Update: April 25 th 2011 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 & O E. 1

2 Chapter : Overview CRE Technology 130 Allée Charles-Victor Naudin Zone des Templiers Sophia Antipolis BIOT FRANCE Phone: Fax: Website: info@cretechnology.com 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 provide specific trainings on our products and softwares. Technical Support: (office hours: 8.30AM-12AM / 2PM-6PM) Mail: support@cretechnology.com SKYPE: support-cretechnology.com INFORMATION You can download the most up-to-date version of this documentation and different other documentations relating to GENSYS 2.0 Core on our web site: 2

3 Chapter : Overview Date Version Comments By August 23th 2010 A Derived from GENSYS documentation. Starting point. XDH April 25 th 2011 B Specific Applications dedicated for Gensys 2.0 Core TD 3

4 Chapter : Overview Table content TABLE CONTENT... 4 FIGURES CONTENT... 7 TABLES CONTENT OVERVIEW EUROPEAN UNION DIRECTIVE COMPLIANCE CE ENVIRONMENT CHARACTERISTICS APPLICATION AND CONNECTION REAR PANEL - CONNECTORS REMOTE CONTROL USING A PC (ETHERNET CONNECTION) OPERATING MODES MANUAL MODE AUTO MODE TEST MODE SEMI AUTO MODE START SEQUENCE PREDEFINED CONFIGURATIONS SINGLE GENERATOR IN CHANGE-OVER MODE SINGLE GENERATOR IN NO-CHANGE-OVER MODE GENERATORS PARALLELING WITH DIGITAL BUS GENERATORS PARALLELING WITH GENSYS 2.0 CORE AND PARALLEL LINE MODULES MULTIPLE GENERATORS WITH STATIC PARALLELING SINGLE GENERATOR PARALLELED WITH MAINS POWER PLANT PARALLELED WITH MAINS USING MASTER 2.0 OR GCR POWER PLANT PARALLELED WITH SEVERAL MAINS USING MASTER 2.0 OR GCR INSTALLING AND COMMISSIONING A GENSYS 2.0 CORE APPLICATION MINIMUM WIRING DIAGRAM COMPLETE WIRING DIAGRAM BEFORE COMMISSIONING (BEFORE GOING ON SITE) DURING COMMISSIONING DEDICATED I/O LINES SPEED GOVERNOR INTERFACE SPEED AND VOLTAGE CONTROL WITH CONTACTS / PULSES ANALOGUE AVR (AUTO VOLTAGE REGULATOR) CONTROL RELAY OUTPUTS CRANK / FUEL / STARTER 2 / STARTER 3 FUNCTIONS WATER PREHEAT / PRE-LUBRICATION / PRE-GLOW FUNCTIONS AIR FAN FUEL FILLING / COOLANT FILLING / OIL FILLING ANALOGUE LOAD SHARE LINES WATCHDOG OUTPUT I/O LINES DIGITAL INPUT DIGITAL OUTPUTS ANALOGUE INPUT PROTECTIONS DISABLE GENERATOR ELECTRICAL FAULT MAINS ELECTRICAL FAULT ALARM

5 Chapter : Overview 8.5 FAULT (SOFT SHUT DOWN) SECURITY (HARD SHUTDOWN) HELP + FAULT (SOFT SHUT DOWN) HELP + GEN. ELECTRICAL FAULT ADDITIONAL FUNCTIONS LOAD SHARING USING INTEGRAL (DE-DROOPING) OPERATOR CONTROLLED RETURN TO MAINS MAINS & GENERATOR ELECTRICAL FAULT OPTIONS GENERATOR ELECTRICAL FAULT GENSYS 2.0 CORE WITH EXTERNAL AUTOMATIC START MODULE REMOTE START UPON EXTERNAL PULSE SAFETY INHIBITIONS USE OF BSM II WITH GENSYS 2.0 CORE GENSYS 2.0 CORE WITH TEM COMPACT PRESETTING COUNTERS / G59 PARAMETERS (ACCESS LEVEL -1) SCADA HOW TO SET A GPID AUTOMATIC LOAD / UNLOAD HEAVY CONSUMER (MARINE SEQUENCE) NON ESSENTIAL CONSUMER TRIP (MARINE SEQUENCE) TO DEACTIVATE THE OUTPUTS, IT IS NECESSARY TO RESET THE ALARM E2729 ON THE FRONT PANEL PHASE OFFSET (DYN11 AND OTHER) THREE PHASE AND 180 TWO PHASE SYSTEMS TEXT FILE & PLC INTRODUCTION VARIABLE NAMING TEXT FILE DESCRIPTION PLC PROGRAMMING LANGUAGE VARIABLES SYNTAX EXAMPLES GENSYS 1.0 GENSYS 2.0 CORE COMPATIBILITY COMMUNICATION CAN BUS GOOD PRACTICES CAN BUS CABLE: MAXIMAL LENGTH OF A CAN BUS: COMMUNICATION SPEED OF GENSYS 2.0 CORE CAN BUS: COM1: INTER GENSYS 2.0 CORE CAN BUS COM2: CAN PROTOCOLS (CANOPEN, J1939, MTU MDEC): COM3: USB COM4: ETHERNET COM5: MODBUS RTU ON SERIAL PORT RS COM6: SD CARD TROUBLESHOOTING MENU OVERVIEW MENU INTRODUCTION DISPLAY MENU CONFIGURATION MENU BASIC CONFIGURATION MENU ENHANCED CONFIGURATION MENU SYSTEM MENU DEDICATED SCREENS USEFUL INFORMATION

6 Chapter : Overview 15 VARIABLES PRECAUTIONS REFERENCES OPTIONS ACCESSORIES CRE TECHNOLOGY

7 Chapter : Overview Figures content Figure 1 Multi-control HMI Figure 2 HMI redundancy Figure 3 - Rear panel Figure 4 Typical menu Figure 5 Typical configuration page Figure 6 - Typical start sequence for fuel engines Figure 7 - Power plant in change-over mode without paralleling Figure 8 - Typical sequence in change over mode Figure 9 - Power plant in change over without paralleling Figure 10 - Power plant with several generators Figure 11 - Generator paralleling with parallel lines Figure 12 - Static paralleling with 4 generators coupled together in emergency situation Figure 13 - Example with 4 generators coupled together in emergency situation Figure 14 - Paralleling with mains Figure 15 - Typical sequence in No Break CO mode Figure 16 - Typical sequence in permanent mode Figure 17 - GCR GENSYS 2.0 Core wiring diagram Figure 18 - Power plant paralleling with mains Figure 19 - Power plant paralleling with several mains Figure 20 - Interconnection of all battery negatives Figure 21 - Speed output Figure 22 Connexion avec un EFC Cummins Figure 23 - PWM dynamic Figure 24 Caterpillar PEEC and ADEM connections Figure 25 - Speed and voltage control with Contacts / Pulses Figure 26 Speed and voltage control pulses Figure 27 - Voltage output Figure 28 - Connections for water preheat, pre lubrication and pre glow Figure 29 - Connection for air fans Figure 30 - Connections for filling Figure 31 - Fuel filling diagram Figure 32 - Wiring parallel lines Figure 33 - Change over with one digital input programmed as "Mains electrical fault" Figure 34 - Permanent mains paralleling with one digital input programmed as "Mains electrical fault" Figure 35 - Permanent mains paralleling with one digital input programmed as "Mains electrical fault" Figure 36 - Permanent mains paralleling with one input as "Mains electrical fault" Figure 37 - Permanent mains paralleling and generator electrical fault Figure 38 - Wiring GENSYS 2.0 Core Auto Start Module Figure 39 Wiring GENSYS 2.0 Core to BSM II Figure 40 - Wiring GENSYS 2.0 Core TEM Figure 41 - Typical GPID controller Figure 42 Automatic load/unload sequence Figure 43 - Automatic load/unload arbitration Figure 44 - Heavy consumer validation Figure 45 - Heavy Consumer Control with active power analysis Figure 46 - Heavy Consumer Control with number of gensets analysis Figure 47 - Configuration of the heavy consumer confirmation output Figure 48 - Non essential consumer trip settings Figure 49 - Non essential consumer trip alarm (1) Figure 50 - Non essential consumer trip alarm (2) Figure 51 - Non essential consumer trip output setting Figure 52 - Non essential consumer trip timers Figure 53 - Non essential consumer trip diagram Figure 54 Phase offset example Figure 55 CAN bus wiring Figure 56 - CAN Bus wiring Figure 57 - GENSYS 2.0 Core GENSYS 2.0 Core Figure 58 - GENSYS 2.0 Core GENSYS 2.0 Core GENSYS 2.0 Core Figure 59 - Mobile generator sets

8 Chapter : Overview Figure 60 - Connecting J6 to broadcast variables Figure 61 - Connecting Magnetic pick up for speed broadcast Figure 62 - CAN bus inhibition schematic (example) Figure 63 - Modular remote CANopen I/O extension module Figure 64 - CANopen coupler wiring Figure 65 MDEC Screens Figure 66 Virtual input screen Figure 67 - Wiring diagram for Volvo EMS Figure 68 - GENSYS 2.0 Core GENSYS 2.0 Core GENSYS 2.0 Core (MODBUS) Figure 69 Generator global view Figure 70 Mains/Busbars global view Figure 71 Synchroscope Figure 72 Engine meters Figure 73 GPID factory setting Figure 74 Cos phi PID Figure 75 kvar shar. gain Figure 76 Timers Figure 77 - kw sharing GPI Figure 78 P=const PI Figure 79 Synchro volt PID Figure 80 Synchroscope frequency & phase PID Figure 81 Modification by variable number Figure 82 Com ports Figure 83 Compilation result screen Figure 84 Download screen Figure 85 Fault screen Figure 86 Information screen Figure 87 Speed regulation details Figure 88 Voltage regulation details Figure 89 - Several generators warning Figure 90 - One generator with mains warning Figure 91 - Standard cables Figure 92 - Access to CRE Technology Figure 93 - CRE Technology distributors

9 Chapter : Overview Tables content Table 1 - COM1 pin out Table 2 - COM2 pin out Table 3 - COM4 pin out Table 4 - COM5 pin out Table 5 - Inputs/Outputs description Table 6 - Typical basic change over configuration Table 7- Typical no change over basic configuration Table 8 - Typical basic multi Generator configuration Table 9 - Typical basic configuration for GENSYS 2.0 Core with parallel line modules Table 10 - Typical basic mains paralleling configuration Table 11 - Paralleling with mains configuration Table 12 - GENSYS 2.0 Core /GCR configuration Table 13 - Power plant paralleling with several mains configuration Table 14 - Speed governor parameters Table 15 - PWM parameters Table 16 - AVR parameters Table 17 - Breaker control configuration Table 18 - Fuel/cooling/oil filling parameters Table 19 - Input parameters Table 20 - Input validity domain Table 21 - Input direction domain Table 22 - Input functions Table 23: Oil pressure calibration points Table 24: Water Temp calibration points Table 25 - Wiring GENSYS 2.0 Core Auto Start Module Table 26 - Wiring GENSYS 2.0 Core TEM Table 27- Label definition bloc Table 28 - Custom logo labels Table 29 - Valid units and accuracy codes Table 30 - Variables with customizable unit/accuracy values Table 31 Available instructions Table 32 DB9 pin out Table 33 - Broadcast variables sent over inter GENSYS 2.0 CAN bus Table 34 Broadcast variables received by BROADCAST DATA from inter GENSYS 2.0 Family CAN bus Table 35 - CAN bus inhibition variables Table 36 - CAN bus inhibition parameters Table 37 - CANopen input and output variables Table 38 - CANopen configuration example Table 39 - MDEC connection Table 40 - Important parameters Table 41 - J1939 message actions (protections) Table 42 - COM5 pin out Table 43 - Power plant configuration Table 44 - Breaker settings Table 45 - Screensaver modes

10 Chapter : Overview 1 Overview 1.1 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 the following technical construction file: CEM 2004/108/EC, which replaces directive CEM (89/336/EEC) relative to electromagnetic emissions as from July 20th This product is developed to respect harmonized norms: EN 55099:2009 EN 55099:2010 EN 55088: /95/EC (replaced directive 73/23/EEC since January 16th 2007). SAE J1939/71, /73, /31 Other norms: EN : 2006 (Industrial location) EN EN EN 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. 1.2 Environment Temperature Operating: 0 to 55 C Storage: -30 to +70 C Humidity: 5 to 95% Tropic proof circuits for normal operation in humid conditions. IP 20 protection 1.3 Characteristics Size 248x197x57mm (9.76x7.76x2.24in) Weight 1.0kg (2.2oz) 10

11 Chapter : Overview 1.4 Application and connection GENSYS 2.0 CORE can be connected to the RDM 2.0 GENSYS 2.0 CORE is a Generator management module Several power plants possibilities Same mainboard as the GENSYS 2.0 Family The GENSYS 2.0 CORE can control a single or a multiple generating sets power plant. You can combine this module with one or more RDM 2.0 remote display. Multi-control HMI: A single RDM 2.0 can control up to 14 GENSYS 2.0 CORE GENSYS 2.O Core COM 4 Ethernet crossover cable RDM 2.O COM 7 Figure 1 Multi-control HMI 11

12 Chapter : Overview HMI redundancy: up to 4 RDM 2.0 by GENSYS CORE RDM 2.O COM 7 GENSYS 2.O Core Patch cable Figure 2 HMI redundancy 12

13 Chapter : Overview 1.5 Rear panel - Connectors Overview Figure 3 - Rear panel 13

14 Chapter : Overview Inputs/Outputs Pin nb Description Terminal capacity (mm² / AWG) A1 A2 Crank relay out Output 6 Fuel relay out Output 7 Comment 2.5 / 12 Supplied via emergency stop input at battery positive voltage; can also be used as configurable relay output. 240 V AC, 5 Amps max. Details in / 12 Supplied via emergency stop input at battery positive voltage; can also be used as configurable relay output. 240 V AC, 5 Amps max. Details in A3 Emergency stop 2.5 / 12 To battery positive, normally closed; direct supply to crank and fuel relay outputs. B1 Generator N 2.5 / 12 Not necessarily connected: if not connected, GENSYS 2.0 Core will calculate a virtual neutral voltage. B2 B3 Generator L1 Generator L2 2.5 / / 12 Generator voltage measurement. 100 to 480 VAC line to line. Frequency: 50 or 60 Hz. These lines must be protected externally with 100 ma / B4 Generator L3 2.5 / VAC fuses. B5 B6 Mains L1 Mains L2 2.5 / / 12 Mains voltage measurement. 100 to 480 VAC line to line. Frequency: 50 or 60 Hz. These lines must be protected externally with 100 ma / B7 Mains L3 2.5 / VAC fuses. C1 to C5 Output 1 to / 12 <350 ma. Over current protected. Reactive load. Each output can be configured with a specific function or programmed with an equation, see details in C5 can also be used as a watchdog output (contact CRE Technology for more info). D1 Generator I1-2.5 / 12 Generator current measurement 0 to 5 Amps. D2 Generator I / 12 Maximum rating: 15 Amps during 10s. D3 Generator I2-2.5 / 12 1V AC consumption. D4 Generator I / 12 External current transformer is normally used. D5 Generator I3-2.5 / 12 D6 Generator I / 12 D7 Not connected 2.5 / 12 E1 Mains open breaker 2.5 / 12 Two configurable relays with one in common, one for E2 Mains close breaker 2.5 / 12 closing, and one for opening. 240 V AC, 5 Amps. E3 Mains common 2.5 / 12 Isolated contact. Details in E4 Bus bar open breaker 2.5 / 12 Two configurable relays with one in common, one for E5 Bus bar close breaker 2.5 / 12 E6 Bus bar common 2.5 / 12 F1 Engine meas / 12 (shielded) F2 Engine meas / 12 (shielded) F3 Engine meas / 12 (shielded) F4 Engine meas / 12 closing, and one for opening. 240 V AC, 5 Amps. Isolated contact. Details in to 10 kohms resistive sensors with programmable gain. Details in to 10 kohms resistive sensors with programmable gain. All Details can be found in

15 Chapter : Overview (shielded) F5 Shield 2.5 / 12 Must be used to protect shielded signals. F6 Water temp meas / 12 0 to 400 Ohms resistive sensors. Details in 7.3 (shielded) F7 Water temp meas / 12 (shielded) F8 Oil pressure meas / 12 (shielded) 0 to 400 Ohms resistive sensors. Details can be found in 7.3 F9 Oil pressure meas / 12 (shielded) G1 ±20 ma / 12 (shielded) G2 Shield 2.5 / 12 G3 ±20 ma / 12 (shielded) G4 Parallel / 12 (shielded) G5 Shield 2.5 / 12 G6 Parallel / 12 (shielded) ±10 V (20 kohms input) or ±20 ma (50 Ohms input). Used as Mains power input measurement with single generator. Used as synchronization input from GCR External analogue synchronizer (ex: GCR terminal 42 or Master 2.0 by parallel lines) when several generators parallel with mains. 5V (10KOhms) compatible parallel lines. Load sharing and power set level (kw only). Compatibility with traditional analogue load share lines (often called Parallel Lines). Compatibility with Wheatstone bridge. Only used if GCR or old ILS Isolated. Details in 6.9 G7 G8 Pickup - Pickup / / Hz to 10 khz. Maximum voltage: 40VAC Used for speed regulation, crank drop out and overspeed (see Cautions in 16). If not wired, the speed measurement can be made by the alternator voltage. But Pickup is recommended. Details in speed settings G9 Speed out / 12 G9: ±10 V analogue outputs to speed governor. G10 Shield 2.5 / 12 G11: ±10V reference input from speed governor (ESG) G11 Speed ref 2.5 / 12 Compatibility with most speed governors. Details in H1 Not connected 2.5 / 12 Analogue output ± 5V isolated. H2 AVR out / 12 Automatic voltage regulator (AVR) control. Compatible H3 Shield 2.5 / 12 with most regulators. Details in 6.3 H4 AVR out / 12 J1 Mains breaker in 2.5 / 12 Digital input with 10 kohms pull-up. Dedicated input for mains breaker feedback. Accepts NO or NC contact to 0V. Not isolated. J2 Gen breaker in 2.5 / 12 Digital input with 10 kohms pull-up. Dedicated input for generator breaker feedback. Accepts NO or NC contact to 0V. Not isolated. J3 Remote start/stop 2.5 / 12 Digital input with 10 kohms pull-up. Dedicated input for remote start/stop request in Auto mode. Accepts NO or NC contact to 0V. Not isolated. J4 Oil pressure Spare input 2.5 / 12 Digital input with 10 kohms pull-up. Default factory setting is input for oil pressure fault. 15

16 Chapter : Overview J5 J6 to J15 Water temp Spare input Spare Input 1 to 10 This sensor is needed to start the engine whatever the mode. Accepts NO or NC contact to 0V. Not isolated. Can be programmed as a spare input. Details in / 12 Digital input with 10 kohms pull-up. Default factory setting is input for water temperature fault. Accepts NO or NC contact to 0V. Not isolated. Can be programmed as a spare input. Details in / 12 Digital inputs with 10 kohms pull-up. 10 inputs can be configured with a specific function or programmed with PLC equations. Accepts NO or NC contact to 0V. Not isolated. Details in 7.1 K1 Power Tank 2.5 / 12 Used for 12V power supply backup during crank time. An externally supplied capacitor can be connected externally between ground and this line for better tolerance to power drop. A value of 1µF per 50µS is a good value. Thus, 47,000µF will add a 50ms delay to power down. Can be adjusted. More is better. K2 K3 Power supply + Power supply / / 12 9 to 40 V, 10 Watt consumption (without actuator). Polarity inversion protection. Note: The "Power supply -" must be wired from the speed governor via 4 mm² wires. See "state of the art" rules wiring diagram. External 5 Amp / 40 VDC fuse recommended. K4 PWM output 2.5 / Hz PWM output. Compatible with Caterpillar and Perkins PWM controlled units. 0-5V protected against short-circuits to 0V. Details in L1 Bus/Mains I / 12 Bus/Mains current measurement. L2 Bus/Mains I3-2.5 / 12 1 to 5 Amps. Maximum rating: 15 Amps during 10s. L3 Bus/Mains I / 12 1VA consumption. L4 Bus/Mains I2-2.5 / 12 External current transformer is normally used. L5 Bus/Mains I / 12 L6 Bus/Mains I1-2.5 / 12 COM1 CAN1 inter GENSYS 2.0 Core Male DB9 (shielded) Isolated CAN bus. Proprietary protocol to communicate with other GENSYS 2.0 Core /MASTER 2.0 units and share data/information. Details in 11.2 SHIELD PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 SHIELD NC CAN-L GROUND-1 NC GROUND-2 16

17 Chapter : Overview PIN 6 PIN 7 PIN 8 PIN 9 GROUND-1 CAN-H NC NC Table 1 - COM1 pin out COM2 CAN2 options J1939 CANopen MTU MDEC Male DB9 (shielded) Isolated CAN bus (125 kb/s factory setting). See details in Used to communicate with remote I/O (see remote I/O CANopen chapter ) and J1939 electronic calculator (electronic engines): details in or MTU protocol (electronic MDEC engine): details in SHIELD SHIELD PIN 1 NC PIN 2 CAN-L PIN 3 GROUND-1 PIN 4 NC PIN 5 GROUND-2 PIN 6 GROUND-1 PIN 7 CAN-H PIN 8 NC PIN 9 NC Table 2 - COM2 pin out COM3 USB USB Type B High Quality GENSYS 2.0 Core with firmware v2.00 (or later) : This port is replaced by Ethernet communication. GENSYS 2.0 Core with firmware v1.xx : 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. Isolated. Details in 11.4 COM4 Ethernet RJ45 CAT5 Standard RJ45 ETHERNET connector. Isolated. Uses TCP/IP protocol to communicate with external world. Details in 11.5 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 Tx pair Tx pair Rx pair NC NC Rx pair 17

18 Chapter : Overview PIN 7 PIN 8 NC NC Table 3 - COM4 pin out COM5 RS485 MODBUS RTU Male DB9 (shielded) 4800, 9600 or bps. Used to communicate with SCADA. MODBUS RTU slave. Read (04 and 03) and write (06 and 16) functions, 2 wires. Isolated. Detail in SHIELD SHIELD PIN 1 NC PIN 2 NC PIN 3 GROUND PIN 4 GROUND PIN 5 B PIN 6 A PIN 7 NC PIN 8 NC PIN 9 GROUND Table 4 - COM5 pin out COM6 Memory slot SD Memory slot used for extensions. Details in 11.7 Table 5 - Inputs/Outputs description Save parameters configuration All GENSYS 2.0 Core parameters used in configuration are stored in a FLASH memory. When a parameter is 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 the GENSYS 2.0 Core power supply is cut or too low. To save the new parameters to the FLASH memory, you must use SHIFT-I : the user must press both [SHIFT] + [i] keys together. This will start the backup sequence and store all parameters in the FLASH memory. Now, the new parameters will be effective even after a power supply failure. During this sequence (a few seconds) an orange led on the upper right of the unit will light up to indicate that information is being stored. 18

19 Chapter : Overview NOTE: Due to the large number of parameters, the back-up procedure may take a few seconds. It is thus essential to save parameters when the motor is stopped. To save all parameters, the user must press on both [SHIFT] + [i] keys at the same time on the GENSYS 2.0 Core front panel. Otherwise, the new parameters will be lost when shutting down the GENSYS 2.0 Core. NEVER SHUT DOWN DURING STORAGE SEQUENCE (ORANGE LED ILLUMINATED). 1.6 Remote control using a PC (Ethernet connection) Setting up the Ethernet connection With Windows XP: Open the control panel. Click on network connections. Click on local network. Click on «Settings». 19

20 Chapter : Overview Select «Ethernet (TCP/IP)». Properties. Enter the addresses as shown above. Note: IP address shown above can be used if GENSYS 2.0 Core IP address is (factory setting). Otherwise, computer and GENSYS 2.0 Core IP addresses should match the same subnet mask as shown below. Example: Subnet mask: Computer IP address: AAA.BBB.CCC.XXX GENSYS 2.0 Core 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 Core: gensys #generic IP address and hostname (factory settings). #Example of 4 GENSYS 2.0 connected to an intranet: genset1 #place optional comments here genset2 #800kVA engine genset3 #450kVA engine genset4 #320kVA engine 20

21 Chapter : Overview 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 start, click on All Programs, Accessories, right click on notepad, and then Run as administrator. If you are prompted for an administrator password or for a confirmation, type the password, or click Allow. 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 Core, you should also adapt Windows hosts file to be able to use the hostname ( 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 Core you want to connect to in your Web browser. -If your computer is connected to your company intranet and you cannot or don 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 Core communication. Reference of this module is A53W Changing GENSYS 2.0 Core IP address GENSYS 2.0 Core IP address can be changed in configuration page: System/Serial ports configuration /Com3/Com4. Once the new IP address is entered, save the new settings by pressing key Shift I on the front panel. Then you will need to restart your GENSYS 2.0 Core for the new settings to take effect. 21

22 Chapter : Overview Viewing web pages with the GENSYS 2.0 Core server Connect GENSYS 2.0 Core to your computer using an Ethernet cross over cable. Start your Web browser (Ex: Firefox or Internet Explorer). Type in the GENSYS 2.0 Core URL or IP address (factory settings or ) according to your GENSYS 2.0 Core and Windows hosts file settings. The password page of the GENSYS 2.0 Core should appear. Enter your password. You can now access the GENSYS 2.0 Core menus. Note: Parameter E4042 allows the user to set the connection time in minutes. Once this time is elapsed without Web communication, the password will be asked for again. GENSYS 2.0 Core 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. However, it is recommended that you disconnect the PC from the unit while the engine is running. Before connecting GENSYS 2.0 Core to your PC, your PC must be configured as described in the previous chapter. Next figure shows a typical GENSYS 2.0 Core menu as seen when accessed from a PC Web browser. Figure 4 Typical menu 22

23 Chapter : Overview In this page, the user can choose from among 6 submenus (Genset electrical meters for example). It is also possible to scroll through the other pages of the menu with the << and >> links. The ESC link acts in the same way as the GENSYS 2.0 Core ESC key: it will display the parent menu. The last 3 links are identical to the Fault / Alarm / Information keys on the GENSYS 2.0 Core front panel. The next figure shows a typical configuration page. The user can change 5 different parameters (in this case, two numerical values and three option lists) and send them to the GENSYS 2.0 Core using the [Save] button. Clicking on the [Save] button changes the parameter immediately. The modified parameter is held in volatile memory, and will be lost on power down unless the backup parameter is used, [SHIFT] + [i]. If backup is used, the parameter is written in flash memory and will be used for the start up. Figure 5 Typical configuration page Downloading a text file When you are connected with a computer, a text file can be transferred between the GENSYS 2.0 Core and the PC. This allows the following actions: Upload new parameters to the GENSYS 2.0 Core. Upload new equations to the GENSYS 2.0 Core. Download parameters from the GENSYS 2.0 Core (safeguard). Download equations from the GENSYS 2.0 Core (safeguard). The data that can be transferred depends on your access level. For more information concerning text files please refer to chapter

24 Chapter : Operating modes 2 Operating modes With the GENSYS 2.0 Core unit, three main operating modes and one special mode allow you to control your generator. Modes are: Manual Automatic Test Mode The special mode is: Semi-automatic. This mode must be enabled when parameter E1614 =1 is enabled. 2.1 Manual mode In manual mode, it is possible to control the generator with the front panel of the GENSYS 2.0 Core. 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. On the front panel, the 2 LEDs above the generator should light up. The left hand LED indicates that a speed greater than zero is measured, whereas the right hand LED indicates that a voltage other than zero is measured. If a speed governor is connected to GENSYS 2.0 Core, 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 Core, 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. Important: 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 the corresponding Led on the front panel should light up. As soon as the generator breaker is closed, the GENSYS 2.0 Core is switched to DROOP MODE for speed and voltage, i.e. the speed and the voltage will decrease when the load increases. This mode can be fully customized (droop % in speed settings/voltage settings) through the menu. Load sharing is controlled with the [+] and [-] keys in droop mode. To stop engine push the [Stop] key. 2.2 Auto 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: One generator with Change Over (see 4.1) 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 24

25 Chapter : Operating modes 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. One generator paralleling with the mains (see 4.2 to 4.6 & option 2 see 17.1): The generator starts with a remote start or if there is a mains failure. Paralleling depends on configuration: NO CHANGE OVER 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. Power plant with several generators without automatic load/unload (see 4): The generator starts with a remote start signal, and parallels with the bus. If there is a dead bus, GENSYS 2.0 Core will check with the other GENSYS 2.0 Core 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 CAN bus ( 11.2) or via the parallel lines ( 4.4). The generators stop with a remote stop signal. Power plant with several generators with automatic load/unload (see 4): The communication between GENSYS 2.0 Core units is via the inter GENSYS CAN bus ( 11.2 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). 2.3 Test mode This mode tests the Auto mode. When you press the [Test] key, the engine starts as if there was a remote start, and GENSYS 2.0 Core will carry out the standard Auto mode sequence. To exit TEST MODE, push the [AUTO] key. 2.4 Semi auto mode Start Synchro Close breaker load Waiting Generator ready Generator on Bus bar Stop Unload Open breaker 25

26 Chapter : Start sequence 3 Start sequence During the start sequence protections are inhibited. This concerns all engine protections. When the engine reaches the required state (E2057 = 6, see next figure) the protections are activated. A timer can be added to inhibit protections during the "safety on" delay (E1514). The timer will start when E2057=6. Figure 6 - Typical start sequence for fuel engines 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 & E1154) for the engine to be allowed to start (E2057 switches to 12). 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 and oil pressure variables (E0030 & E0029) 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. 26

27 Chapter : Predefined configurations 4 Predefined configurations 4.1 Single generator in change-over mode Figure 7 - Power plant in change-over mode without paralleling Variable number Variable label Variable value 1179 Gen. number Nb. of gen Nb. of Master Mains parallel Change-over 1153 Mains regul. X 1158 ILS compatible No 1177 Synchro mode Dynamic 1515 Deadbus manag. X 1258 Load/Unl. mode Inhibited 1846 Break Ma Fault Mains 1841 Fault start Yes Table 6 - Typical basic change over configuration In Change over mode, as shown in table 3, 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". If remote start is on when mains are present the generator starts, GENSYS 2.0 Core opens the mains breaker, then closes the generator breaker and takes the load. 27

28 Chapter : Predefined configurations E0022 Mains voltage 400 V E2201 Mains electrical fault triggered by a protection or digital input set as "Mains electrical fault" Fastest mains electrical fault E2002 Remote start on terminal J3 E1085 Mains back timer E0003 Genset voltage Genset ready 400 V E2001 Generator CB Switc hov er delay E1459 E1142 Cool down E1459 Switc hov er delay E1142 Cool down E2000 Mains CB E1459 Swithover delay E1459 Swithov er delay Second black First black Sec ond blac k First black There are 2 blacks There are 2 blacks START FOR EMERGENCY will only start if a mains protection or a digital input is programmed as "Mains electrical Fault ". START FOR TEST or switch load from mains to genset Figure 8 - Typical sequence in change over mode 4.2 Single generator in no-change-over mode GENSYS 2.0 Core Mains Utility Figure 9 - Power plant in change over without paralleling Variable number Variable label Variable value 1179 Gen. number Nb of gen Nb of Master Mains parallel NoChangeOver 1153 Mains regul X 1158 ILS compatible No 1177 Synchro mode Dynamic 1515 Deadbus manag. X 28

29 Chapter : Predefined configurations 1258 Load/Unl. mode Inhibited 1846 Break Ma Fault Mains 1841 Fault start Yes Table 7- Typical no change over basic configuration In "No change over" mode (1148) GENSYS 2.0 Core only starts on receiving a remote start signal and doesn't manage the mains breaker. 4.3 Generators paralleling with digital bus Figure 10 - Power plant with several generators Variable Variable label Variable value number 1179 Gen. number 1 to 14 : this value must be different for each device on the same bus 1147 Nb of gen. 2 N Nb of Master Mains parallel No ch.over 1153 Mains regul X 1158 ILS compatible No 1177 Synchro mode Dynamic 1515 Deadbus Yes manag Load/Unl. mode X 1020 MA kw <-> 0 20mA 1021 MA 0kW setting 0 Table 8 - 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. 29

30 Chapter : Predefined configurations 4.4 Generators paralleling with GENSYS 2.0 Core and parallel line modules Figure 11 - Generator paralleling with parallel lines Variable Variable label Variable value number 1179 Gen. number 1 to 14 : this value must be different for each device on the same bus 1147 Nb of gen. 2 N Nb of Master Mains parallel No ch.over 1153 Mains regul X 1158 ILS compatible Yes 1177 Synchro mode Dynamic 1515 Deadbus manag. No 1258 Load/Unl. mode Inhibited Table 9 - Typical basic configuration for GENSYS 2.0 Core with parallel line modules When GENSYS 2.0 Core is in ILS compatible 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 compatible with CAN inter GENSYS 2.0), with ILS analogue parallel lines. 4.5 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 magnetisation 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. 30

31 Chapter : Predefined configurations Figure 12 - Static paralleling with 4 generators coupled together in emergency situation Sequence: Speed Voltage 1500tr/min 400V 80V Time 9s Figure 13 - Example with 4 generators coupled together in emergency situation. Loss of voltage Each GENSYS 2.0 Core is ordered to start. All breakers (CB1, CB2, CB3 & CB4) close as ordered by GENSYS 2.0. DG1, DG2, DG 3, & DG4 start. All generators reach the speed defined by the E1896 setting (CANBUS synchronization). There is a residual voltage of 80V. All C1outputs close simultaneously to activate excitation (after dialogue between GENSYS 2.0 units). Alternator voltages increase gradually at the same time. The plant is available to take up required load. Breakers are closed when engine is stopped. There is a residual voltage of 80V. 31

32 Chapter : Predefined configurations Advantages Full plant availability in less than 10 seconds. Gradual magnetization of the step-up transformer (no transient short-circuit) Configuration One GENSYS 2.0 Core per genset. CAN bus must be connected between GENSYS 2.0 Core units. An "Excitation" output (e.g. exit C1) must be configured on each GENSYS 2.0 Core 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 Core must be equipped with a speed sensor (magnetic sensor / Pick-up). 4.6 Single generator paralleled with mains This function needs OPTION 2 to be installed Configuration: Figure 14 - Paralleling with mains 32

33 First Black Synchro back Short transfert from G E to Mains Sync hro Short transfert from mains to G E Synchro back Short transfert from G E to mains G E ready G E ready Chapter : Predefined configurations In permanent mode (1148) and peak shaving mode (1153), a mains power measurement is required. Internal via L1-L6 inputs (Mains I1, I2, I3), or external via G1-G3 inputs (0-20 ma). Variable number Variable label Variable value 1179 Gen. number Nb of gen Mains parallel NoBreak CO / Permanent 1153 Mains regul Base load / Peak shav ILS compatible No 1177 Synchro mode Dynamic 1515 Deadbus manag. X 1258 Load/Unl. mode Inhibited Table 10 - 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 and takes the entire load upon mains loss even if the remote start 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 Mains paralleling mode: Choice of mains paralleling mode is configured through parameter E / 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 Core opens the mains breaker. When remote start is off, the main 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 Core synchronizes the load transfer (ramps down), opens the breaker and then stops the generator. E0022 Mains voltage 400 V Triggered by fastest "Mains E2201 Mains electrical fault electrical fault" E2002 Remote start on terminal J3 E0003 Genset voltage 400 V E2001 Generator CB E1142 Cool down E1142 Cool down E1152 E1151 E1152 E2000 Mains CB E1459 Swithover delay E1085 Mains back timer Unload ramp Load ramp Unload ramp There is only 1 black START FOR EMERGENCY will only start if a mains protection or a digital input is programmed as "Mains electrical Fault ". No black START FOR TEST or to transfert load from mains to GE. Figure 15 - Typical sequence in No Break CO mode 33

34 Chapter : Predefined configurations First Black Synchro back Transfert load from GE to Mains Sy nc hro Load ramp Bas e load or peak shaving (CHP for ex ample) Unload ramp GE ready GE ready Ramp configurations are available in the Configuration / active Power regulation menu. The paralleling time depends on the load, the ramp time and the high and low thresholds. 2/ Permanent mode When the remote start is on, GENSYS 2.0 Core starts the generator, synchronizes and parallels with the mains, then ramps up load until it reaches its set point. In base load mode (E1153), 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), the mains have a constant load and the generator takes the utility load variations. E0022 Mains voltage 400 V E2201 Mains electrical fault Triggered by fastest "Mains electrical fault" E2002 Remote start on terminal J3 E0003 Genset voltage Cool down 400 V E2001 Generator CB E1142 Cool down E1152 Unload ram p E2000 Mains CB E1459 Swithover delay E1085 Mains back timer E1152 Unload ram p E1151 Load ramp There is only one black START FOR EMERGENCY will only start if a mains protection or a digital input is programmed as "Mains electrical Fault ". No black. Mains CB is always closed START FOR PRODUCTION / base load or peak shaving Figure 16 - Typical sequence in permanent mode 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 alldigital 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. Variable number Variable label Variable value 1179 Gen. number 1 to 14 : this value must be different for each device on the same bus (*) 1147 Nb of gen. 2 N 14 (*) 1148 Mains parallel No ch.over 1153 Mains regul X 34

35 Chapter : Predefined configurations 1158 ILS compatible Yes 1177 Synchro mode Dynamic 1515 Deadbus manag. Yes 1258 Load/Unl. mode X 1020 MA kw <-> 20mA MA 0kW setting Ext kw measure +/- 10V Table 11 - Paralleling with mains configuration (*) In this instance, 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 13 generators. To allow Power Factor regulation, the "Mains breaker in" (J1) input to GENSYS Core must be connected. Power Factor regulation is not an option Interfacing GENSYS 2.0 Core with GCR Figure 17 - GCR GENSYS 2.0 Core wiring diagram GCR (39-40) GENSYS 2.0 Core (G4-G6): parallel lines (0-3V) to control active power. GCR (42-43) GENSYS 2.0 Core (G1-G3): mains synchronization bus (+/- 3V). GENSYS 2.0 Core (K3): -VBat from speed governor. Variable number Variable label Variable value 1464 Mains kw Meas. External 1461 Ext kw measure +/- 10V 1020 MA kw <-> 20mA MA 0kW setting 0 Table 12 - GENSYS 2.0 Core /GCR configuration 35

36 Chapter : Predefined configurations 4.7 Power plant paralleled with mains using MASTER 2.0 or GCR Analog load sharing lines Synchronization bus GENSYS Core#1 GENSYS Core#2 GENSYS Core #n GCR PLC Réseau Mains kw CPA2 Load Figure 18 - Power plant paralleling with mains 4.8 Power plant paralleled with several mains using MASTER 2.0 or GCR Figure 19 - Power plant paralleling with several mains 36

37 Chapter : Predefined configurations 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 documentation. Variable number Variable label Variable value 1179 Gen. number 1 to n 1147 Nb of gen. n (>=2) 4006 Nb of Masters 1 to n 1148 Mains parallel No ch.over 1153 Mains regul. X 1158 ILS compatible Yes 1177 Synchro mode Dynamic 1515 Deadbus manag. Yes 1258 Load/Unl. mode X Table 13 - Power plant paralleling with several mains configuration 37

38 Chapter : Installing and commissioning a GENSYS 2.0 Core application 5 Installing and commissioning a GENSYS 2.0 Core application 5.1 Minimum wiring diagram 38

39 Chapter : Installing and commissioning a GENSYS 2.0 Core application 5.2 Complete wiring diagram 39

40 Chapter : Installing and commissioning a GENSYS 2.0 Core application 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 Core units are used, each of the 0V power supplies (pin K3) must be connected to each other with a 4mm² cable (use an adapter for the 2.5mm² connection to the GENSYS 2.0 Core power connector itself). 1/ Power supply circuit breaker Terminal K3 (0V) should never 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 +). Note: If the K3 (0V) terminal is disconnected and the bus bar voltage is applied to the GENSYS 2.0 Core, there is the risk of getting AC voltage on the CANBUS terminals. 2/ Interconnection of all battery negatives Figure 20 - Interconnection of all battery negatives 3/ Rental fleet & Marine & HV generating sets CAN Bus isolators are fitted inside the GENSYS 2.0 Core unit so it is possible to use it safely in MARINE applications and on rental fleets Vibrations: In case of excessive vibrations, the module must be mounted on suitable anti-vibration mountings Real time clock battery: If the battery is disconnected, remove the rear panel and connect a 3V battery to the ST1 jumper (+battery: ST1 up; -battery: ST1 down). Battery maintenance must be provided separately from the GENSYS 2.0 Core unit. 40

41 Chapter : Installing and commissioning a GENSYS 2.0 Core application 5.3 Before commissioning (before going on site) Schematics check How? Be sure you have the latest power plant schematics. Why? To be sure the wires will be present on site (Can bus connector, shielded wires...). What? 0 Volt wiring Shields Speed governor / GENSYS 2.0 Core Interface Automatic Voltage Regulator / GENSYS 2.0 Core Interface (droop current transformer must be removed) CAN Bus MASTER 2.0 GCR Check the list of inputs /outputs How? Check if the required function is present in the list of preset functions. If in any doubt check with distributor. Why? To evaluate if an input/output needs an extra equation. To evaluate quote / development time. To evaluate necessary password clearance: Level 1 (consumer), Level 2 (Distributor), or Level 3 (CRE Technology only). 5.4 During commissioning Start with safe conditions How? Why? Disconnect the GENSYS 2.0 Core connector labelled as E (controls breakers). Disconnect the wires between GENSYS 2.0 and the speed governor (G9 / G11). Disconnect the wires between GENSYS 2.0 and the AVR (H2 / H4). Check important GENSYS 2.0 Core parameters (See chapter 4.2). Ask the technician who wired the power plant to lock the generator breaker open. So as to be sure not to cause a false paralleling during commissioning. Download the text file from the GENSYS 2.0 Core. How? With a PC and Internet explorer. 41

42 Chapter : Installing and commissioning a GENSYS 2.0 Core application Why? To store all parameters before starting the commissioning. How? As described in 11 Always use a text file corresponding to the current firmware version. Never use an old text file coming from a previous version. Check speed detection. How? Why? Press on the [MANU] key. Lock the fuel closed. Access the information menu. Press and hold the start button for 5 sec. While the starter turns over, check that GENSYS 2.0 Core RPM is close to 200RPM. To be sure that the GENSYS 2.0 Core will release the starter motor at the correct speed (around 400RPM). To have over speed protection. Start the generator, check speed detection. How? Set the speed governor potentiometer to its minimal value. In [Manu] mode, press and hold [Start] button for 10s. Adjust the speed to 1500 RPM (using speed governor potentiometer). This is given as example. May be set at 1800 RPM for 60Hz applications, or other values depending on the installation. In the information menu check that Frequency= when RPM=1500RPM. You may have to adjust the number of teeth on the gear where the measure is taken (for example). Press [Stop] to stop the generator. Check the 5 minimum protections before carrying out any other tests: Over speed Over voltage Emergency stop Oil Pressure Water temp How? Short-circuit the sensors. For over speed and over voltage, set the thresholds to 101%. Check the control of the dead bus breaker 42

43 Chapter : Installing and commissioning a GENSYS 2.0 Core application How? Be sure there is no critical load connected to bus bar Plug the E connector into GENSYS 2.0 Core Start the engine in manual mode by pressing [Manu] [Start] Press the generator breaker [0/I] key. Check the breaker settings ( 6.4.1) 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/I] Key. The breaker should open and the led should go out. Check mains / bus ref L1, L2 & L3 How? In [Manual] mode, press and hold [Start] button for 10s. Close the generator breaker by pushing the [0/I] Key. Enter Synchronization menu to check that phase difference is 0. Check synchronization How? Unplug connector E Check Voltage on bus bar Set the parameter Fail to synchronize at 500s. [Start] the generator in [Auto] mode. Check that you are now in synchronization mode using the information screen key [i]. Adjust the phase and frequency PID. Frequency sweep is important over the 49-51Hz range. PID phase is important around the synchronization point. When the difference between phases is stable and near to 0, measure the voltages (L1 L2 and L3) directly on the circuit breaker between generator and bus bar. When you are sure there is no wiring problem, stop the generator. Set the Fail to synchronize parameter according to the consumer's request. Connect the E connector. Start in automatic mode. The generator must be paralleled in less than 10s. 43

44 Chapter : Installing and commissioning a GENSYS 2.0 Core application Synchronization test Go to [Manu] mode. Use the [+] key to increase frequency to 51Hz. Go back to [Auto] mode. Check that the correction is OK on the synchroscope. Load sharing / kw regulation For this application, check the stability of KW and kvar regulation. After the mains breaker closes, check load ramp (P=CsteGPID) 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 Core 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). 44

45 Chapter : Dedicated I/O lines 6 Dedicated I/O lines Inputs/outputs are associated with functions. Some I/Os are dedicated; others are programmable using configuration parameters. 6.1 Speed governor interface This interface is used to control engine speed. The Speed governor control is used to manage Speed set points, Synchronisation, KW Load sharing and KW set points. The Speed governor interface can be: Analogue output PWM 500Hz digital output (CATERPILLAR/PERKINS) Digital pulse output (see 6.2) Analogue speed governor output The following procedure must be used to match the interface with the speed governor: Connect the ref. wire only. Set the recommended gain and offset (if not in the list, contact CRE Technology). Start the generator at 1500 RPM (MANU mode). Measure the voltage between Ref. and the remote voltage input on the speed governor side. Adjust GENSYS 2.0 Core output voltage (G11 G9) using the offset. Connect the control wire. Check the maximum speed range in manual mode with the + and - buttons. The range must be within +/- 3Hz. Deviation ESG amplitude (1076) ESG offset (1077) + G9 Speed out + G11 Speed ref Figure 21 - Speed output The ESG offset adjustment (E1077) can be set between -100 and +100 (-10VDC to + 10VDC), and is added to the external speed reference (G11). The Speed ref (G11) doesn't need to be connected if there is no voltage reference available. 45

46 Chapter : Dedicated I/O lines 0V must be wired with 4 mm² cable as follows: battery speed governor GENSYS 2.0 Core. See table below for presets. For specific settings contact your dealer. Manufacturer Model ESG Amplitude (1076) ESG offset (1077) HEINZMANN E6 10% 0% B3 KG6 / System E6 Terminal G9 (out) % 46.50% E3 NC Terminal G11 (ref) Remark CUMMINS BARBER COLMAN WOODWARD PANDAROS DC6 ECM pour QSK23 / QSK40 / QSK45 / QSX15 / QSK 60 24% 26% B3 A3 1.00% 00.00% 10 (Barber Colman Frequency bias input) 06 (5Volts) Voltage converter to isolate the signal on the line. (DC/DC) (advise) EFC 2% 0% 8 9 Cf. Fig 34 ECM (QST30) 1.00% -3.00% 18 15(7,75v) All models 5% -1.65% ILS input 4v with analog input DPG % -1.05% ILS signal 2,5V A/D ILS+speed 1.6% -27% ILS signal Digital supply (+5V) 1.6% 25% ILS signal BAT % 90.00% 25.00% 0% Shunt Shunt 26 (com) on 0V - (Without U&I) 2301D 25.00% 00.00% G11 connected to 0v 2301A Speed only Pro-act / Pro-act II EPG System ( P/N : / 99.00% -1.00% connected to 0V 25.00% 00.00% Aux + Aux - Auxconnected to 0V 25.00% 30.00% 11 NC open 46

47 Chapter : Dedicated I/O lines ) MTU MDEC 25.00% (5v) Programmable 20.00% VOLVO EDC % % 24 / conn. F 25 / conn. F EDC III 20.00% 25,00% Pot signal NC PERKINS ECM 25.00% % Deutz EMR 8.00% to % 26.20% TEM compact 30 3 (5v) /- 1.5 Hz not to reach EMR over-speed See application note A40Z GAC All ESD -20% -63.8% N P Ghana PWC % -25% J G Control SCANIA 16 ltr full 20% -36% electronic engine CATERPILLAR EMCPII interface 5% % 2 1-2Hz and +0,8Hz (although the GENSYS 2.0 output still increase) JOHN DEERE LEVEL III ECU 38% 34% 23.80% -15% G2(speed input line) 915 G2 D2(sensor return)914 5V(ref speed) 999 Two different wirings for the same governor. Table 14 - Speed governor parameters Connecting GENSYS 2.0 Core to a Cummins EFC: Because of the very high sensitivity of Cummins EFC module input, please use the schematic below to connect your GENSYS 2.0 Core to the EFC. This way, GENSYS 2.0 Core analogue speed output can be set higher (parameter E1076) according to the resistors used. 47

48 Chapter : Dedicated I/O lines Speed governor EFC Cummins speed input k 1.5k speed ref speed out G9 (Speed Out) G11 (Speed Ref) 2 ( battery - ) K3 (0v) Gensys2.0 Figure 22 Connexion avec un EFC Cummins PWM 500Hz (CATERPILLAR/PERKINS) K4 output is a 500Hz PWM output signal between 0 and 5V. 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 Core parameters as shown below. Variable Label Value Description number E Hz ACT 1 Activates the speed control with 500Hz PWM. In this mode the analogue speed output (G9 / G11) is unavailable. E1077 ESG offset 70% Is the PWM duty cycle set for nominal frequency. E1076 ESG amplitude 30% Is the range of the PWM duty cycle to control engine speed. For example, if you have set 20.0%, the PWM will vary +/- 10% around the nominal duty cycle value. Table 15 - PWM parameters Offset = 70% Amplitude = 30% PWM (%) Min correction 0 55 Figure 23 - PWM dynamic Max correction Deviation (E2058) 48

49 Chapter : Dedicated I/O lines Raise Hz Lower Hz Raise Volt Lower Volt Figure 24 Caterpillar PEEC and ADEM connections 6.2 Speed and voltage control with Contacts / Pulses GENSYS 2.0 Core K1 K2 K3 K4 C1 C2 C3 C4 K1 K2 K3 K4 Figure 25 - Speed and voltage control with Contacts / Pulses Parameters Parameter Value Description Menu E1260 +f [E2341] Output C1 Configuration/Transistor digital outputs E1261 -f [E2342] Output C2 Configuration/Transistor digital outputs E1262 +U [2343] Output C3 Configuration/Transistor digital outputs E1263 -U [2344] Output C4 Configuration/Transistor digital outputs Calibration procedure Here follows the procedure for calibrating the +Hz and Hz outputs on the GENSYS 2.0 Core, necessary in order to have good frequency droop compensation and load sharing. Show the following parameter on the information screen: E2058. Place the external speed potentiometer in the centre mid position. 49

50 Chapter : Dedicated I/O lines Set the following parameters as follows: -E1598 on 50 which is about 1 percent load sharing difference (dead band on E2058) -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 0 which is Integral gain (I) phase -E1113 on 0 which is Integral gain (I) Frequency. Note: For best results in sync it's important to set the GPID synch to high values (80 to 20). Start the engine using the GENSYS 2.0 Core in manual mode. Engine should run near its nominal speed with deviation caused by mechanical droop. Put engine in Automatic mode. If a difference in speed is measured, GENSYS 2.0 Core should vary the output until the engine is running at nominal speed. Set frequency compensation for a recovery time of 10 sec for 0.5 Hz compensation (E1874). If the generator is varying its speed but over or undershoots the nominal speed, the length of the E1873 pulse is too long. Make it a little bit shorter. If it takes too long for the generator to reach nominal speed the E1874 period is too long. Make it a little bit shorter. If you are not able to get the right compensation then the following needs to be checked: Does the potentiometer still turn if the GENSYS 2.0 Core is sending an output signal? If not, the potentiometer is not able to control a sufficient speed range. If every pulse causes overshooting it can be caused by the potentiometer motor running on, even when the pulse is off. A shunt resistor over the motor input may solve this problem. With GENSYS 2.0 Core in automatic mode, load the generator in island mode operation (if possible using full load). Check that it still compensates the frequency according to specification: 0,5Hz in 10 sec (In this case also refer to item 10, note two). If this is OK the Frequency compensation is set. Switch on one engine in auto mode and load it to 100%. Disconnect the output to close the generator breaker of the next engine. Start the next engine in auto mode and wait until the information screen shows that it is synchronizing, then simulate the breaker being closed on the Generator auxiliary input. The information screen should show that it is in Load sharing mode. Check the value of E2058, which should read as follows: Around 6000 for the engine which is supplying the load. Around for the engine which is not supplying the load. If lower than or higher than 6000 is shown, you have to increase the Load sharing Gain. If higher than or lower than 6000 is shown, you have to decrease the Load sharing Gain. 50

51 Chapter : Dedicated I/O lines If you are still not able to reach these settings you can do the following: Reduce the load sharing 3 times. Set parameter E1473 to 1 instead of 3, which makes the Load sharing Gain 3 times stronger. Re-check the value of E2058. The same procedure has to be followed to calibrate the voltage control. 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) = E1598 = Maxi( Hz) = E2342 = pulse -Hz GENSYS 2.0 wants the genset E1600 Load sharing / Synchro pulses only GENSYS 2.0 wants the genset E2341 T=700/E2058 seconds Frequency Hz=E0020 DEADBAND=0. Frequency centre pulses only GENSYS 2.0 wants the genset E2342 = pulse -Hz GENSYS 2.0 wants the genset to go faster E1873 E2341 E1873 E1874 E2342 = pulse -Hz E1874 Summation of both signals E1873 E2341 E1873 E1874 Figure 26 Speed and voltage control pulses 51

52 Chapter : Dedicated I/O lines 6.3 Analogue AVR (Auto Voltage Regulator) control AVR output can be an analogue output, or a digital pulse output. Analogue output is detailed here, digital pulse output is detailed in 6.2 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: Start engine (MANU Mode), then set gain E1103:= 0 and Offset E1104:=0 on GENSYS2.0. Set the AVR system to 400 VAC using its potentiometer. If you can adjust to 400VAC on the AVR go to chapter 5 If you cannot adjust to 400 VAC on the AVR go to chapter 6 Gain and Offset adjustment: Enter maximum correction (E2038 = ) with Shift and + buttons. From the following table, choose the best values for Gain and offset to obtain 430VAC ±5V: GAIN OFFSET If necessary, modify Gain and then Offset to obtain 430VAC ±5. Enter minimum correction (E2038 = ) with Shift and - buttons, then check that you have 370VAC ±5 Set to no correction (E2038 = 0) and check that you have 400VAC. Gain and Offset adjustment if you cannot obtain 400V 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 (1103) H2 AVR out + 47R AVR offset (1104) H4 AVR out - Figure 27 - Voltage output 52

53 Chapter : Dedicated I/O lines See table below for preset settings. For specific setting contact your dealer. Manufacturer Model AVR gain (1103) AVR offset (1104) Termina l H2 Termina l H4 Remark STAMFORD MX A2 (+) A1 (-) Trim pot of AVR fully CW SX A2 (+) A1 (-) Trim pot of AVR fully CW BASLER AEC Remove the shunt AVC63-4 AVC63-4A APR63-5 APR125-5 SSR63-12 DECS32-15-xxx Use VAR control included in the DECS. DECS63-15-xxx DECS xxx DECS300 VR VAR+ VAR- Remove the shunt MARATHON ELECTRIC DVR Aux input A Aux input B DVR Replace with SE350 or DVR2000E AVK Cosimat Pot + Pot - N+ MA A2(+) A1(-) MarelliMotori M8B P Q Remove the shunt PQ M8B nF capacitor between 8 and M. Don t connect shield. M405A nF capacitor between 6 and M. Don t connect shield. KATO K65-12B K125-10B Or 4 3 Or 7 Jumpers have to be removed. Available soon MECC ALTE SPA UVR Pot + Pot - 50kOhms in serial with H2 LEROY SOMER R Pot Pot Remove the shunt input + input - R Pot input + Pot input - Remove the shunt CATERPILLAR R Pot input +(6) Pot input (7) R Pot Pot input + input - DVR KVAR/PF Remove the shunt. Pot ineffective Remove the shunt VR kOhms in serial with H2 CDVR P12.6 P12.3 Table 16 - AVR parameters 53

54 Chapter : Dedicated I/O lines 6.4 Relay outputs Breakers GENSYS 2.0 Core 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). These outputs allow you to control various types of breaker. This chapter explains the available setups and their associated variables. Variables E2000 Digital input for GENSET breaker return E2001 Digital input for Mains breaker return E2016 Genset breaker control E2017 Mains breaker control E1149 Delay before breaker opening/closure failure E1992 Choice of Genset (Genset) breaker relay work mode E1993 Choice of Mains (Mains) breaker relay work mode E1994 Time before undervoltage trip coil control contact closure E1995 Time before a new closure request is authorized E1893 Trip coil min. pulse length. Note: Breaker control can be viewed by showing variables E2016/2017 (Mains/Genset relay) and E2000/2001 (breaker status info). Whatever the setup chosen, any opening or closure of the relays by the GENSYS 2.0 Core is shown by the values of E2016 and E2017 changing (1=closure, 2=opening). When the breaker gives the correct feedback, the GENSYS 2.0 Core LED display lights up and variables E2000 (Mains) or E2001 (Genset) switch to 1. The delay for a breaker to close before a failure is detected is set to 5 seconds as standard (Configuration/Enhanced configuration/modification by variable n /1149). 54

55 Chapter : Dedicated I/O lines Working modes: The Configuration/Enhanced configuration/ gen/mains breaker setup menu allows you to chose the working mode of these relays via the variables E1992 for the mains and E1993 for the generating set. Table below explains the different functioning modes featured by GENSYS 2.0 Core. E1992 (Mains) Relay output mode /E1993 (Genset) 0 Continuous contact to open E1 (Mains) / E4 (Genset) Chronogram Positive pulse to close E2 (Mains) / E5 (Genset) 1 (default setting) (Contactor) Continuous contact to open E1 (Mains) / E4 (Genset) CLOSED OPEN Continuous contact to close E2 (Mains) / E5 (Genset) CLOSED OPEN 2 Undervoltage coil opening E1 (Mains) / E4 (Genset) Pulse to close E2 (Mains) / E5 (Genset) 3 Undervoltage coil opening E1 (Mains) / E4 (Genset) CLOSED OPEN Continuous contact to close E2 (Mains) / E5 (Genset) 4 (Breakers without undervoltage coils) Pulse to open E1 (Mains) / E4 (Genset) Pulse to close E2 (Mains) / E5 (Genset) CLOSED OPEN 5 Pulse to open E1 (Mains) / E4 (Genset) CLOSED OPEN Continuous contact to close E2 (Mains) / E5 (Genset) Table 17 - Breaker control configuration CLOSED OPEN 55

56 Chapter : Dedicated I/O lines 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/Enhanced configuration/ Modification by variable n menu. Bobine à Manque E1994 Output Close Breaker Feedback E1995 Close Open Close WARNING: Never switch from one mode to another when the plant is in use. An unwanted breaker state modification may occur. 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) Fuel & Crank The standard functions for these two relay outputs are for normal Fuel and Crank relay applications. Access to settings in the GENSYS2.0 Core menu: /Configuration/Enhanced configuration/digital transistor output/ >> / >> / unused Crank is A1 (OUTPUT 6), and Fuel is A2 (OUTPUT 7). These two outputs are relays and are fully configurable through the Enhanced configuration / Digital transistors output/ >> / >> menu or through equations. 6.5 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 behaviour 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). 56

57 Chapter : Dedicated I/O lines For multiple starters (E1138 = 2 or 3), the outputs can be configured with the Starter 2 (E2267) and 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) Note: 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 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...). Configuration/Enhanced configuration/ start:stop sequence / >>: Cra.1 drop out E1325:= 400rpm Cra.2 drop out E1326:= 380rpm Cra.3 drop out E1327:= 380rpm. 6.6 Water preheat / Pre-lubrication / Pre-glow functions GENSYS 2.0 Core J6: Spare Input 1: Preheating (2273) J7: Spare Input 2: Manual water preheat (2224) J8: Input 3: Spare Manual oil prelub. (2225) J9: Spare Input 4: Manual preglow request (2226) Output 1: C1 Output 2: C2 Pre heat relay Pre lubrication relay J10: Input 5: Manual start request (2227) Output 3: C3 Pre glow relay F6 / F7 F8 / F9 Water temperature sensor Oil pressure sensor Output 1 function (1260) = Water preheats (2083) Output 2 function (1261) = Pre lubrication (2084) Output 3 function (1262) = Pre glow (2085) Figure 28 - Connections for water preheat, pre lubrication and pre glow 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 Core start button, or if J10 is closed. 57

58 Chapter : Dedicated I/O lines Auto mode Pre-heat is activated if J6 is closed and if temperature is under the pre-set threshold (E0030 < E1154). Note: The water temperature sensor is required in this instance. Pre-lubrication will be activated when engine is in pre-start (E2057 = 1) if pressure is under the threshold (E0029 < E1155). If the threshold (E1155) is 0, then pre-lubrication is active while the engine is in pre-start (E2057 = 1). In the last case the oil pressure sensor isn t required. Pre glow is active when engine state is pre glow or start (E2057 = 12 or 2). 6.7 Air fan GENSYS 2.0 Core J5: water temp input Output 1: C1 Air fan relay F6 / F7 Water temperature sensor Output 1 function (1260) = Air fan (2215) Figure 29 - Connection for air fans 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 Manual mode AIR FAN output is activated if engine speed is other than Auto 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 (E2057=0) 58

59 Chapter : Dedicated I/O lines 6.8 Fuel filling / Coolant filling / Oil filling GENSYS 2.0 Core 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) J11: Input 6: Man cool fill (2253) J12: Input 7: oil low level (2246) J13: Input 8: oil high level (2247) J14: Input 9: Manu oil fill (2254) Output 1: C1 Output 2: C2 Output 3: C3 Fuel fill relay Coolant fill relay Oil fill relay F1/F2 Level sensor F3/F4 Level sensor Output 1 function (1260) = Fuel filling (2229) Output 2 function (1261) = Coolant filling (2242) Output 3 function (1262) = Oil filling (2245) Figure 30 - Connections for filling Manual mode Output is only activated if J8 is closed Auto mode The 3 filling features all have exactly the same behaviour. 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. Fuel filling Cooling filling Oil filling Low level input E2230 E2243 E2246 High level input E2231 E2244 E2247 Filling output E2229 E2242 E2245 Table 18 - Fuel/cooling/oil filling parameters 59

60 Chapter : Dedicated I/O lines Fuel filling (2229) Fuel high level (2231) Fuel low level (2230) Figure 31 - Fuel filling diagram Pre-set filling 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. GENSYS 2.0 Core Output 1: C1 Analogue input 1: F1 / F2 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 1BLOC E2230:=E0031 LT 40; E2231:=E0031 GT 80; E2020:=( E2230 OR E2020) AND (!E2231) BEND Don t forget to configure the output 1 in Used by equations. 60

61 Chapter : Dedicated I/O lines 6.9 Analogue load share lines It is possible to use traditional analogue load share lines (often called Parallel Lines) with the GENSYS 2.0 Core product. The example shown is in association with a BARBER COLMAN product. GENSYS 2.0 BARBER COLMAN DYN /80109 Parallel lines + G6 10 Parallel lines + Parallel lines - G4 11 Parallel lines - Figure 32 - Wiring parallel lines Change the following parameters in the "Configuration/Enhanced configuration/powerplant overview" menu to activate parallel lines: ILS compatible E1158= YES (0) Deadbus manage. E1515= NON (1) 6.10 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. 61

62 Chapter : I/O lines 7 I/O lines 7.1 Digital input They are divided into dedicated and configurable inputs. For Digital inputs 1 to 10 (J6 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 modified 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 [ << ] and [ >> ] soft keys to change page (2 inputs per page), and [ ] and [ ] to choose the parameter. The description of the function is given on the next line, and can be modified with the [ + ] and [ - ] keys. Do not forget to use [SHIFT] + [ i ] to save modified values. The following table shows all input associated parameters. Not delayed Delayed Default label Label Validity Direction Delay Function value value J1 N.A. E2000 Mains breaker N.A. N.A. E1453 N.A. N.A. J2 N.A. E2001 Gen breaker N.A. N.A. E1454 N.A. N.A. J3 E2787 E2002 Remote start N.A. N.A. E1455 E1990 N.A. J4 E2788 E2804 Oil Pres/In J4 L2804 E4035 E1456 E1998 E1996 J5 E2789 E2805 Wat.Temp/In J5 L2805 E4036 E1457 E1999 E1997 J6 E2790 E2806 Spare Input J6 L2806 E1287 E1297 E1277 E1267 J7 E2791 E2807 Spare Input J7 L2807 E1288 E1298 E1278 E1268 J8 E2792 E2808 Spare Input J8 L2808 E1289 E1299 E1279 E1269 J9 E2793 E2809 Spare Input J9 L2809 E1290 E1300 E1280 E1270 J10 E2794 E2810 Spare InputJ10 L2810 E1291 E1301 E1281 E1271 J11 E2795 E2811 Spare InputJ11 L2811 E1292 E1302 E1282 E1272 J12 E2796 E2812 Spare InputJ12 L2812 E1293 E1303 E1283 E1273 J13 E2797 E2813 Spare InputJ13 L2813 E1294 E1304 E1284 E1274 J14 E2798 E2814 Spare InputJ14 L2814 E1295 E1305 E1285 E1275 J15 E2799 E2815 Spare InputJ15 L2815 E1296 E1306 E1286 E1276 Table 19 - Input parameters 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. 62

63 Chapter : I/O lines Validity Validity input variable numbers (E1287 to 1296) can be set as: Num Label Function 2330 Never Never active: should be selected if you do not use the input Always Always active: input will be monitored as long as GENSYS 2.0 has power Post-Start Input will be monitored at the end of the "safety on delay *E1514+ (*) 2331 Stabilized Input will be monitored when genset is ready for use (E2057 = 6) Spare scenario Input will be monitored as defined in equations. Table 20 - Input validity domain (*) 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 E Direction Direction input variable numbers: (E1297 to 1306) For each of the ten 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 0V and is opened when active Table 21 - Input direction domain Delay Direction input variable numbers: (E1277 to 1286) For each input, delay can be defined in ms steps between 0 and 6553 s Input functions Function input variable numbers (E1267 to 1276) can be set as indicated in the following table. Value Function Description 0 Unused Should be selected if you do not use the input. 1 Used by equations If the effect of the input activation is not listed below, choose "used by equations" 2224 Manual water preheat request 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 Manual oil prelube request Can be chosen if a pre lubrication pump is installed on the engine; can be used in conjunction with digital transistor output. Will only work in manual mode Manual preglow request Can be chosen if pre heating plugs are installed on the engine; can be used in conjunction with digital transistor output. Will only work in manual mode Fault reset request 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 Core front panel on Fault and Alarm displays. 63

64 Chapter : I/O lines 2227 Manual start request To be selected if a remote start command is to be installed Manual stop request To be selected if a remote stop command is to be installed - different from emergency stop Manual +f request To be selected if a remote frequency increasing command is to be installed Manual -f request To be selected if a remote frequency decreasing command is to be installed Manual +U request To be selected if a remote voltage increasing command is to be installed Manual -U request To be selected if a remote voltage decreasing command is to be installed Fuel high level To be selected for a max level sensor or a calculation; can be used in conjunction with digital transistor output Fuel low level To be selected for a min level sensor or a calculation; can be used in conjunction with digital transistor output Coolant high level To be selected for a max level sensor or a calculation; can be used in conjunction with digital transistor output Coolant low level To be selected for a min level sensor or a calculation; can be used in conjunction with digital transistor output Oil high level To be selected for a max level sensor or a calculation; can be used in conjunction with digital transistor output Oil low level To be selected for a min level sensor or a calculation; can be used in conjunction with digital transistor output Securities inhibition Will inhibit all protections. These alarms and faults remain listed in the faults and alarm logging No cranking To be selected to prevent engine from starting Ext. secu.(hard shut down) If external protections are installed, for immediate stop of the engine. See recommendations in "Directions" paragraph Ext. fault(soft shut down) If external protections are installed, for immediate opening of Genset breaker and stopping of the engine after cooling down timer has expired. See recommendations in "Directions" paragraph External alarm If external protections are installed, to report an alarm. See recommendations in "Directions" paragraph Generator electrical fault If external protections are installed, protection will open genset breaker and try to synchronize again. See recommendations in "Directions" paragraph Mains electrical fault If external protections are installed, protection will open mains breaker and try to synchronize again. See recommendations in "Directions" paragraph Non essential trip alarm Remote non essential load Help + Fault ( Soft shut down) To be selected to stop the engine after cool down. The GENSYS 2.0 Core will ask another engine to start before stopping itself Help + Gen Electrical Fault To be selected to activate the "gen electrical fault" action. The GENSYS 2.0 Core will ask another engine to start before stopping itself Remote stop horn To be selected to stop the external Horn. Useful if one output is set as "Horn". to be used in conjunction with digital outputs 2336 Gen. breaker Close manual To be selected if manual remote close button for genset breaker is programmed Gen. breaker Open manual To be selected if manual remote open button for genset breaker is programmed Mains breaker Close To be selected if manual remote close button for mains breaker 64

65 Chapter : I/O lines manual is programmed Mains breaker Open manual To be selected if manual remote open button for mains breaker is programmed Generator breaker Aux To be selected if a different input for the generator breaker position is required Mains breaker Aux To be selected if a different input for the mains breaker is required Remote start To be selected if a different input for remote start is required Oil pressure fault To be selected if a different input for oil pressure fault is required Water temperature fault To be selected if a different input for water temperature fault is required Priority generator To be selected if load/unload features depend on a priority genset; see Configuration -> load / unload menu 2257 Synchronization forced Will force GENSYS 2.0 Core to synchronize the output with the governing system. AVR will act so as to synchronize the genset. The Power mode (E2088) is forced to Synchronization (1) Fixed kw forced Will force GENSYS 2.0 Core to give constant power delivery. The output governing system will maintain a fixed power output from the genset. The Power mode (E2088) is forced to Fixed kw (4) kvar sharing forced The output to AVR will share reactive load with other gensets, using the inter GENSYS 2.0 Core CAN bus. (E.g. to be used in manual mode). The AVR cont. mode (E2090) is forced to kvar sharing (5) Voltage Droop forced Will force the GENSYS 2.0 Core to apply Droop to the AVR command. Set with *E The AVR cont. mode (E2090) is forced to Voltage droop (1) No manu mode Will inhibit the "Manu" key on the GENSYS 2.0 Core front panel. GENSYS 2.0 Core will never be in Manu mode even if you press the GENSYS 2.0 Core "Manu" key External manu mode request Will put GENSYS 2.0 Core into Manual mode. Will have the same effect as the GENSYS 2.0 Core "Manu" key Running with breaker open Allows the engine to run in Auto mode without paralleling or closing its breaker Select speed 2 Will select the second speed set point Select volt 2 Will select the second voltage set point Select KW 2 Will select the second power output set point Select Pnom 2 Will select the second nominal power (active and reactive) Preheating Can be chosen if a coolant pre heating system is installed; can be used in conjunction with a digital transistor output. Will work in auto mode Manu fuel fill To be selected for a manual fuel refill; to be used in conjunction with digital outputs Manu coolt fill To be selected for a manual coolant refill; to be used in conjunction with digital outputs Manu oil fill To be selected for a manual lubricant refill; to be used in conjunction with digital outputs Heavy consumer request To be selected to activate the "Heavy consumer control" special sequence. See below, Unload brk1 in Order output to close generator breaker n 1 upon startup if the nominal power<e

66 Chapter : I/O lines 5001 Unload brk2 in Order output to close generator breaker n 1 upon startup if the nominal power<e Unload brk3 in Order output to close generator breaker n 1 upon startup if the nominal power<e Unload brk4 in Order output to close generator breaker n 1 upon startup if the nominal power<e Unload brk5 in Order output to close generator breaker n 1 upon startup if the nominal power<e4005 Table 22 - Input functions Dedicated inputs In the menu list, each input is named after its pin number on the wiring of GENSYS 2.0 Core. Polarity can be normally open or normally closed. Program this according to the wiring you will have on site. As a reminder: J1 is the Mains breaker state. J2 is the Genset breaker state. J3 is the remote start input. J4 is the oil pressure switch. J5 is the cooling temperature switch. [E2000, E2001, E2002, E2003, E2004] 7.2 Digital outputs Output1 to Output5 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. The "Crank" and "Fuel" relay outputs can be set up for other functions. The initial settings are for "Crank" and "Fuel". Polarity cannot be changed for these relay outputs. "Crank" output function can be set with [E1989]; Fuel output function is set with [E1916] Output configurable functions Value Function Description 0 Unused To be selected if output is not wired. 1 Used by equations To be selected if output is used by equations Water preheat Can be used for coolant pre heat system Pre-lubrication Can be used for pre lubrication pump Pre glow Can be used for cylinder pre heating plugs 2018 Crank Can be used for external crank relay 2019 Fuel Can be used for external fuel relay 2211 Excitation Can be used to activate an external AVR in a static synchronizing configuration [see Configuration -> power plant overview] Will activate an external excitation relay when engine state [E2057] is: engine ready [5]; generator ready [6]; wait after stop request [7]; cool down [8]. In the case of dynamic paralleling [E1177 = 0], the output will also be activated in the start [2], warm up [3], and nominal speed [4] states. 66

67 Chapter : I/O lines 2212 Fuel (energize to stop) Can be used for an external relay if fuel solenoid has to be energized to stop the engine. Will activate an external fuel relay [Energize to stop] when engine is running [E0033 > 0] and 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] Generator breaker order Can be used to open or close genset breaker. The outputs configured with this function will have exactly the same behaviour as the outputs for the Generator breaker [E4 to E6] Mains breaker order Can be used to open or close genset breaker. The outputs configured with this function will have exactly the same behaviour as the outputs for the Mains breaker [E1 to E3] Alarms summary Fault summary: will activate an output when there is at least one alarm triggered by GENSYS 2.0 Core Securities summary Fault summary: will activate an output when there is at least one Security triggered by GENSYS 2.0 Core Faults summary Fault summary: will activate an output when there is at least one fault triggered by GENSYS 2.0 Core Gen. elec faults summary Fault summary: will activate an output when there is at least one mains elec. fault triggered by GENSYS 2.0 Core Mains elec. faults summary Output will be activated whenever a protection triggers a mains electrical fault Trip out 1 Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15 ; This is the first trip; Non Essential consumer trip 2725 Trip out 2 Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15; This is the 2nd trip activated [E1894] seconds after the previous one. Non Essential consumer trip 2726 Trip out 3 Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15; This is the 3rd trip activated [E1894] sec. after the previous one. Non Essential consumer trip 2727 Trip out 4 Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15; This is the 4th trip activated [E1894] sec. after the previous one. Non Essential consumer trip 2728 Trip out 5 Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15; This is the 5th trip activated [E1894] sec. after the previous one. Non Essential consumer trip 2774 Trip out direct Output activated by the protection in the "Non essential consumer trip" sequence. See 9.15; This one is activated directly. Non Essential consumer trip 2213 Smoke limiter 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 Core start button is pressed or with a manual start request. In Auto mode: when engine state *E2057+ is Start *2+, Warm up *3+ and Nominal speed * Warm up This output will activate when engine is warming up. Will activate an output at start. In Manu mode, when GENSYS 2.0 Core 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 *E2057+ is Start *2+ and Warm up * Horn 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] 67

68 Chapter : I/O lines triggers, and will reset when the GENSYS 2.0 Core 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) Air fans To be wired to fan relay Generator breaker Close Can be used to close genset breaker [100 ms pulse] 2221 Generator breaker Open Can be used to open genset breaker 2220 Mains breaker Close Can be used to close mains breaker Mains breaker Open Can be used to open mains breaker. Generates a 100ms pulse on the output, when Generator/Mains breaker [E2016/E2017] wants to close/open 2229 Fuel filling 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 Coolant filling Can be used for a compressor in conjunction with "Coolant high level" and "Coolant low level" or "Manual air fill" functions attributed to spare digital inputs. Oil filling [2245] Can be used for oil level filling in conjunction with "Oil high level" and "Oil low level" or "Manu oil fill" functions attributed to spare digital inputs f f U U The behaviour will change according to the mode. In Manual 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 Manual +f request [E2233]. Likewise for the other functions; -f activates with [-] key or Manual f request [E2234]; -f activates with [+]+SHIFT keys or Manual +U request *E2235+; -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 no action range for the speed [E1598] and for the voltage [E1599], the impulsion delay for the speed [E1600] and for the voltage [E1601] Damper Will activate in stop sequence to stop the engine when damping flap is fitted. Will be activated when there is an engine fault [2046] Light test This will activate the output whenever the light test key is pressed on the front panel of GENSYS 2.0 Core, or an input programmed for light test is active 2331 Generator ready Output will be active when start sequence is completed and voltage is present at the generator. In Auto mode, the output will be activated when the engine state *E2057+ is Gen ready *6+. In Manual mode the output will be activated when the speed [E0033] is positive Generator stopped Output will be active when genset is at rest. In Auto mode, the output will be activated when the engine state *E2057+ is Waiting [0]. In Manual mode the output will be activated when there is no speed [E0033] [ + ] key 2263 Shift & [ + ] keys 68

69 Chapter : I/O lines 2264 [ - ] key 2265 Shift & [ - ] keys These key are useful in Manu mode to control the speed and the voltage Manu mode Output will be active when GENSYS 2.0 Core is in manual mode Starter 2 Will be active when a second engine starting system is present and programmed in Configuration -> Start sequence menu Starter 3 Will be active when a third engine starting system is present and programmed in Configuration -> Start sequence menu Ana1 threshold Output will be active when the measurement of analogue input 1 [oil pressure] is under the set value; it will not de-activate until measurement is over [set value + hysteresis value]. To be programmed and used with the following parameters: Oil threshold *E1175+, Oil hysteresis *E Ana2 threshold 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. *E Ana3 threshold Output will be active when the measurement of analogue input 3 [1st spare measure] is over or under the set value; it will not deactivate until measurement is under or over [set value +/- hysteresis value]. To choose the direction of the protection, see Configuration -> 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. *E Ana4 threshold Output will be active when the measurement of analogue input 4 [2nd spare measure] is over or under the set value; it will not deactivate until measurement is under or over [set value +/- hysteresis value]. To choose the direction of the protection, see Configuration -> engine/battery settings [SS measure 2 min or max thresh.]. To be programmed and used with the following parameters: Meas 2 thresh. *E1430+ and Meas 2 hyst. *E Available in Auto 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 Core is in Auto mode and the power state [E2071] is not in fault [40, 100 or 255] Heavy consumer authorization Output activated when heavy consumer starting is allowed in the "Heavy consumer control" sequence. See below, Unload brker 1 Order output to close generator breaker n 1 upon start if the nominal power<e Unload brker 2 Order output to close generator breaker n 1 upon start if the nominal power<e Unload brker 3 Order output to close generator breaker n 1 upon start if the nominal power<e Unload brker 4 Order output to close generator breaker n 1 upon start if the nominal power<e Unload brker 5 Order output to close generator breaker n 1 upon start if the nominal power<e

70 Chapter : I/O lines Polarity For each of the five outputs, two options are possible: NE: normally energized; the output will de-energize when required, according to its function. ND: normally de-energized; the output will energize when required. 7.3 Analogue input Oil pressure configuration You can define oil pressure measurement parameters through the menu. Go to configuration menu: Enhanced configuration / Analog inputs. You can now choose units (mbar, Bar, kpa, PSI) and degree of accuracy (number of digits after decimal point): Water temperature configuration You can define water temperature measurement parameters through the menu. Go to configuration menu: Enhanced configuration / Analog inputs You can now choose units ( C or F) and degree of accuracy (number of digits after decimal point): 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): Calibration of analogue inputs 1/ Oil and water Ohms 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 Ohms Water Temp calibration points are [E1199 to E1209], which correspond to 0 to 400 Ohms. 70

71 Chapter : I/O lines Please enter calibration points using this table: Ohm VDO 5b VDO 10b VDO 25b AC 10b Veglia 8b Veglia 12b Dat 10b Table 23: Oil pressure calibration points Ohm VDO 120 VDO 150 Veglia Datcon L Datcon H AC Table 24: Water Temp calibration points 2/ Engine measurements 1 and 2 Spare 1 engine measure calibration points are [E1210 to E1220]. 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 ohms (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 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. 71

72 Chapter : I/O lines 2/ Configuration Spare analogue input calibration table should be set as shown below to mimic digital input. GENSYS 2.0 Core F1 F2 -BAT 3/ Parameters Calibration table for a normally closed input: V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 calib V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res V N Spare1 res 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: 72

73 Chapter : input to DI/spare analog input spare virtual input 1 E2283:= E0031 ; Calibration table is similar for a normally opened input; you need only change Analog input in numeric/spare analog input spare virtual input E2283:=!E0031 ; 73

74 Chapter : Protections 8 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. 8.1 Disable This gives no effect. 8.2 Generator electrical fault This action triggers a Generator electrical fault. Protection will open genset breaker and try to synchronize again. Number of attempts can be configured. 8.3 Mains electrical fault This action triggers a Mains electrical fault. Protection will open mains breaker and try to synchronize again. Number of attempts can be configured. 8.4 Alarm This action triggers an Alarm. 8.5 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. 8.6 Security (Hard Shutdown) This action triggers a Hard shutdown. Genset breaker will open and engine will be stopped immediately without cooling down. 8.7 Help + Fault (Soft Shut down) This action triggers a Soft shutdown with Help call. Before the soft shutdown sequence, GENSYS 2.0 Core 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 Core 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. 8.8 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 Core 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 Core will open the corresponding breaker and try to synchronize again. The number of attempts can be configured. 74

75 Chapter : Additional functions 9 Additional functions 9.1 Load sharing using integral (de-drooping) 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 Core 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 are in state E2071=29 (several generators paralleled with mains), the central frequency is disabled Procedure 1. In manual mode, using [+] and [-], adjust the speed control output (G9-G11) to obtain the desired frequency +/-2Hz from each genset. (see paragraph 6.1) 2. Test that load sharing is working properly (default values inhibit the integral). 3. Activation of central frequency with genset 1: On the front panel of the GENSYS 2.0 Core (or on the PC) Choose menu: Configuration/modification by variable number, and set E1476 to 2. Choose menu: Configuration/Active power regulation: -KW sharing GPI -G = 50 %( E1102) -P = 5 %( E1900) -I = 2 %(E1901) - Central Hz gain -G = 25% (E1902) 4. Adjust genset speed to give 49Hz using the speed governor (GENSYS 2.0 Core in manual mode without load). 5. Switch to TEST mode. When the breaker is closed frequency should return to 50.00Hz within 5 seconds. Adjust the Hz central gain (E1902) to adjust the time if needed. 6. Repeat step 5 for all gensets. 7. Test the load sharing by changing the nominal frequency of one generator to 49Hz. -> bus frequency should remain at 50 Hz and kw load sharing within 2% of that desired. The stability of load sharing is adjusted with kw sharing GPI / I (E1901) Remarks: E1902 = stability of de-drooping (only activated in the master GENSYS 2.0 Core). 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 Core units. 75

76 Chapter : Additional functions E1102 = Global gain of load sharing is obtained by multiplying the PI and the central Hz gain. E2739 = 1 I am the master (I control the frequency). E2739 = 0 I am a slave (I share load using the integral) GCR synchronization & mains paralleling When using the central frequency (de-drooping) 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 & G3 of GENSYS digital input 1(E2006) is closed during mains mains breaker feedback is connected to terminal J1 Don t forget to allow parameter E1476 and E1020 to be modifiable by modbus and equations TEST (E2006 EQ 1) AND (E2000 EQ 0) EQ 1 THEN ELSE TEND; BLOC BEND BLOC BEND E1476:=0; E1020:=20000 E1476:=2; E1020:= 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 number Label Description Default value Disable value V1102 Load sharing G Parameter to set the Global gain V1900 Load sharing P Parameter to set the Proportional gain. 5 1 V1901 Load sharing I Parameter to set the Integral gain. 2 0 V1902 Hz centre gain Parameter to control the central frequency, acting 25 0 as a frequency standard V1476 XXXXXX 2 0 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. 76

77 Chapter : Additional functions 9.2 Operator controlled return to mains Explanation 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. The GENSYS 2.0 Core waits for E2584 = 1 (Virtual input 40) before re-synchronizing the engine to the mains How to set this function The E1620 variable must be set to 1. The Virtual Input 40 must be set as used by equations (E1699=1) This virtual input can be associated to: a digital input: Ex: E2584= E2006; a CANopen deported digital input: Ex: E2584= E0158; an equation result: E2584= (E2440 GT 1000) AND (E2006 EQ 1) Summary E1620 = 1. E2584 = Virtual Input 40 to allow the genset to return the load to the mains. E1699 = 1: (E2584 (VI 40) is "used by equations") Parameters used E1620 Inhibition of Variable 13= Operator return to Mains ( + E2584) E2584 Virtual input Spare 40 E1699 Virtual Input 40 associated function. 9.3 Mains & Generator electrical fault options Mains electrical fault management Parameters (default value in bold): E1846: Open breaker: selects the breaker that will be opened upon a "Mains electrical fault". Choose between the "Mains" breaker or the "Generator" breaker or "both". E1841: Fault start: allows the engine to start upon a "Mains electrical fault". You can select "Yes" to start the engine or "No". E1840: Start delay (0.0): is the delay between the "Mains electrical fault" and the engine start. It will delay a digital or virtual input. In the case of an internal detection, this delay bypasses the delay of the protection. E1842: No load delay (60.0): is the time for which the engine runs without load when the generator breaker is opened. If the delay is 0, the generator will never stop. 77

78 Chapter : Additional functions Default configuration Diagram of behaviour in change over mode and in mains paralleling mode. Configuration : Change over with one digital input programmed in "Mains electrical fault" When Start on Mains electrical fault is Yes Generator CB E2001 Mains CB E2000 Mains electrical fault E2201 Voltage bus presence E2054 Timer before start on Mains electrical fault Start s equence Mains back timer Produc tion reques t E2072 Figure 33 - Change over with one digital input programmed as "Mains electrical fault" Configuration : permanent mains paralleling with one digital input programmed in "Mains electrical fault" Breaker openned on Mains electrical fault is Mains Start on Mains electrical fault is Yes Generator CB E2001 Mains CB E2000 Mains electrical fault E2201 Bus voltage presence E2054 Mains back timer Sy nchronization Produc tion reques t E2072 Figure 34 - Permanent mains paralleling with one digital input programmed as "Mains electrical fault" Start on fault and open generator on fault This parameter is useful in permanent mains paralleling mode with "open generator breaker on mains failure". It can be used if the generator nominal power is not high enough to take the load in island mode. In this case, the generator will provide power, but if there is a mains failure the generator will not take the load alone, and opens its breaker. In case the setup of the unit does not generate an engine start upon mains failure, it will run with no load and stop after a preset time (E1842). 78

79 Chapter : Additional functions Configuration : permanent mains paralleling with one digital input programmed in "Mains electrical fault" B reaker openned on Mains electrical fault is Generator Start on Mains electrical fault is No Remote start is always On Generator CB E2001 Mains CB E2000 Mains electrical fault E2201 Bus voltage presence E2054 Produc tion reques t E2072 Mains bac k timer Sy nc hroniz ation N o load running timer Mains bac k timer Figure 35 - Permanent mains paralleling with one digital input programmed as "Mains electrical fault" Configuration : permanent mains paralleling with one digital input programmed in "Mains electrical fault" B reaker openned on Mains electrical fault is Generator Start on Mains electrical fault is Yes Generator CB E2001 Mains CB E2000 Mains electrical fault E2201 Bus voltage presence E2054 Produc tion reques t E2072 Mains back timer Sy nc hroniz ation No load running timer Mains back timer Figure 36 - Permanent mains paralleling with one input as "Mains electrical fault" NOTE: Never use No start on 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. 79

80 Chapter : Additional functions 9.4 Generator electrical fault Parameters (default value in bold): E1843: TM re-synch. (30.0): the delay before the generator tries to re-synchronize with the Mains after a "Generator electrical fault". E1844: Nb re-synch. (3): number of attempts to re-synchronize. In the case of a generator electrical fault, the generator breaker is opened and the GENSYS 2.0 is in state 40. In this state, the alternator is de-excited (if wired) during a timer (E1265). After this timer, if the fault is still present, there is a hard shutdown. Otherwise GENSYS 2.0 Core will try to re-synchronize. Power state E2071 Paralleled Fault Sync Paralleled Fault Sync Paralleled Fault Sync Paralleled Fault Sync Paralleled Fault Stop Generator CB E2001 Generator electrical fault E Figure 37 - Permanent mains paralleling and generator electrical fault 9.5 GENSYS 2.0 Core with external automatic start module Overview This chapter describes how to interface the GENSYS 2.0 Core with an engine which has got its own automatic start module. The start sequence is redundant in the system. The following diagram shows the main functions of each device: Remote start Crank Auto Start Module Start sequence Engine protections Oil pressure Water temp Pickup Start request Generator ready Engine alarm Engine fault GENSYS 2.0 Core Synchronisation Electrical protections GE breaker control PF control kw control Monitoring Mains/Bus voltage Governor AVR 3*U 3*I Engine M Figure 38 - Wiring GENSYS 2.0 Core Auto Start Module 80

81 Chapter : Additional functions Signal description Direction Auto Start Module (ASM) GENSYS 2.0 Start request GENSYS 2.0->ASM Remote start input C5 Genset ready (opt) ASM->GENSYS 2.0 Core Digital output J15 Engine Alarm ASM->GENSYS 2.0 Core Digital output J7 Engine Fault ASM->GENSYS 2.0 Core Digital output J6 Table 25 - Wiring GENSYS 2.0 Core Auto Start Module GENSYS 2.0 Core does not need oil pressure and water temp digital inputs. This table is shown as an example only and can be customized as needed. 9.6 Remote start upon external pulse To set the GENSYS 2.0 Core to start upon an external pulse input, 2 solutions can be used: Use a relay Set an external input Setting external input This variable E2514 (Virtual Start) must be maintained at «1» after the first rising edge and go to 0 after the second rising edge. Example is for the J15 WARNING: if section empty or missing, existing equations will be lost; PROG 1 PULSE ON REMOTE START E2585 = Value of the E2815 with one cycle less to detect a ( E2815 EQ 1) AND (E2585 EQ 0) Detection of a top E2585:= E2815; E2514:=((E2514 OR ((E2815 EQ 1) AND (E2585 EQ 0))) AND ((E2514 AND ((E2815 EQ 1) AND (E2585 EQ 0))) EQ 0)) BEND. 81

82 Chapter : Additional functions Do not forget to set the input. GENSYS 2.0 Core must be informed that J15 (in this example) is used by a custom equation: V N DIJ15 function 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 changing the equation: (E2815 EQ 1) AND (E2585 EQ 0) to (E2815 EQ 0) AND (E2585 EQ 1). 9.7 Safety Inhibitions Objective Safety inhibitions are mandatory on certain types of application, particularly in safety generators used in public spaces (norm NF E ). The aim is to inhibit the oil pressure and water temperature safeties on the GENSYS 2.0 Core. Thus, in the case of a fault, the generator remains in operation. Other protections (over speed, overload, etc...) are still active if set 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 Oil pressure and water temp Logical Input J11 GENSYS 2.0 inhibit security spare input 8 J12 oil pressure spare input 9 J13 is water temperature fct spare input J12 fct spare input J13 speed user param: start speed user param: stop speed Oil pressure sign Water temp sign Virtual input 1 alarms inhibition ; 82

83 Chapter : Additional 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 ELSE BLOC E1456:=E2812; E1457:=!E2813; E2283:=0; E1273:=1; E1274:=1 BEND TEND BEND 9.8 Use of BSM II with GENSYS 2.0 Core When you have a lot of analogue values to monitor, BSM II can be connected to GENSYS 2.0 Core to log measurements and process data efficiently. This chapter will explain this type of configuration Schematic GENSYS 2.0 Core CAN2 (COM3) 120 Ohms active if end of bus A40W6 BSMII 5 CANH ; 7 CAN L + R 120 Ohms Figure 39 Wiring GENSYS 2.0 Core to BSM II Note 1: An A40W2 cable (a CRE technology product) is recommended to connect GENSYS 2.0 Core to BSM II. Connect CAN H (terminal 5) of BSM II to the Blue/white striped wire and connect CAN L (terminal 7) of BSM II to White/Blue striped wire. Note 2: If BSM II is at the end of the CAN bus, add one 120 resistor in parallel with terminals 5 and 7. 83

84 Chapter : Additional functions Configuration The communication between GENSYS 2.0 Core and BSM II uses a CANopen protocol. BSM II is a slave unit and GENSYS 2.0 a master unit. GENSYS 2.0 Core 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 Core (limited by the number of messages sent from GENSYS 2.0 Core) Procedure 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 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: -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 II. Note 1: 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. Note 2: Variable transmitted AO Var. AO Var. AO Var. AO Var. AO Var. AO Var Alarm E0516 kw mains E0036 Hz mains E0023 U13 mains E kw GE E0018 Hz GE E0020 cos GE E0021 Sum Digital V1 E0000 V2 E0001 V3 E0002 I1 E I2 E0007 I3 E0008 kw1 E0009 kw2 E0010 Sum Digital = each bit of this parameter represents a logic variable. Bit0 = breaker in mains (E2000) Bit1 = breaker in GE (E2001) Bit2 Bit14: free Bit15: forbidden (this bit gives the result a bad negative value) kw3 E0011 PwrMngt Status E2071 Engine Status E Free 22 Free 23 Free 20 free 24 Free 84

85 Chapter : Additional functions Custom procedure This procedure shows 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 Core as described in Download the text file (level 1 equation) A43Z090100a_1.txt to the BSM II. Customisation: see notes below. Note1: Change the Node ID of BSM II See BSM II user's manual to choose the node ID in the BSM II. Then change this Node ID in the settings of the GENSYS 2.0 Core (default ID equal 1): -Go to CANopen menu: configuration / << / CANopen -In each input/output message used, change "Mod. ID" to the correct value. Note2: Delete message If you do not need to send all variables set in default equations, you can delete output messages. Go to CANopen menu: configuration / << / CANopen / Output message Change Typ. Out mess to UNUSED to remove the message Change Mod. ID to 0 Note3: Add message Each message sends a maximum of 4 Analogue values to BSM II. Go to CANopen menu: configuration / << / CANopen / Output message Set "Mod. ID" to the correct Node ID of the BSM II. Set Typ. Out mess to ANALOG Set Nb of Outputs (Max 4) Add equation described in Note 4 (below) Note 4: Customize the variables sent to BSM II All variables are transferred as analogue outputs from GENSYS 2.0 Core to BSM II. Analogue output AO1 AO8 AO9 AO16 AO17 AO32 GENSYS 2.0 Variable E2432 E2439 E2682 E2689 E2708 E2723 All variables are transferred as analogue inputs from BSM II to GENSYS 2.0. Analogue input AI1 AI44 GENSYS 2.0 Variable E0285 E0328 To transfer a variable from GENSYS 2.0 Core to BSM II, write the equation below in level 1: Example: This example copies the KW measurement (E0018) to Analog Output 1 Allocate AO1 (E2432) to the measure of kw (E0018) E2432:=E0018; 85

86 Chapter : Additional functions Transfer several digital variables (max 15) via one analogue output. Each bit of the AO is equal to a digital variable. allocate AO8 to digital mains(b6) + 6 Digital Outputs(DO6=b5 -> DO1=b0); E2439:= 0; E2439:= X (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. 9.9 GENSYS 2.0 Core with TEM compact This chapter describes how to interface the GENSYS 2.0 Core with the TEM compact from Deutz Engines. The association of the TEM and the GENSYS 2.0 Core is an excellent solution to parallel a generator set with a Deutz Engine prime mover Overview: Some functions are redundant: the kw regulation and the start sequence. The following diagram shows the main function of each device: TEM Start sequence Engine protections KW control Gas protections Actual kw kw demand Remote I/O 2* 0-20mA Start request + Hz -Hz Generator ready Engine alarmt Engine fault Can Open GENSYS 2.0 Core Synchronisation Electrical protections kw measurement GE breaker control PF control Remote start Mains voltage Deutz gas engine AVR 3*U 3*I M Figure 40 - Wiring GENSYS 2.0 Core TEM 86

87 Chapter : Additional functions Signal description Start request kw demand 0-20mA Remark Direction TEM Compact used only if the kw set GENSYS 2.0 Core ->TEM X141-4 point is in the TEM X142-4 Used to start/stop and GENSYS 2.0 Core /Wago to fix the kw set point. ->TEM GENSYS 2.0 Core / Wago C5 Wago output 2 Genset ready TEM->GENSYS 2.0 Core X31-5 J15 X31-6 TEM Alarm Relay TEM->GENSYS 2.0 Core X31-1 J7 X31-2 TEM Fault Relay TEM->GENSYS 2.0 Core X31-3 J6 X Hz Digital signal GENSYS 2.0 Core ->TEM X141-6 C1 X Hz Digital signal GENSYS 2.0 Core ->TEM X141-7 C2 X142-7 Pickup G7 G8 Analog AVR AVR=MX321 GENSYS 2.0 Core ->AVR H2 H4 signal Actual kw 0-20mA GENSYS 2.0 Core -> TEM Wago output 1 Table 26 - Wiring GENSYS 2.0 Core TEM Note: this wiring diagram is only an example; you can use a different wiring setup if necessary. The following text file is the text file of an application tested on site: Power plant (example): One single genset in parallel with mains in base load mode. No emergency start. Manual breaker on the mains side. Motorized breaker on generator side. Generator set: Engine: DEUTZ TBG 616V12K, 450/525kW 1800RPM. TEM COMPACT engine management system Generator: Newage/Stanford 1800RPM, 480/277V, 910kVA AVR MX321 Power management: GENSYS 1.0 (CRE technology), Soft V

88 Chapter : Additional functions Remote analog I/O 0-20mA (Wago) Copy the downloadable text file from the website and paste it in a new text only file. You can download it to a GENSYS 2.0 Core as a starting point before commissioning. This file is only a guide and is not enough to start a new application Presetting counters / G59 parameters (Access level -1) Access to these specific features is done using a special password: 1. First connect with password level 2 «CREProd». - Go in menu System/Passwords/Level-1 password. - Set parameter E1610 to the desired feature you want to access (G59 or Meter preset). - Validate and save your settings by pressing [SHIFT] + [ i ]. 2. Go back to the login page (press 3 times on ESC). - Enter password «CustMenu». - Now you can access to the special features you have selected. Presetting meters With this option you can set or reset all the counters. Don t forget to save the new settings by pressing key [SHIFT] + [ i ] at the same time. G59 option 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). When the protections are locked, thresholds, timers and controls are also locked. Don t forget to save the new settings by pressing key [SHIFT] + [ i ] at the same time Scada GENSYS 2.0 Core 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. 88

89 Chapter : Additional functions 9.12 How to set a GPID Principle A GPID allows the control of any system in a simple way. Figure 51 shows a typical GPID. P Set point + G I Deviation - Measure D G: global gain P: proportional gain I: integral gain D: derivative gain Figure 41 - Typical GPID 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 parameter 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) Empirical setting method First set G to 50%. Set the parameters P, I 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 I 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. 89

90 Chapter : Additional functions 9.13 Automatic load / unload This function automatically controls the start and stopping of several generators of a power plant depending on the load request, whether paralleling with the mains or not. Coordination with the other GENSYS 2.0 Core units is via the CAN bus (COM1). Required configuration to allow automatic load / unload: All the remote start inputs must be on, on each GENSYS 2.0 Core (connected to 0V). At least 2 generators must have GENSYS 2.0 Core units. If remote start is off, the generator never starts. A generator can run in "Forced running" mode using a digital input. Select a digital input with the function "Priority generator". Activate this input. The generator starts, synchronizes, closes its breaker and stays on the bus bar until "Remote start/stop" is de-activated. 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. 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. How to determine the priority generator (which starts/stops) by using the variable "Load/Unl. mode" (E1258): Load/Unload mode [E1258] can be: Inhibited: [0]; the different GENSYS 2.0 Core units installed on the power plant do not interact to start or stop gensets according to the load demand. Digital Input: [1]; if selected on all the GENSYS 2.0 Core units installed on 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 Core is set as priority generator, this GENSYS 2.0 Core will start first. The next to start will be decided by increasing genset number, which is defined in the power plant overview settings menu. (E.g. if genset 2 has priority, then genset 3 will be the next to be started upon increasing load, then genset 4; by decreasing load demand, genset 4 will be stopped first, then genset 3...). Hours run: [2] the genset to start/stop will automatically be selected according to the GENSYS 2.0 Core hour meter. On increasing load demand, the next genset to be started is the one with fewest hours run; on decreasing load demand, the next genset to be stopped is the one with highest hours run. Custom E16: [3] the genset start/stop sequence will follow the priority number set in each GENSYS 2.0 Core in the variable [E1617]. Please refer to the application note: A40Z Figure 42 Automatic load/unload sequence 90

91 Chapter : Additional functions Load threshold [E1256]: Percentage of the genset nominal power (defined in the power plant overview settings menu) at which GENSYS 2.0 Core will ask another genset to start and share the load after the following timer. TM before load [E1257]: Timer for load sharing request. Unload dep stp. [E1914]: Used to select the "unload dependant stop" sequence. Please refer to the application note: A40Z GENSYS 2.0 Core calculates the power that will remain on the bus bar (in % for each engine remaining) if it decides to stop (and open its breaker). If this percentage is under the required threshold (E1915), then GENSYS 2.0 Core will stop. If not it will wait until threshold is reached. Unload thresh. [E1254]: Only used if E1914 is set as NO: load dependent stop not used. It is the percentage of the genset nominal power (defined in the power plant overview settings menu) at which GENSYS 2.0 Core will ask a genset to stop sharing the load after the following timer. Unload dp. thrs [E1915]: Only used if the E1914 is set as YES: load dependent is used. GENSYS 2.0 Core calculates the power that will remain on the bus bar if it decides to stop. This is the threshold below which GENSYS 2.0 Core decides to stop. It is a percentage of the genset nominal power (defined in the power plant overview). TM bef. unload [E1255]: Timer used before deciding to reduce the number of gensets in load/unload management. Note: To force the start of a generator in load / unload mode, during commissioning for example, remote start and digital input (in "Priority generator" mode) must be activated. In "Hour run" mode, 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. Coordination between generators is activated only during a load or unload request, i.e. in the next start/stop on load request. During a load request, only the stopped and available generators coordinate (auto mode selected; no hard fault). During an unload request, only the started generators coordinate. GENSYS 2.0 Core units in manual mode do not take part in start or load sequence ARBITRATION ORDER 3 Genset 3 is in forced RUN -> Genset 4 will start first, and stop last upon load change Figure 43 - Automatic load/unload arbitration 91

92 Chapter : Additional functions 9.14 Heavy consumer (marine sequence) Introduction This function is used in Marine applications. Note that GENSYS 2.0 Core includes this function but does not have any type approval. Please contact your distributor if you need a Marine approved product. Certain external parameters must be analysed by the GENSYS 2.0 Core units before accepting heavy consumer load. If Power Plant can accept load, each GENSYS 2.0 Core accepts load. If Power Plant cannot accept load, another engine is started. Analysis of available kw, number of generators on Busbar, or both. One input for each GENSYS 2.0 Core is used to start analysis of power available on plant. One output for each GENSYS 2.0 Core is used to accept heavy Consumer request Menu Settings Heavy consumer [E1911]: Power necessary for the heavy consumer. Min number of genset [E1912]: Minimum number of engines in case of heavy consumer request. CT Heavy [E1913]: You can choose between: Disable [0]: Heavy consumer function is not used (default). KWatt [1]: GENSYS 2.0 Core analyzes acceptable load on the Power plant. Engines start if necessary Min Number [2]: Minimum number of Engines necessary on the power plant for heavy consumer. KWatt & Min number [3]: Analysis of both the power available and minimum number necessary. Examples that use Heavy Consumer Control: Using of a crane in a harbour, manoeuvring a ship in/out of harbour using bow thrusters, etc Procedure To set the Heavy Consumer Control mode, go to the "Enhanced Configuration/Special functions/heavy Consumer control" menu. This can be accessed through the keyboard on GENSYS 2.0 Core, or with internet explorer as show below: Figure 44 - Heavy consumer validation 92

93 Chapter : Additional functions See diagrams below: Heavy Consumer demand Power Plant = 2 GEs of 100 KW each Heavy Consumer = 75 KW time KW of Power Plant 200 KW 100 KW time KW available Start and Synchronisation of second GE 100 KW time Heavy Consumer authorization time Figure 45 - 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 time Heavy Consumer authorization time Figure 46 - Heavy Consumer Control with number of gensets analysis Configuration of the confirmation output (/Configuration/digital transistor output/): Figure 47 - Configuration of the heavy consumer confirmation output 93

94 Chapter : Additional functions 9.15 Non essential consumer trip (marine sequence) Introduction This function is used in Marine applications. Note that GENSYS 2.0 Core includes this function but does not have type approval. Please contact your distributor if you need a Marine approved product. If the generator reaches the overload or under frequency threshold (following timers), GENSYS 2.0 Core triggers outputs to trip non essential loads. This chapter will describe how to use these features Procedure To set the different thresholds and timers, go to the "Enhanced Configuration/Special functions Non essential consumer trip" menu: Figure 48 - Non essential consumer trip settings Using different thresholds and timers, you can create a fast standard protection: Note: The settings of timer 1 and timer 2 are the same for overload and under frequency protection. See diagrams below: 94

95 Chapter : Additional functions KW2 E2729 is activated KW1 timer 1 t E2729 is activated KW2 timer 2 KW1 t Figure 49 - Non essential consumer trip alarm (1) Min Hz 1 t E2729 is activated timer 1 Min Hz 2 Min Hz 1 t E2729 is activated timer 2 Min Hz 2 Figure 50 - Non essential consumer trip alarm (2) Configuration of the trip output (/Configuration/digital transistor output/): Figure 51 - Non essential consumer trip output setting 95

96 Chapter : Additional functions When the variable E2729 is activated, each trip output will activate after the same timer (E1894): E2728:=1 E2727:=1 E2727:=1 E2726:=1 E2726:=1 E2726:=1 E2725:=1 E2725:=1 E2725:=1 E2725:=1 E2724 : =1 E2724:=1 E2724:=1 E2724:=1 E2724:=1 E1894 E1894 E1894 E1894 E1894 Figure 52 - Non essential consumer trip timers If the variable E2729 becomes inactive, the outputs previously activated will keep the same status. If variable E2729 becomes active again, the trip outputs continue as before. 1 0 E2729 E2724 E2725 E2726 " " " E2727 E2728 " " " " Figure 53 - Non essential consumer trip diagram To deactivate the outputs, it is necessary to reset the alarm E2729 on the front panel Phase offset (Dyn11 and other) Introduction This special function, only available with option 8, provides a choice of phase offset [E1929] between mains and Gen voltage measurement. That means that GENSYS 2.0 Core will command the breaker to close with the selected phase angle shift. You must take care before choosing this function. 96

97 E4039 = 0 Chapter : Additional functions Example: Figure 54 Phase offset example Menu Settings Phase offset [E1929]: This parameter can be chosen from the following values: 0, +30, +60, +90, +120, +150, 180, -30, -60, -90, -120, three phase and 180 two phase systems Parameter E4039 allows you to select the system to be used in the Configuration/Basic configuration/genset menu. System used E4039 Three phase (default value) Two phase SYSTEM PARAM. CONNECTIONS 3 phase phase + Neutre 97

98 Chapter : Text file & PLC 10 Text file & PLC 10.1 Introduction The core system of the GENSYS 2.0 Core is based on a list of predefined variables. These variables can be used in a proprietary programming language. This language uses simple keywords in an ASCII text file. This text file is downloaded from GENSYS 2.0 Core (details in ). It is stored as a binary program for use with flash memory. A copy of the source file is also stored on GENSYS 2.0 Core for documentation and readability purposes. This copy can be retrieved at any time to be modified or transferred to another GENSYS 2.0 Core. 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 behaviour 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 or from the GENSYS 2.0 Core to set or retrieve the whole setup of the GENSYS 2.0 Core. 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 Variable naming The file named A53 Z x.xls 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 ) 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. All the parameters (Variable from 1000 to 1999 and from 4000 to 4999) of the GENSYS 2.0 Core 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 GENSYS 2.0 Core, as described in

99 Chapter : Text file & PLC 10.3 Text file description The text file is made up of 5 parts: Parameter definitions Label definitions Unit definitions Custom PLC Initialization definitions Custom PLC Equation definitions Parameter 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 (only for clarification) (Ex: Gen Nominal KW) The minimal value (only for clarification) (Ex: ) The maximal value (only for clarification) (Ex: ) Ex: {PARAMETERS} V Y Gen nominal kw V N Gen PT ratio 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 (for de-rating purposes for example) whereas the N attribute in the second line sets Generator PT ratio as "read only" for MODBUS and PLC equations. It is possible to modify the values directly in the text file before uploading it into the GENSYS 2.0 Core. The user must be sure that the modified value is within the minimum / maximum range. 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 GENSYS 2.0 Core or to activate special features independently. 99

100 Chapter : Text file & PLC 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: Analogue inputs Cycle label Virtual input L0029 AI oil press. L1442 Cycle 1 (h) L2283 Virtual in 1 L2565 Virtual in 21 L0030 AI water temp. L1443 Cycle 2 (h) L2284 Virtual in 2 L2566 Virtual in 22 L0031 AI spare 1 L1444 Cycle 3 (h) L2285 Virtual in 3 L2567 Virtual in 23 L0032 AI spare 2 L1445 Cycle 4 (h) L2286 Virtual in 4 L2568 Virtual in 24 Spare input L1446 L1447 Cycle 5 (h) Cycle 1 (d) L2287 Virtual in 5 L2288 Virtual in 6 L2569 Virtual in 25 L2570 Virtual in 26 L2657 User meter 1 L2659 User meter 2 L2804 Oil Pres/In J4 L2805 Wat.Temp/In J5 L2806 Spare Input J6 L2807 Spare Input J7 L2808 Spare Input J8 L2809 Spare Input J9 L2810 Spare InputJ10 L2811 Spare InputJ11 L2812 Spare InputJ12 L2813 Spare InputJ13 L2814 Spare InputJ14 L2815 Spare InputJ15 L1448 L1449 L1450 L1451 Cycle 2 (d) Cycle 3 (d) Cycle 4 (d) Cycle 5 (d) L2289 Virtual in 7 L2290 Virtual in 8 L2291 Virtual in 9 L2292 Virtual in 10 L2293 Virtual in 11 L2294 Virtual in 12 L2295 Virtual in 13 L2296 Virtual in 14 L2297 Virtual in 15 L2298 Virtual in 16 L2299 Virtual in 17 L2300 Virtual in 18 L2301 Virtual in 19 L2302 Virtual in 20 L2571 Virtual in 27 L2572 Virtual in 28 L2573 Virtual in 29 L2574 Virtual in 30 L2575 Virtual in 31 L2576 Virtual in 32 L2577 Virtual in 33 L2578 Virtual in 34 L2579 Virtual in 35 L2580 Virtual in 36 L2581 Virtual in 37 L2582 Virtual in 38 L2583 Virtual in 39 L2584 Virtual in 40 Table 27- Label definition bloc Page logo label T0249 GENSYS 2.0 Core T0250 CRE product T0251 Genset Paralleling T Table 28 - Custom logo labels 100

101 Chapter : Text file & PLC 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: <space>! # $ ( ) * + / : ; < = > [ ] ^ _. - All other characters are considered as insecure, and their use is prohibited. Their use can result in a bad display. Ex: {LABELS} L1130 Note: Sample label 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 remain 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 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 (GENSYS 2.0 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. The table below lists the different units supported by GENSYS 2.0 Core. Only the 4 analogue inputs have an entry in this bloc (see file named Z xls 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: {UNITS} U U A

102 Chapter : Text file & PLC The tables below give you the list of codes which correspond to the supported units and 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 Code Unit Code Unit Code Unit Code Unit Code Unit Electrical Power Pressure Volume Time kw 13 Bar 20 L 24 s 01 V 08 kwh 14 mbar 21 m3 25 h 02 kv 09 kvar 15 kpa 22 mm3 26 days 03 ma 10 kvarh 16 PSI 23 Gal Time related 04 A Rotating speed Temperature 27 Hz/s 05 ka 11 rpm m3/h Frequency Percent 18 C 29 L/h 06 Hz 12 % 19 F 30 Gal/h Code Accuracy (Accura cy code 32768). Table 29 - Valid units and accuracy codes Code Variable number Native analogue inputs Default unit code Default accuracy code Description Label Analogue measure of oil pressure (0-400Ohm) AI oil press Analogue measure of water temp (0-400Ohm) AI water temp Analogue measure of analogue 1 (0-10kOhm) AI spare Analogue measure of analogue 2 (0-10kOhm) AI spare 2 Analogue inputs for CANopen & CANopen extensions analogue input 1 Analog in analogue input 2 Analog in analogue input 3 Analog in analogue input 4 Analog in analogue input 5 Analog in analogue input 6 Analog in analogue input 7 Analog in analogue input 8 Analog in analogue input 9 Analog in analogue input 10 Analog in analogue input 11 Analog in analogue input 12 Analog in analogue input 13 Analog in analogue input 14 Analog in

103 Chapter : Text file & PLC analogue input 15 Analog in analogue input 16 Analog in analogue input 17 Analog in analogue input 18 Analog in analogue input 19 Analog in analogue input 20 Analog in analogue input 21 Analog in analogue input 22 Analog in analogue input 23 Analog in analogue input 24 Analog in analogue input 25 Analog in analogue input 26 Analog in analogue input 27 Analog in analogue input 28 Analog in analogue input 29 Analog in analogue input 30 Analog in analogue input 31 Analog in analogue input 32 Analog in analogue input 33 Analog in analogue input 34 Analog in analogue input 35 Analog in analogue input 36 Analog in analogue input 37 Analog in analogue input 38 Analog in analogue input 39 Analog in analogue input 40 Analog in analogue input 41 Analog in analogue input 42 Analog in analogue input 43 Analog in analogue input 44 Analog in 44 Virtual inputs (first block) Virtual input Spare 1 Virtual in Virtual input Spare 2 Virtual in Virtual input Spare 3 Virtual in Virtual input Spare 4 Virtual in Virtual input Spare 5 Virtual in Virtual input Spare 6 Virtual in

104 Chapter : Text file & PLC Virtual input Spare 7 Virtual in Virtual input Spare 8 Virtual in Virtual input Spare 9 Virtual in Virtual input Spare 10 Virtual in Virtual input Spare 11 Virtual in Virtual input Spare 12 Virtual in Virtual input Spare 13 Virtual in Virtual input Spare 14 Virtual in Virtual input Spare 15 Virtual in Virtual input Spare 16 Virtual in Virtual input Spare 17 Virtual in Virtual input Spare 18 Virtual in Virtual input Spare 19 Virtual in Virtual input Spare 20 Virtual in 20 Virtual inputs (second block) Virtual input Spare 21 Virtual in Virtual input Spare 22 Virtual in Virtual input Spare 23 Virtual in Virtual input Spare 24 Virtual in Virtual input Spare 25 Virtual in Virtual input Spare 26 Virtual in Virtual input Spare 27 Virtual in Virtual input Spare 28 Virtual in Virtual input Spare 29 Virtual in Virtual input Spare 30 Virtual in Virtual input Spare 31 Virtual in Virtual input Spare 32 Virtual in Virtual input Spare 33 Virtual in Virtual input Spare 34 Virtual in Virtual input Spare 35 Virtual in Virtual input Spare 36 Virtual in Virtual input Spare 37 Virtual in Virtual input Spare 38 Virtual in Virtual input Spare 39 Virtual in Virtual input Spare 40 Virtual in 40 Table 30 - Variables with customizable unit/accuracy values 104

105 Chapter : Text file & PLC Initialization definition blocks The beginning of these blocks 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 GENSYS 2.0 Core. 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 by the PLC when the power supply of the module is turned ON. They won t be run again until power supply is turned OFF and then ON again. The purpose of these blocks is to provide custom equations to the user. They are run during the power up stage. 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 the programming language see chapter Equation definition blocks The beginning of this 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 which are run cyclically. These equations are run every 100ms (PLC cycle time). Non standard equations can be entered here to handle user defined features like thresholds, Input/Output expansions, PID controls For further details on the programming language see chapter End of file Every text file must end with the "{END OF FILE}" statement. GENSYS 2.0 Core 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 126Kbytes. NOTE: 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 GENSYS 2.0 Core, it will be rejected. 105

106 Chapter : Text file & PLC Warning: Power control and protections are disabled while the GENSYS 2.0 Core 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 PLC programming language It is strongly advised that you follow training before using custom PLC equations on a power plant. Contact your local dealer for details on training sessions. The PLC equations use a simple language with a small number of commands. The code is intrinsically linear, each equation being executed one after the other (without any loop). Level 1 equations are executed first, followed by level 2 equations. This way, level 2 equation results can overwrite any conflicting level 1 equation. The "INIT" part is only executed upon start-up, and the "PROG" part is executed every 100 ms. All the GENSYS 2.0 Core variables can be used in the equations in the way defined below: -E0xxx and E5xxx are read only as measurements/inputs. They can t be changed by equations. -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). E2xxx parameters are PLC outputs. They can be read and written by custom equations. Note: -Variables E1xxx/E4xxx are parameters stored in FLASH (non volatile memory). In level 2 and above, the user can allow the parameters to be written by PLC equations or via MODBUS. -Be very careful when modifying a parameter through equations, as unexpected behaviour (due to an error in your equations for example) may damage your generator. -It is advisable to include tests in the equations to verify that the engine is stopped prior to changing a parameter. Otherwise, make modifications in the "INIT" block if possible. These parameter modifications will not be saved in FLASH memory, i.e. parameters will be reset to their previous value if power supply is turned OFF and then ON again, unless the user saves them manually. -Use document A53 Z x.xls to get a complete list of all GENSYS 2.0 Core variables. -Variables E2xxx/E5xxx are outputs from the PLC, they can be read and written by PLC equations without restrictions. The table below gives a list of all available instructions that can be used in custom PLC equations: Instruction family PLC instruction Definition Program PROG INIT. Starting point of PLC equations Starting point of INIT equations End of equations Blocs BLOC BEND Starting and ending points of a block of equations Logical operators AND OR XOR Logical operation used on a whole variable (i.e. these are not bit to bit operators) Unary operators! Bit to bit complement - Sign change > Right shift 106

107 Chapter : Text file & PLC < Left shift $ Hexadecimal value Arithmetical operators + Addition - Subtraction * Multiplication / Division INC Increment DEC Decrement Bit operators ^ Rotation right Access one bit # Bits mask Affectation := Affectation Comparison operators EQ Equal NE Not Equal GT Greater Than LT Less Than GE Greater or Equal LE Less or Equal Array [...] Array element Tests TEST THEN ELIF ELSE TEND Table 31 Available instructions Instructions are separated by a semicolon (;) except before reserved words BEND, ELIF, ELSE and TEND. INIT and PROG blocks are terminated by a dot (.). Each instruction is terminated by a semicolon (;) except before reserved words (BEND, ELIF, ELSE, TEND) Variables Variable type and size The PLC equations only use 16 bit signed integer values. This means that all variables and data should be between and This is an important point to keep in mind when comparing values or doing calculations. For example, 20000*10 will produce a calculation overflow. For the same reason, variables displayed with decimal digits are treated in the equations as if the decimal point wasn t there. For example, a power supply voltage of 24.5 V will be treated as 245 in the equations. Be careful when entering values which have digits after the decimal point. If you have one digit after the dot, you have to multiply the number by 10. If you have two digits, multiply by 100. For instance, the battery voltage measure (variable E0041), is from 0.0 to , so you have one digit after the dot. If you want to compare the battery voltage to 25.0 volts, you have to write: TEST E0041 GT 250 THEN... To know the number of digits after the dot, look in the A53 Z x.xls file. In the 'Mini' / 'Maxi' columns, the number of digits after dot appears. 107

108 Chapter : Text file & PLC Locked variables versus dynamic variables The PLC works with two complete sets of variables. The first set is a snapshot of the values before the execution of the equations The second set of variables is the result of the different equations already executed. Before execution of the very first equation, the second set is an exact copy of the first set of variables. It is then altered by the results of the custom equations. Access to these two sets of variables is differentiated by the way you refer to a variable: Eyyyy means that you want to use the value of variable YYYY before any equation was executed. Xyyyy means that you want the actual value of variable YYYY, which has been modified by previous equations. When the cycle controller, checks the validity GENSYS 2.0 Core (range min / max) values of variables X2nnn. If the value is legal, it is kept in memory for further operation. If the value is invalid, the internal variable will retain the value it had just before the PLC cycle ( the value E2nnn). Note that as the first set is a picture of the variables before execution of the equations, it can be viewed as read only. This means that when you write the following equation: E2680 := 320; The value 320 will be attributed to variable 2680 in the second set of variables as well Syntax examples Test examples: TEST condition THEN instruction TEND; TEST condition THEN BLOC instruction; instruction; ;instruction BEND TEND; TEST condition THEN BLOC instruction; instruction; ;instruction BEND ELIF condition THEN BLOC instruction; instruction; ;instruction BEND ELIF condition THEN BLOC instruction; instruction; ;instruction BEND ELSE BLOC instruction; instruction; ;instruction BEND TEND; Calculation / instruction examples: E2680:=(E2000+E2001+E2002+E2003)/4; E2000:=2; E2680[E2000+1]:=10; E2680:=(E0030 GT 1450) AND ((E0030 GT 1500) OR E2680); Condition examples: TEST E2050 EQ 1 THEN... TEST E0030 GT 1500 THEN... TEST (!E2046) AND E2055 AND ((E2071 EQ 14) OR (E2071 EQ 15)) EQ 1 THEN The following example is a small text file that could be sent to a GENSYS 2.0 Core using a level 2 passwords. In this example, the following variables are used: E0160 is the value of CANopen digital input 1 from an extension module. 108

109 Chapter : Text file & PLC E1710 is a user parameter. It will be used as the period of a counter. E1711 is another user parameter used as the duty ratio of the counter. E2440 is a user variable used as a counter in this example. E2441 and E2442 are two user variables. {INIT L2} INIT 2 BLOC E2440 := E1710; E2441 := 0; E2442 := 1 BEND. {EQUATIONS L2(every 100ms)} PROG 2 E2440 is used as a counter that decreases from parameter E1710 down to 0; TEST E2440 GT 0 THEN ELSE TEND; DEC E2440 E2440 := Set the values of E2441 and E2442 depending on digital input 1 (E0160) and the counter E2440; BEND. TEST E0160 AND (E2440 LT E1711) EQ 1 THEN ELSE TEND BLOC BEND BLOC BEND {END OF FILE} E2441 := 1; E2442 := 0 E2441 := 0; E2442 := 1 The INIT block initializes counter E2440 to the value set by the user in parameter E1710. Variable E2441 is set to zero, and variable E2442 is set to one. These initializations are done when the GENSYS 2.0 Core powers up. 109

110 Chapter : Text file & PLC The PROG block is executed once every 100ms. In this block, if variable E2440 is not zero, it is decreased by one. Otherwise, it is re-set to the value of parameter E1710. Then we check if CANopen digital input 1 is set to one and counter E2440 is lower than the value set in user parameter E1711. If this is the case, E2441 is set to one and E2442 is set to zero. Otherwise, E2441 is set to zero and E2442 is set to one. For example if E1710 is set to 100 and E1711 is set to 20, E2441 can be seen as a PWM with a cycle time of 10s (100*100ms) and a duty ratio of 20% when CANopen digital input is set to one. Here, E2442 is simply the complement of E GENSYS 1.0 GENSYS 2.0 Core compatibility Using a GENSYS 1.0 configuration file in a GENSYS 2.0 Core 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 Core which use new variables. Certain GENSYS 1.0 variables have been redefined with new functions in the GENSYS 2.0 Core. The digital input variables have been moved: E2004 becomes E2804 E2005 becomes E E2015 becomes E2815 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 Core. A timer may now be associated to 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 Core. Also check the read/write authorisation (Y/N) which is associated with each parameter: V N J1939 sc adres V N J1939err delay V N Fail to O/C br V N Div D ILS V N Div D Q share V N RESET delay V N CAN Speed V N Fail to start V y Branch P-oil V Y Brnch T-water V Y Branch Speed V Y Com2 protocol V Y J1939 Address V Y CT speed

111 Chapter : Text file & PLC V Y CT Oil Pres V Y CT Cool Temp V Y CT Oil Pres V Y CT Cool Temp V Y CT speed V Y CT Malfonction V Y CT Protection V Y CT Orange V Y CT Red V Y Opt4Param V Y Opt4Param V Y Opt4Param V Y Opt4Param V Y Opt4Param V Y Fuel relay fct V N CANopenErDelay V N CT Fail synch V N Phase offset The parameters listed above are shown with their default settings for the GENSYS 2.0 Core. If your configuration file or variables modify these parameters, make sure their use is the same as in the GENSYS 2.0 Core. 111

112 Chapter : Communication 11 Communication 11.1 CAN bus good practices This chapter explains and describes good practices used to ensure a good reliable CAN communication. This advice is true for all CAN bus connections and should be applied to both GENSYS 2.0 Core units for inter GENSYS 2.0 Core bus, and for second CAN communication port (COM1 and COM2). Figure 55 CAN bus wiring Here is the standard pin out of a DB9 CAN connector compared with a GENSYS 2.0 Core implementation: GENSYS 2.0 Core Standard SHIELD GROUND PIN 1 NC Cable Drain PIN 2 CAN-L CAN-L PIN 3 GROUND-1 CAN GND PIN 4 NC free PIN 5 GROUND-2 +24V POWER PIN 6 GROUND-1 free PIN 7 CAN-H CAN-H PIN 8 NC free PIN 9 NC 0V POWER Table 32 DB9 pin out Note: GROUND-1 and GROUND-2 are each protected with a 47 ohm resistor. CAN bus cable: The CAN bus cable must be able to carry the CAN signals (CAN-L and CAN-H). These 2 signal wires should be a 120 Ohm twisted pair (Ex: Belden's 3105A, 3082A-3087A ( LAPP CABLE Unitronic bus DeviceNet or CAN ( or equivalent). The CAN bus-bus cable must be shielded, and must have a drain wire connected to the cable shield. This drain connects to pin 1 of each connector. The connector housing must be connected to the cable shield, and metallic shells should be used if possible. 112

113 Chapter : Communication For better results, a common GROUND should be used for all connected devices (this can be verified easily with an ohmmeter, for example). The total length of the cable must not exceed 250m for a CAN communication speed of 250kb/s. This length may decrease with lower quality cables. The CAN bus must be linear (no star connections) and both ends of the bus must be connected to 120 Ohm termination resistors. GENSYS 2.0 Core includes 120 Ohm termination resistors on COM1 and COM2. These termination resistors can be connected to the CAN bus via DIP switches at the rear of the module. Only the GENSYS 2.0 Core located at an end of a CAN bus should have its termination resistor activated. Warning: Never plug or unplug CAN bus connector when power is on. This may cause internal damage. 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 Ohm termination resistors should also be used appropriately. Table below indicates the maximal length of a CAN bus depending on the communication speed. Communication speed (kbits/s) Maximal length (metres) Communication speed of GENSYS 2.0 Core CAN bus: COM1: 125kbps communication speed. COM2: o 125kbps communication speed for CANopen (factory setting). Maximal length: 500m. Can be changed from 10 to 1000kbps in menu Configuration/Enhanced configuration/canopen. o 250kbps for J1939+CANopen communication. o 125kbps for MTU MDEC communication COM1: Inter GENSYS 2.0 Core CAN bus This CAN bus is a communication bus between different GENSYS 2.0 Core /MASTER 2.0 units of the same power plant. It allows GENSYS 2.0 Core units to synchronize with each other, manage dead bus connections, share active and reactive load, send data from one module to the other and other features. This CAN bus uses a CRE technology proprietary protocol. 113

114 Chapter : Communication The figure below shows the connections between each GENSYS 2.0 Core unit. The termination resistors are integrated inside GENSYS 2.0 Core and can be activated with a switch located at the rear of the module (under the plug marked OFF / 120Ω ). COM port is marked on the rear. You need to extract the plug to change the switch. The termination resistor is connected to the CAN bus when the switch is pushed toward the 120 Ohm side. When the switch is towards ON, resistor is active on bus. When switch is pushed to the other side, the resistor is not active on the bus. R R GENSYS GENSYS GENSYS Figure 56 - CAN Bus wiring Terminals 2 and 7: 1 twisted pair cable. Terminals 3 and 5: 1 twisted pair cable. R: 120 Ohms termination resistor (included inside GENSYS 2.0 Core) You can also use CRE technology accessories as shown below in figures 64 and 65 to connect several GENSYS 2.0 units together. Contact your local distributor to help you choose accessories that fit your needs. Figure 57 - GENSYS 2.0 Core GENSYS 2.0 Core Note: The 120 Ω termination resistors must be activated using the micro switch on the rear of the units. 114

115 Chapter : Communication Figure 58 - GENSYS 2.0 Core GENSYS 2.0 Core GENSYS 2.0 Core Note: The 120 Ω termination resistors must be activated using the micro switch on the rear of the units. The next figure shows the wiring for rental generators. Figure 59 - Mobile generator sets Note: Each GENSYS 2.0 Core is connected with its genset with 2x A40W6 and 1xA40W3. The 120 Ω termination resistors must be activated using the micro switch on the rear of the units CAN bus fault CAN bus communication is monitored by GENSYS 2.0 Core modules and compared to the GENSYS 2.0 Core parameters. GENSYS 2.0 Core continuously transmits data on the COM1 CAN bus so each GENSYS 2.0 Core can always know how many GENSYS 2.0 Core units are connected to the CAN bus and are switched on. The number of GENSYS 2.0 Core units should always be equal to the number of generators configured on the power plant settings of the GENSYS 2.0 Core (parameter E1147). In case of discrepancy between parameter E1147 and the number of GENSYS 2.0 Core units seen on the CAN bus, a CAN bus error is shown. This can also be the case if: Two or more GENSYS 2.0 Core units share the same generator number (parameter E1179). Termination resistors are not used correctly. CAN bus cable is not properly connected 115

116 Chapter : Communication This CAN error can only be RESET when the correct number of GENSYS 2.0 Core modules can be seen on the CAN bus. As with every error managed by GENSYS 2.0 Core, the consequence of this error can be set up with parameter E1259. E1259 = 0: no action E1259 = 1: generator electrical fault E1259 = 2: mains electrical fault E1259 = 3: alarm E1259 = 4: soft shut down E1259 = 5: hard shut down E1259 = 6: droop mode; generate an alarm (default setting) This fault only affects the working of a power plant with several GENSYS 2.0 Core units (E1147 > 1). If a remote start occurs on a GENSYS 2.0 Core set up to manage Deadbus situations (E1515 = 0) and a CAN bus fault has already been triggered, GENSYS 2.0 Core 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 Core will synchronize the generator before connecting to the bus bar. In Auto mode, if there is a remote start and a CAN bus fault, the GENSYS 2.0 Core starts and closes its breaker after a delay that depends on the generator number (E1179), but only if the dead Bus management is on (E1515 = 0) and there is no voltage on the bus bar. Otherwise it will try to synchronize with 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 power factor regulation. If the mains are not connected, both speed and voltage droop is applied. With generators paralleled and the bus CAN fault control variable (E1259) set to 6, the generators with GENSYS 2.0 Core are in speed droop and power factor regulation when paralleled with the mains. When not paralleled with mains they are in speed and voltage droop regulation. Note: If you need to disconnect a GENSYS 2.0 Core from the inter GENSYS 2.0 CAN bus, you must change the number of generators (parameter E1147) on all other GENSYS 2.0 Core units of the power plant. When the power plant is set to load/unload mode (Parameter E1258 set to "Hours run" or "Digital in"), all generators will start using droop mode if a CAN bus error occurs. 116

117 Chapter : Communication Broadcasting data between multiple GENSYS 2.0 Core units It is possible to send up to 10 digital variables and 2 analogue variables from one GENSYS 2.0 Core unit to all other GENSYS 2.0 Core units connected to the same inter GENSYS 2.0 CAN bus (COM 1). It is necessary to use a PC to create Broadcast Data by Inter GENSYS 2.0 CAN bus equations. Variables sent to other GENSYS 2.0 Core units are described in the table below: NOTE: When you assign a variable to broadcast data (ex: E2752:=...) remove the E from in front of the variable name: this is the number of the variable you assign, not the variable itself. Example to send digital input or analogue input to each GENSYS 2.0 Core: 2752:=2002 BEND Variables which are sent via "Broadcast Data by Inter GENSYS 2.0 CAN bus": Variable number Description E st digital variable sent over CAN bus COM1VarDigCAN01 E nd digital variable sent over CAN bus COM1VarDigCAN02 E rd digital variable sent over CAN bus COM1VarDigCAN03 E th digital variable sent over CAN bus COM1VarDigCAN04 E th digital variable sent over CAN bus COM1VarDigCAN05 E th digital variable sent over CAN bus COM1VarDigCAN06 E th digital variable sent over CAN bus COM1VarDigCAN07 E th digital variable sent over CAN bus COM1VarDigCAN08 E th digital variable sent over CAN bus COM1VarDigCAN09 E th digital variable sent over CAN bus COM1VarDigCAN10 E st analogue variable sent over CAN bus COM1VarAnaCAN01 E nd analogue variable sent over CAN bus COM1VarAnaCAN02 Table 33 - Broadcast variables sent over inter GENSYS 2.0 CAN bus You can select what should be sent on the CAN bus by using custom PLC equations. These equations contain the number of the variable/parameter to be sent: E27xx:= YYYY; With E27xx being one of the broadcast variables and YYYY being the number of the variable you want to send to the other GENSYS 2.0 Core. In the equation below, the broadcast variable E2752 is used to send the value of variable E2002 to all the other GENSYS 2.0 Core units connected on CAN bus COM1: E2752:=2002; 117

118 Chapter : Communication Broadcast variables received from other GENSYS 2.0 Family are listed in the table below: Variable number E0536 to E0545 E0546 to E0547 E0552 to E0561 E0562 to E0563 E0568 to E0577 E0578 to E0579 E0584 to E0593 E0594 to E0595 E0600 to E0609 E0610 to E0610 E0616 to E0625 E0626 to E0627 E0632 to E0641 E0642 to E0643 E0648 to E0657 E0658 to E0659 E0664 to E0673 E0674 to E0675 E0680 to E0689 E0690 to E0691 E0696 to E0705 E0706 to E0707 E0712 to E0721 E0722 to E0723 E0728 to E0737 E0738 to E0739 E0744 to E0753 E0754 to E0755 Description 1st to 10th Can bus extension digital input variables received from 1 to 10 GE01 1st and 2nd Can bus extension analogue variables received from GE01input 1 to 2 GE1 1st to 10th digital variables received from GE02Can bus extension digital inputs 1 to 10 GE2 1st and 2nd analogue variables received from GE02Can bus extension analogue inputs 1 to 2 GE2 1st to 10th digital variables received from GE03Can bus extension digital inputs 1 to 10 GE3 1st and 2nd analogue variables received from GE03Can bus extension analogue inputs 1 to 2 GE3 1st to 10th digital variables received from GE04Can bus extension digital inputs 1 to 10 GE4 1st and 2nd analogue variables received from GE04Can bus extension analogue inputs 1 to 2 GE4 1st to 10th digital variables received from GE05Can bus extension digital inputs 1 to 10 GE5 1st and 2nd analogue variables received from GE05Can bus extension analogue inputs 1 to 2 GE5 1st to 10th digital variables received from GE06Can bus extension digital inputs 1 to 10 GE6 1st and 2nd analogue variables received from GE06Can bus extension analogue inputs 1 to 2 GE6 1st to 10th digital variables received from GE07Can bus extension digital inputs 1 to 10 GE7 1st and 2nd analogue variables received from GE07Can bus extension analogue inputs 1 to 2 GE7 1st to 10th digital variables received from GE08Can bus extension digital inputs 1 to 10 GE8 1st and 2nd analogue variables received from GE08Can bus extension analogue inputs 1 to 2 GE8 1st to 10th digital variables received from GE09Can bus extension digital inputs 1 to 10 GE9 1st and 2nd analogue variables received from GE09Can bus extension analogue inputs 1 to 2 GE9 1st to 10th digital variables received from GE10Can bus extension digital inputs 1 to 10 GE10 1st and 2nd analogue variables received from GE10Can bus extension analogue inputs 1 to 2 GE10 1st to 10th digital variables received from GE11Can bus extension digital inputs 1 to 10 GE11 1st and 2nd analogue variables received from GE11Can bus extension analogue inputs 1 to 2 GE11 1st to 10th digital variables received from GE12Can bus extension digital inputs 1 to 10 GE12 1st and 2nd analogue variables received from GE12Can bus extension analogue inputs 1 to 2 GE12 1st to 10th digital variables received from GE13Can bus extension digital inputs 1 to 10 GE13 1st and 2nd analogue variables received from GE13Can bus extension analogue inputs 1 to 2 GE13 1st to 10th digital variables received from GE14Can bus extension digital inputs 1 to 10 GE14 1st and 2nd analogue variables received from GE14Can bus extension analogue inputs 1 to 2 GE14 Table 34 Broadcast variables received by BROADCAST DATA from inter GENSYS 2.0 Family CAN bus 1/ Example 1: broadcast analogue and digital data In this example, two GENSYS 2.0 Core units are connected together using CAN bus COM1. In this configuration there will be one GENSYS 2.0 Core (GENSYS 2.0 Core #1) which sends variables and the other GENSYS 2.0 Core (GENSYS 2.0 Core #2) which receive variables. Both of them will send two broadcast variables on CAN bus COM1, one being digital input J6, the other one being analogue value E0033 (engine speed). Each of the two values will be usable by both GENSYS units. One will be a digital value (input J6) and the other will be an analogue value. 118

119 Chapter : Communication Input J6 (E2006) J6 GENSYS 2.0 Core N 1 E2006 E0552 E2752 inter GENSYS 2.0 CAN bus Input J6 (E2006) GENSYS 2.0 Core J6 N 2 E2006 E2752 E0536 To other GENSYS 2.0 Core Slave Figure 60 - Connecting J6 to broadcast variables Magnetic pick-up (E0033) G7-8 GENSYS 2.0 Core N 1 E0033 E0562 E2762 inter GENSYS 2.0 CAN bus Magnetic pick-up (E0033) GENSYS 2.0 Core G7-8 N 2 E0033 E2762 E0546 To other GENSYS 2.0 Core Slave Figure 61 - Connecting Magnetic pick up for speed broadcast To send value from GENSYS 2.0 Core #1 to GENSYS 2.0 Core #2, write this equation: to send digital and/or analogue oil pressure and speed input variables to the other GENSYS 2.0 Core; E2752:=2006; E2762:=33 BEND 119

120 Chapter : Communication Digital input J6 from GENSYS 2.0 Core number 1 is sent on the CAN bus using the 1 st digital broadcast variable E2752, so it will be stored on variable E0536 of GENSYS 2.0 Core number 2. Engine speed E0033 from GENSYS 2.0 Core number 1 is sent on the CAN bus using the 1 st analogue broadcast variable E2762, so it will be stored on variable E0546 of GENSYS 2.0 Core number 2. On GENSYS 2.0 #2, these values can be read if the following variables are used: E0536 which is the value of the GENSYS 2.0 Core #1 J6 input (E2806). E0546 which is the value of the GENSYS 2.0 Core #1 engine speed input. The same equations should be written on GENSYS 2.0 Core number 2: Example to send digital and / or analogue oil pressure and speed variables to other GENSYS 2.0 Core units; E2752:=2006; E2762:=33 BEND Digital input J6 from GENSYS 2.0 Core number 2 is sent on the CAN bus using the 1 st digital broadcast variable E2752, so it will be stored on variable E0552 of GENSYS 2.0 number 1. Engine speed E0033 from GENSYS 2.0 Core number 2 is sent on the CAN bus using the 1 st analogue broadcast variable E2762, so it will be stored on variable E0562 of GENSYS 2.0 number 1. On GENSYS 2.0 Core #1, these values can be read if the following variables are used: E0552 which is the value of the GENSYS 2.0 Core #2 J6 input (E2806). E0562 which is the value of the GENSYS 2.0 Core #2 engine speed input (E0033). 2/ Example 2: application example In this example, which uses 3 GENSYS 2.0 Core units, a remote start signal connected to the J2 digital input (E2002) of one GENSYS 2.0 Core is broadcast to the other GENSYS 2.0 Core units of the power plant. Thus, only one remote start signal is needed. Equation written on GENSYS 2.0 Core start input is only connected to GENSYS 2.0 Core #1 and is sent to the other units via CAN bus (COM1);example to send digital input to the other GENSYS 2.0 Core units; X2752:=2002 BEND Equation written in all other GENSYS 2.0 Core units of the power to receive remote start digital input from GENSYS 2.0 Core #1; X2514:=E0536 BEND 120

121 Chapter : Communication The broadcast data is received in variable E0536 on all other GENSYS 2.0 Core units and then copied to variable E2514 (equation above). Important: Even if CAN bus inhibition is activated between GENSYS 2.0 Core units (see below), broadcast data is always sent and received on the inter GENSYS 2.0 CAN bus (COM1) CAN bus inhibition COM1 CAN bus is mainly used by GENSYS 2.0 Core modules to send power management data to each other. CAN bus inhibition is used to prevent one GENSYS 2.0 Core from taking into account data coming from one or more GENSYS 2.0 Core 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 E2691 to E2704 are used to decide with which modules the GENSYS 2.0 Core should communicate power management data. Variable E2691 E2692 E2693 E2694 E2695 E2696 E2697 E2698 E2699 E2700 E2701 E2702 E2703 E2704 Description Ignore power management data from GE01 Ignore power management data from GE02 Ignore power management data from GE03 Ignore power management data from GE04 Ignore power management data from GE05 Ignore power management data from GE06 Ignore power management data from GE07 Ignore power management data from GE08 Ignore power management data from GE09 Ignore power management data from GE10 Ignore power management data from GE11 Ignore power management data from GE12 Ignore power management data from GE13 Ignore power management data from GE14 Table 35 - CAN bus inhibition variables If one of these variables is set to one, power management data from the corresponding GENSYS 2.0 Core will not be taken into account. Note that broadcast data is 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 Core. The 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 Core units are connected together with a CAN bus on COM1. If it is necessary to split a complete plant with a tie breaker, for example in a security application, it is necessary to modify normal functioning: In normal functioning, the tie breaker is closed, each GENSYS 2.0 Core communicates with the others by CAN. When the tie breaker is open, all GENSYS 2.0 Core units need to know that they have to consider the power plant differently, with two separate bus bars. 121

122 Chapter : Communication To allow this, we will use CAN bus inhibition. Figure 62 - CAN bus inhibition schematic (example) When the tie breaker is closed, all four GENSYS 2.0 Core 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 Core unit (no CAN inhibition). When the tie breaker is open, generators DG1 and DG2 should communicate but ignore data from DG3 and DG4. In the same way, generators DG3 and DG4 should communicate but ignore data from DG1 and DG2. To do so, inhibition variables should be set as follows: E2693 and E2694 set to 1 on generators DG1 and DG2. E2691 and E2692 set to 1 on generators DG3 and DG4. Feedback from the tie breaker can be connected to a GENSYS 2.0 Core digital input and then used in custom PLC equations to set or reset these inhibition variables. 1/ How to set theses functions: Special variables can be used to inhibit CAN bus variable use. Each GENSYS 2.0 Core is able to ignore (inhibit) all the others, depending to the state of the inhibition can variable. Note that this does not affect BROADCAST DATA, but only genset related functions. The following table describes these variables. To take effect (inhibition active), the variable must be set at 1. Note: breaker. In the GENSYS 2.0 Core, control of inhibition is often associated with feedback from the Tie 122

123 Chapter : Communication Variable E2691 E2692 E2693 E2694 E2695 E2696 E2697 E2698 E2699 E2700 E2701 E2702 E2703 E2704 E2705 E2706 Genset inhibited Inhibition variable for GE 1 on CAN bus Inhibition variable for GE 2 on CAN bus Inhibition variable for GE 3 on CAN bus Inhibition variable for GE 4 on CAN bus Inhibition variable for GE 5 on CAN bus Inhibition variable for GE 6 on CAN bus Inhibition variable for GE 7 on CAN bus Inhibition variable for GE 8 on CAN bus Inhibition variable for GE 9 on CAN bus Inhibition variable for GE 10 on CAN bus Inhibition variable for GE 11 on CAN bus Inhibition variable for GE 12 on CAN bus Inhibition variable for GE 13 on CAN bus Inhibition variable for GE 14 on CAN bus Inhibition variable for GE 15 on CAN bus Inhibition variable for GE 16 on CAN bus Table 36 - CAN bus inhibition parameters 11.3 COM2: CAN protocols (CANopen, J1939, MTU MDEC): COM2 is a CAN bus communication port. It can be configured to communicate with external devices using three different CAN protocols: CANopen (factory setting): used to control remote I/O modules. J1939+CANopen: used to control J1939 electronic engines and remote I/O modules. MTU MDEC: MTU proprietary protocol to control MDEC electronic controller. To select the protocol you want to use on COM2, go on page Enhanced configuration / J1939/MDEC COM2 set as CANopen Industrial CANopen extension modules can be used to increase the number of digital/analogue inputs and outputs of GENSYS 2.0 Core. Figure 63 - 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 11.1 CAN bus good practices. Also refer to the CANopen extension module s user manual for correct wiring on the CANopen module side. 123

124 Chapter : Communication Modular remote I/O can also be added to GENSYS 2.0 Core using the CANOPEN protocol and DB9 connector. For the remote I/O wiring see the figure below. Figure 64 - CANopen coupler wiring CAN L must be connected to pin 2 of the DB9. CAN H must be connected to pin 7 of the DB9. CAN GND must be connected to pin 5 of the DB9. Drain must be connected to the shield of the DB9. An end resistor of 120 must be connected to each end of the cable between CANH and CANL. This resistor exists inside GENSYS 2.0 Core and can be activated with a switch accessible from the rear of the unit and located under the plug marked OFF / 120Ω. COM port is marked on the rear. You need to extract the plug 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 Core 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: The ID of the CANopen extension module (most modules use DIP switches to set their ID). The type of data contained in the message (analogue or digital). 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: 44 analogue inputs. 128 digital inputs. 32 analogue outputs. 64 digital outputs. To ensure proper communication between GENSYS 2.0 Core and CANopen extension modules, the following rules should be followed: 124

125 Chapter : Communication 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 numbers Description E0157 to E0284 CANopen digital inputs 1 to 128 E0285 to E0328 CANopen analogue inputs 1 to 44 E2368 to E2431 CANopen digital outputs 1 to 64 E2432 to E2439 CANopen analogue outputs 1 to 8 E2682 to E2689 CANopen analogue outputs 9 to 16 E2708 to E2723 CANopen analogue outputs 17 to 32 Table 37 - CANopen input and output variables The lower variable number is associated to the lower message number configured. The following example will help you understand the relationship between GENSYS 2.0 Core CANopen variables and physical CANopen I/Os. CANopen mapping example: In this example, 3 CANopen modules are connected to CAN bus COM2 of GENSYS 2.0 Core. All these modules offer different kinds of input. CANopen module Physical I/Os available in the module Configuration Messages as set in GENSYS 2.0 CANopen inputs menu Associated Variable number ID coupleur = 1 4 analog input 0-20mA 2 analog inputs PT100 Msg 1: ID = 1 ; type = Analog ; nb of inputs = 4 Msg 2: ID = 1 ; type = Analog ; nb of inputs = 2 E0285 E0286 E0287 E0288 E0289 E analog inputs Msg 3: ID = 1 ; type = Digital ; nb of inputs = 2 E0157 E0158 ID coupleur = 2 2 thermocouple analog input Msg 4: ID = 2 ; type = Analog ; nb of inputs = 2 E0291 E

126 Chapter : Communication CANopen module Physical I/Os available in the module Configuration Messages as set in GENSYS 2.0 CANopen inputs menu Associated Variable number 4 digital inputs Msg 5: ID = 2 ; type = Digital ; nb of inputs = 4 E0159 E0160 E0161 E0162 E0293 Msg 6: ID = 3 ; type = Analog ; nb of inputs = 4 E0294 E0295 E0296 ID coupleur = 3 10 thermocouple analog inputs Msg 7: ID = 3 ; type = Analog ; nb of inputs = 4 E0297 E0298 E0299 E0300 Msg 8: ID = 3 ; type = Analog ; nb of inputs = 2 E0301 E0302 Table 38 - CANopen configuration example COM2 as MDEC (MTU) on COM2 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 servicelife 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 CANopen remote I/O modules. 1/ MDEC configuration To correctly communicate with GENSYS 2.0 Core, MDEC internal variables have to be configured. The MDEC should be configured as follows to activate the CAN communication: 200 set to set to set to 201. For more information on MDEC configuration contact your MTU dealer. 126

127 Chapter : Communication 2/ GENSYS 2.0 Core configuration To activate the MTU CAN connection enter Enhanced configuration/ J1939/MDEC menu, and select MTU protocol. Download the custom language. MDEC has labels and codes or numbers which correspond to the MDEC variables: Z090210_2_vxxx.txt corresponds to the English version. Z090210_3_vxxx.txt corresponds to the French version. Note: v2.05 is the corresponding software version of your GENSYS 2.0 Core. 3/ MDEC GENSYS 2.0 Core wiring C h g C2 GENSYS 2.0 Core COM2 / 7 COM2 / 2 COM2 / 5 G9 G11 0V 0V X003 connector N M G F E AA q MDEC Label GENSYS 2.0 terminal MDEC X1 connector X003 connector Digital output to stop request and C1 h 25 emergency stop g to ground 26 to ground Digital output to start request C2 N 43 M 44 to ground CAN High COM 2 pin 7 G 49 CAN Low COM 2 pin 2 F 50 CAN ground COM 2 pin 5 E 51 Analogue speed command G9 AA 8 Analogue speed reference G11 q 36 Table 39 - MDEC connection 127

128 Chapter : Communication Useful GENSYS 2.0 Core parameters are listed below to ensure proper communication with the MDEC module: Variable Label Valu Description number e V1076 ESG amplitude 50.0 Speed output amplitude to have a trip frequency of +/-3Hz. V1077 ESG offset 0.00 Offset to obtain nominal frequency. V1156 Local language 3 Custom language selected for MDEC labels on the GENSYS 2.0 Core screen. V1311 PC language 3 Custom language selected for MDEC labels on your PC. V1710 User param Time to stop request on digital output C1 (1.0 sec. here) V1711 User param Nominal speed for MDEC through CAN bus. V1712 User param Delay (*100ms) before triggering an MTU CAN bus error. (30 seconds here). V1852 Branch P-oil 352 The Analogue oil pressure that comes from the MTU CAN bus will be used. (*) V1853 Branch T-water 400 The Analogue water temperature that comes from the MTU CAN bus will be used. (*) V1854 Branch Speed 331 The Speed measure that comes from the MTU CAN bus will be used. (*) V1855 Opt4 protocol 1 To choose the MTU MDEC CAN bus protocol on COM2. V1856 MTU CANbusNode 6 Each device on the MTU CAN bus has a node number. GENSYS 2.0 uses have the number 6. V1857 MTUPV Protection control for over speed from MDEC (E0332). (**) CT V1858 MTUPV CT 3 Protection control for combined alarm yellow from MDEC (E0339). (**) V1859 MTUPV CT 5 Protection control for combined alarm red from MDEC (E0343). (**) V1860 MTUPV CT 0 Protection control for low oil pressure from MDEC (E0355). (**) V1861 MTUPV CT 0 Protection control for very low oil pressure from MDEC (E0356). (**) V1862 MTUPV CT 0 Protection control for low fuel pressure from MDEC (E0358). (**) V1863 MTUPV CT 0 Protection control for very low fuel pressure from MDEC (E0359). (**) V1864 MTUPV CT 0 Protection control for low coolant level from MDEC (E0363). (**) V1865 MTUPV CT 0 Protection control for low coolant level, charge air, from MDEC (E0386). (**) V1866 MTUPV CT 0 Protection control for high coolant temperature from MDEC (E0403). (**) V1867 MTUPV CT 0 Protection control for very high coolant temperature from MDEC (E0404). (**) V1868 MTUPV CT 0 Protection control for high charge air temperature from MDEC (E0407). (**) V1869 MTUPV CT 0 Protection control for high oil temperature from MDEC (E0414). (**) V1870 MTUPV CT 0 Protection control for low charge air temperature from MDEC (E0422). (**) V1871 MTUPV CT 0 Protection control for low engine speed from MDEC (E0426). (**) Table 40 - Important parameters 128

129 Chapter : Communication (*) the standard sensors required for oil pressure, water temperature and engine speed don t need to be connected to GENSYS 2.0 Core. The value of these 3 analogue inputs (E0029, E0030, E0033) will be taken from the MTU CAN bus. (**) control can take the following values: 0: disable. 1: Generator electrical fault. 2: Mains electrical fault. 3: Alarm. 4: Fault (soft shut down). 5: Security (hard shut down). 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 Core). E2662 to E2677 as output variables (GENSYS 2.0 Core 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

130 Chapter : Communication 5/ Specific screens for MDEC dedicated pages: Engine monitoring can be done via the Display/\Engine meters menu: Variables from MDEC Figure 65 MDEC Screens 6/ Additional information In the standard configuration GENSYS 2.0 Core 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 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 Core COM5. 7/ 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. 130

131 Chapter : Communication If you want to use an MDEC alarm that is not handled directly by GENSYS 2.0 Core, you can use a virtual input as described in the following example: If an alarm from MDEC not managed with the standard program is required, you can use a virtual input. For example, if you want to handle an MDEC alarm for SS Power Reduction Active (E0338), you can use the virtual input 2 (E2284). In the Enhanced / Configuration\>>\Virtual input menu, set virtual input 2 with the function (E1329). Choose External alarm, and load the following equation in a text file: E2284:=E0338; You can also change the label of the virtual input to be displayed on screen when the alarm occurs. Figure 66 Virtual input screen 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 alarm sources are available and can be detected using MDEC fault code numbers. The MDEC fault code is read by GENSYS 2.0 Core and stored in MDEC (GENSYS 2.0 Core 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 J1939 Communication J1939 is a common CAN protocol used on modern electronic ECUs. To use J1939 communication on COM2, you must enter the Enhanced configuration / J1939/MDEC menu and select J1939 (2) protocol. Then select the type of engine in the list (E4034). 1=Scania 5= Standard 2=Volvo 6= Custom 3=Perkins 7= Cummins 4=Iveco 131

132 Chapter : Communication Then GENSYS 2.0 Core will be set for your engine communication automatically. The parameter E4034 allow you to delay the communication breakdown alarm J1939 ( E8051). If set to 0, no J1939 alarm occur. GENSYS 2.0 Core can communicate with most J1939 engines, even those not mentioned in this document. For those engines please contact CRE technology or your local distributor. Set the GENSYS 2.0 Core address by setting E1856 to 17(17 is the default setting) and setting the potential faults. Press SHIFT + I to save the configuration into the FLASH memory. Connect the engine CAN bus to COM2 with an A40W2 cable or equivalent (see note below). Switch the power supply OFF then ON again to reset the system. Note: connect: -CAN Hi to terminal 2 of GENSYS 2.0 Core COM2 connector. -CAN Lo to terminal 7 of GENSYS 2.0 Core COM2 connector. -GND to terminal 5 of GENSYS 2.0 Core COM2 connector. SHIELD must be connected to mechanical ground. Communication speed is 250 Kbits, non modifiable. 1/ J1939 fault Variable E2511 is used to detect a J1939 reception error. If E2511 equals 1, it means that no CAN frames have been received from the ECU for more than 2 seconds. This error is not latched and resets to 0 (zero) as soon as a new CAN frame is received. 2/ Engine Speed Variable E0330 contains the engine speed value read from J1939 (in RPM, from 0 to 8031). To use this J1939 speed value instead of the GENSYS 2.0 Core internal speed measurement, set E1854 variable to 330. To use GENSYS 2.0 Core internal speed measurement set E1854 to 33 (default value). 3/ Coolant temperature Variable E0333 contains coolant temperature value read from J1939 (in C, from -40 to +210). To use this J1939 coolant temperature value instead of the GENSYS 2.0 Core internal measurement, set variable E1853 to 333. To use GENSYS 2.0 Core internal temperature measurement set E1853 to 30 (default value). 4/ Oil pressure Variable E0331 contains oil pressure value read from J1939 (in Bars, from 0.00 to 10.00). To use this J1939 oil pressure value instead of the GENSYS 2.0 Core internal measurement, set variable E1852 to 331. To use GENSYS 2.0 Core internal oil pressure measurement set E1852 to 29 (default value). 132

133 Chapter : Communication 5/ Engine diagnostic status The GENSYS 2.0 Core 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 Core fault/alarm system. GENSYS 2.0 Core 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 Core 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. 6/ J1939 messages Each of the following J1939 messages/alarms can be configured to serve one of 8 internal GENSYS 2.0 Core protections (see 8 for full explanations): Value Behaviour 0 Disable 1 Generator electrical fault 2 Mains electrical fault 3 Alarm 4 Soft Shutdown 5 Hard Shutdown 7 Help + Fault (Soft shut down) 8 Help + Gen. Electrical fault Table 41 - J1939 message actions (protections) Red "lamp" This message is used to relay trouble code information that is of a severe enough condition that it warrants stopping the engine. Variable E0403 contains the "Red lamp" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Red lamp" message from the engine, variable E1866 must be set (hard Shutdown is the default value). Amber "lamp" This message is used to relay trouble code information that is reporting a problem with the engine system where the engine need not be immediately stopped. Variable E0386 contains the "Amber lamp" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Amber lamp" message from the engine, variable E1865 must be set (disabled is the default value). Protect "lamp" This message is used to relay trouble code 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. Variable E0363 contains the "Protect lamp" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Protect lamp" message from the engine, variable E1864 must be set (disabled is the default value). 133

134 Chapter : Communication Malfunction "lamp" A message used to relay only emissions-related trouble code information. This message is only illuminated when there is an emission-related trouble code active. Variable E0359 contains the "Malfunction lamp" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Malfunction lamp" message from the engine, variable E1863 must be set (disabled is the default value). Very high engine speed This message is used to relay that the engine speed is above the most severe high level threshold set for the engine. Variable E0358 contains the Very high engine speed value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the Very high engine speed" message from the engine, variable E1862 must be set (hard Shutdown is the default value). High engine speed This message is used to relay that the engine speed is above the least severe high level threshold set for the engine. Variable E0332 contains the "High engine speed" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "High engine speed" message from the engine, variable E1857 must be set (disabled is the default value). Very high coolant temperature This message is used to relay that the coolant temperature is above the most severe high level threshold set for the engine. Variable E0356 contains the "very high coolant temperature" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Very high coolant temperature" message from the engine, variable E1861 must be set (soft Shutdown is the default value). High coolant temperature This message is used to relay that the coolant temperature is above the least severe high level threshold set for the engine. Variable E0343 contains the "High coolant temperature" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "High coolant temperature" message from the engine, variable E1859 must be set (disabled is the default value). Very low oil pressure This message is used to relay that the oil pressure is below the most severe low level threshold set for the engine. Variable E0355 contains the "Very low oil pressure" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Very low oil pressure" message from the engine, variable E1860 must be set (Hard Shutdown is the default value). 134

135 Chapter : Communication Low oil pressure This message is used to relay that the oil pressure is below the least severe low level threshold set for the engine. Variable E0339 contains the "Low oil pressure" value read from J means Not Activated. 1 means Activated. To set the behaviour of the GENSYS 2.0 Core when receiving the "Low oil pressure " message from the engine, variable E1858 must be set (disabled is the default value). Note: All the parameters are available through Web pages in the Enhanced configuration/system/j1939 menu. 7/ Custom Frames Custom Rx 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 5 different frames you can set to fit your needs. The following variables are used to define those 5 custom Rx messages: E2675, E2676, E2677, E2678, and E2679 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 in variables E0410-E0417, E0420-E0427, E0430-E0437, E0440-E0447 and E0450-E0457. Custom RX frame Frame ID variable Frame Raw data variables 1 E2675 E0410 to E E2676 E0420 to E E2677 E0430 to E E2678 E0440 to E E2679 E0450 to E0457 Please refer to J1939/71 standards to find the frame ID that fits your needs. Note that there are no additional web pages to configure these custom RX frames. Please use custom PLC equations to access custom RX variables. The variables are only accessible by equations. Custom Tx Frame 135

136 Chapter : Communication If needed, a custom frame can be sent (every 25 or 50 ms) by the GENSYS 2.0 Core to the J1939 device. Refresh time depends on E1917 parameter as follows: 0 is 50ms refresh time rate. 1 is 25ms refresh time rate. The Variable E2662 defines the size of the frame (from 0 to 8 bytes). A value of -1 switches off custom TX frame transmission. The Variables E2663, E2664, E2665, E2666 define the ID of the frame to be send sent (E2663 being the least significant byte; E2666 is the most significant byte). The Variables E2667 to E2674 contain the raw data to be sent (E2667 contains data byte 1). Note that there are no additional web pages to configure the custom TX frame. Please use custom PLC equations to access custom TX variables. 8/ Specific engine notes VOLVO EMS2 This electronic control unit has no other means of control than J1939 CAN bus. Note: Do not use CIU module with GENSYS 2.0 Core. 120 ohms termination resistor is included on the rear panel of GENSYS 2.0 Core. GENSYS 7 2 A2 A N4007 J1939 High J1939 Low Batt Switched Emergency Stop EMS2 +V Batt 8 poles connector Figure 67 - Wiring diagram for Volvo EMS2 CUMMINS: Most of Cummins J1939 engines enables display of three values: Motor speed. Oil pressure. Temp ature of the water coolant. On engines QSX15-G8, GENSYS 2.0 Core can control the speed via the bus J1939( if the ECU Cummins has such a control frame). This is particularly the case of embedded software Cummins (N12013 Calibration ). Contact your Cummins distributor or CRE Technology for more information on the engines which can be driven by bus J1939. IVECO: Oil pressure value from Iveco engines is never sent by J1939 CAN bus. Additional sensor should be connected to GENSYS 2.0 Core to get an analogue measurement used in association with an analogue input program like VDO. 136

137 Chapter : Communication The Fuel relay is used to supply power to the control unit. A different Crank output sequence must be used because the crank signal command must be given after the control unit is powered up. GENSYS 2.0 Core output supply: The C1 output1 sends the crank signal 2 seconds after the normal Crank output. The following signals can be recovered from the control unit: Digital oil pressure. Analogue oil pressure. Digital water temperature COM3: USB This communication port is no longer used in GENSYS 2.0 Core firmware as from version 2.0. PC connection is now provided via the RJ45 Ethernet communication port COM4: ETHERNET The Ethernet port allows two communication protocols: HTTP for the visualization and configuration of GENSYS 2.0 Core PC. Modbus TCP control GENSYS 2.0 Core SCADA. To communicate through Modbus TCP, you need to set up the following data on GENSYS 2.0 Core: Modbus slave identifier (E1634) which can be set up in menu System/Serial port configuration. IP address of the GENSYS 2.0 Core which can be set up in menu System/Serial port configuration. Use Ethernet communication port 502 on your PLC or computer software (standard Modbus TCP port). For more details on the Ethernet configuration, see Chapter: navigation remotely via a PC (Ethernet connection). For more details about the Modbus functions supported, see Chapter COM5: MODBUS RTU on serial port RS485 All GENSYS 2.0 Core internal variables (Measurements, parameters, PLC outputs ) can be monitored remotely through an RS485 communication bus using a MODBUS RTU protocol, GENSYS 2.0 Core being a MODBUS slave. It is also possible to enter parameters into the GENSYS 2.0 Core. All digital and analogue input/output values and all other parameters which appear in the GENSYS 2.0 Core menus can be obtained by the serial port RS485, DB9 male COM4. Parameters (E1nnn) are in read only mode (factory setting) but can be individually switched to Read/Write mode using the embedded Web site. Measurements (E0nnn) are Read only, variables E2nnn are in Read/Write mode. Warning: 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 E1nnn 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 Core. Please refer to chapter 10 for more details on this Read/Write attribute. 137

138 Chapter : Communication MODBUS supported functions are: 03 Read holding registers. 04 Read input registers. 06 Preset single register. 16 Preset multiple registers. Note: MODBUS register addresses have an offset of +1 compared to variable numbers. This means that you should use address 1 (one) in a MODBUS request to get the value of GENSYS 2.0 Core variable E0000. MODBUS settings can be found in the System/Serial communication ports menu, where you can set: MODBUS slave address E1634 (valid MODBUS slave address is in the range 1 247). Communication speed (4800, 9600, bauds). Note: GENSYS 2.0 Core doesn t support broadcast requests (i.e. requests sent with ID address set to zero). Other serial port parameters are: 8 data bits No parity bit 1 stop bits COM5 pin out is as follows: Pin number Description 5 B signal 6 A signal 3, 4, 9 GROUND 1, 2, 7, 8 Not connected Table 42 - COM5 pin out Wiring on the serial port can be achieved using 2 wires (plus GROUND and SHIELD) in point to point mode (1 master and 1 slave) or in multi-drop mode (1 master and several slaves). The following figure shows the wiring between the GENSYS 2.0 Core and an RS485 modem. Figure 68 - GENSYS 2.0 Core GENSYS 2.0 Core GENSYS 2.0 Core (MODBUS) 138

139 Chapter : Communication The RTU address of the variables is the same as their number plus 1, converted into hexadecimal. For example, variable 2000 (Mains break in) has for RTU address 07D1h (2001). See the Z xls file to locate the variable number. Supported functions: 04 Analogue reading 03 Register reading 16 Preset multiple registers Example: Here are two MODBUS RTU frames (request from a remote device and answer from GENSYS 2.0). In this case GENSYS 2.0 Core slave address is 5, and the request is to read variables E0000, E0001 and E0002. The result is a function 04 request starting at address 1 (variable E000) and ending at address 3 (variable E0002). MODBUS Request: Fields Value (hex) Slave address 05 Function 04 MSB start address 00 LSB start address 01 MSB number of registers 00 LSB number of registers 03 CRC16 -- GENSYS 2.0 Core answers Response: Field Value (hex) Slave address 05 Function 04 Number of bytes 06 (3 registers * 2 bytes per register) 1st byte (MSB of 1st reg.) xx 2nd byte (LSB of 1st reg.) xx 3rd byte (MSB of 2nd reg.) xx 4th byte (LSB of 2nd reg.)xx 5th byte (MSB of 3rd reg.) xx 6th byte (LSB of 3rd reg.) xx CRC COM6: SD card GENSYS 2.0 Core is equipped with a SD card slot. This is used to save GENSYS 2.0 Core information on a regular basis using flash memory. Memory cards must be FAT16 format and no larger than 2Go. High capacity SDHC cards and FAT32 format are not compatible. 139

140 Chapter : Communication Backup 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 : 140

141 Chapter : Communication Variable E4041 allows you to choose the recording time in seconds. As soon as the SD card is inserted into the GENSYS 2.0 Core, 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. To avoid damaging information, only remove the SD card when the LED at the top right of the display (see below) is turned off. To view the archive, open the logger.csv file using Excel. Each line of recording is date marked. Select the first column (A) with saved values. Click on "Data", then "convert". Select "limited". Select Table, Comma and Semicolon. Click "Next". 141

142 Chapter : Communication The variables, values, dates and times are now laid out in columns. 142

143 Chapter : Troubleshooting 12 Troubleshooting GENSYS 2.0 Core displays a "sensor lost" fault at the time of start: Check voltage AC on terminal (B1 to B4). Check the speed increases until 1500 RPM If you don t have these values and engine stops: Increase the "sensor lost" timer (default value 4 sec.) You can increase this timer with variable E1458 in Configuration/Speed control setting. During starting, GENSYS 2.0 Core displays oil pressure fault or not ready: If you are in manual mode, you must push and hold start or GENSYS 2.0 Core will display this fault. If you are in automatic mode, check that your J4 input activates and deactivates correctly. Change the timing of security inhibitions at start-up. If you use an analogue input for the oil pressure, check Variable E1155: oil pressure threshold. GENSYS 2.0 Core is powered and LED blinks: Calibration lost, the GENSYS 2.0 Core must be returned to CRE Technology to be re-calibrated. GENSYS 2.0 Core displays a "GENSYS CAN Bus" fault: If the flaw appears during parameter backup, check the connection between GENSYS 2.0 Core units. Check the number of the set and number of sets is correct, this is in Power plant overview menu. Check the connection between GENSYS 2.0 Core. The fault appears when you backup the parameters GENSYS 2.0 Core 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. This fault can occur if the opening of the circuit breaker has not been controlled by the GENSYS 2.0 Core. See if another module is able to control the circuit breaker. The engine starts but runs above/ below Rated speed. Adjust ESG offset or trim speed pot This output (G9-G11) is used to interface with the speed governor. The main objective being to bias the speed/fuel rack for synchronizing, Load sharing, ramping Load on and off. This output only alters the Power (KW) it can be set by parameters E 1077 ESG Offset and E1076 ESG Amplitude (span). 143

144 Chapter : Troubleshooting 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. Thus the span to achieve the required span (± 2.5Hz) is ± 2.5 Volts, therefore the settings are E1076=25% and E1077=25%. If you start the engine with output connected the speed may not be at rated, if so adjust the speed to be back at rated. N.B. On some electronic engines the input may need configuring with the manufacturers software. In some case it may be turned off and may not respond. Only the engine manufacturer can tell you this information. Below describes how to set the gain and offset if you do not have previously tried settings. The ESG offset adjustment (E1077) is settable between -10V and +10V, and it s added to the external speed reference (G11) (see figure 47). The Speed ref (G11) doesn t need to be connected if there is no voltage reference available. Connect only the ref wire. Set the gain and offset.you need to know what the ref voltage is and the span For instance the ref voltage may be 5V and have a span of 2.3 to 2.7 volts, you are trying to achieve the centre of the voltage span (2.5V) using the setting of E1077 in percent. So 10volts =100%, thus 2.5 equals 25%. So set -25% in E1077. Next you need the span setting in E1076, again 2.3 = 23% and 2.7 =27%. You need 2% span therefore from the nominal (25%) so set E1076 at 2%. Start the generator, set rated speed. Stop generator. Connect the control wire. Start the generator. Measure the rated Frequency. If required adjust GENSYS 2.0 Core output voltage a small amount (E1077) thus adjusting the offset to get back to rated. Check the maximum range of speed in manual mode with [+] and [-]. This range must be near +/- 3Hz. When you power up the GENSYS 2.0 Core, the display does not work: Check the bootstrap button on the back of GENSYS 2.0 Core is off. Remove the power and change the position of the bootstrap. 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 0V. 144

145 Chapter : Menu overview 13 Menu overview 13.1 Menu introduction To have access to the menu you need to have an RDM 2.0 screen or a PC. 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. Level 1: will give access to all menus and level 1 equation. Level 2: will give access to all menus and level 2 equations. 3 main menus are available: Display will give information about the genset, 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 Core according to the needs of your plat. 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 Core system DISPLAY Menu This menu gives access to the following information: Generator electrical meter These meters are displayed in real time. Scrolling through this menu, you will display the following values: Phase to neutral voltage for each phase [E0000, E0001, E0002] Phase to phase voltage for each phase [E0003, E0004, E0005] Current for each phase [E0006, E0007, E0008] Active power for each phase [E0009, E0010, E0011] Reactive power for each phase [E0012, E0013, E0014] Power factor for each phase [E0015, E0016, E0017] Average active and reactive power, frequency and power factor [E0018, E0019, E0020, E0021] Active and reactive energy meters [E0025, E0026 / E0125, E0126] The "Global view" screen will display all parameters listed above on a single screen. This is particularly useful in pre-commissioning phase. 145

146 Chapter : Menu overview Generator global view Figure 69 Generator global view 1/ Generator phase to neutral voltages This screen displays the three phase to neutral voltage measurements. 2/ Generator phase to phase voltages This screen displays the three phase to phase voltage measurements. 3/ Generator currents This screen displays the three current measurements. 4/ Generator kw This screen displays the three kw measurements. 5/ Generator kvar This screen displays the three kvar measurements. 6/ Generator PF This screen displays the three power factor measurements. 7/ All generator parameters This screen displays all electrical parameters measurements. 8/ KW meter & kvar meter This screen displays KWh and kvarh calculation Mains / Bus bars electrical meters These meters are displayed in real time. Scrolling through this menu, you will display the following values: Phase to neutral voltage for each phase [E0793, E0794, E0795] Phase to phase voltage for each phase [E0796, E0797, E0798] Current for each phase [E0799, E0800, E0801] Active power for each phase [E0802, E0803, E0804] Reactive power for each phase [E0805, E0806, E0807] 146

147 Chapter : Menu overview Power factor for each phase [E0808, E0809, E0810] Active and reactive energy meters The "Global view" screen will display all parameters listed above on a single screen. This is particularly useful in pre-commissioning phase Mains / Bus bars Global view Figure 70 Mains/Busbars global view 1/ Bus/Mains phase neutral voltages This screen displays the three phase to neutral voltage measurements. 2/ Bus/Mains phase-phase voltages This screen displays the three phase to phase voltage measurements. 3/ Bus/Mains currents This screen displays the three current measurements. 4/ Bus/Mains kw This screen displays the three kw measurements. 5/ Bus/Mains kvar This screen displays the three kvar measurements. 6/ Bus/Mains PF This screen displays the three power factor measurements. 7/ All Bus/Mains parameters This screen displays all Bus/mains parameter measurements. 8/ Bus/Mains KW meter & kvar meter This screen displays kwh and kvarh measurements. 147

148 Chapter : Menu overview Synchronization This page will show: Synchroscope (phase difference) Differential frequency (bar graph) Differential voltage (bar graph). Synch check relay status (Phase difference, frequency difference, voltage difference, phase sequence) Phase Offset (shows the parameter [E1929] set for the phase angle shift). Figure 71 Synchroscope Power plant overview This menu will show the power plant parameters (parameters shared by different GENSYS units, for up to 14 generating sets): 1/ Generator 1 to 16 This screen will show the percentage of nominal active power supplied by each genset in real time; [E0042 to E0057] 2/ Generator 1 to 16 kvar This screen will show the percentage of nominal reactive power supplied by each genset in real time; [E0132 to E0147] 3/ Generator 1 to 16 - nominal kw This screen will show the nominal active power of each genset [E0073 to E0088] 4/ Generator 1 to 16 - nominal kvar This screen will show the nominal reactive power of each genset [E0089 to E0104] 5/ Generator 1 to 16 - state code This screen will show the machine status [E2071] of each genset 148

149 Chapter : Menu overview Data logging 5 pages will show the FIFO event data logger selected in the data logger configuration page. You can download the summary file with a computer connection. Configuration can be undertaken in: FIFO data logger. Data login archive can be delete in the menu System/ Date Time meter/. Data loggin reset Generator fuel control 1/ Speed/kW settings / control Whatever the configuration (internal or external speed controller, constant power production or peak shaving...) or the status of the genset (synchronizing, load sharing...) is, all parameters will be displayed. Depending on the configuration some will remain inactive. The percentage values are between and percent % correction is equal to an increase of + 3 Hz. Active speed [E2027]: speed set point of the internal governor. Is equal to the value entered in Configuration/speed control settings menu. Load pulse [E1074]: is equal to the value entered in Configuration /speed control settings menu. Speed droop [E1075]: is equal to the value entered in Configuration / speed control settings menu. Active P setpt [E2048]: Active power set point showed in kw Gen synchro [E2028]: shows the percentage of correction of synchronization signal GCR synchro [E2092]: shows the percentage of correction of external synchronization (with mains) kw // mains [E2029]: shows the percentage of correction of power control when running parallel to the mains. Load pulse [E2030]: shows the percentage of load pulse correction (anticipated impact of load). RPM droop [E2031]: droop correction signal. kw sharing [E2032]: shows the percentage of correction of active load sharing between gensets. +/- Hz manu [E2025]: shows the percentage of correction of manual speed control ([+] and [-] keys of the front panel) Speed signals [E2058]: sum of the speed correction signals. 2/ Speed/kW meters Engine speed [E0033]: current engine speed in rpm. Generator kw [E0018]: current active power Generator excitation control 1/ Excitation control settings Voltage setpoint [E2039]: Voltage signal to AVR (usually the set point of the AVR). PF // mains [E1110]: power factor set point when generator is paralleled with mains. Volt droop [E1105]: used when reactive load sharing is not done through the inter GENSYS CAN bus, in manual mode, and when there is a CAN bus fault. U=constant [E2033]: shows the percentage of correction sent to the AVR to keep voltage set point. Volt synchro [E2034]: shows the percentage of voltage synchronization correction signal sent to the AVR. PF control [E2035]: shows the percentage of correction sent to the AVR to keep power factor set point. kvar sharing [E2036]: shows the percentage of correction sent to the AVR for reactive load sharing. Volt droop [E2037]: shows the percentage of correction sent to the AVR for droop. Manual volt [E2038]: shows the percentage of correction sent to the AVR by manual control (shift+[+] and shift+[-] keys of the front panel). This value is equal to zero in auto and test modes. Excitation [E2040]: sum of the AVR correction signals. 149

150 Chapter : Menu overview 2/ Excitation meters These show the 3 phase voltages and genset kvar. [E0000, E0001, E0002, E0019] Engine meters On two different screens is the information related to the engine. All parameters have a bar graph display; whenever a threshold is reached, the bar graph will blink, both on the GENSYS 2.0 Core screen and on PC with browser. 1/ Engine meters (1/2) Figure 72 Engine meters Analogue resistive sensors: oil pressure [E0029], water temperature [E0030], battery voltage [E0040] and engine speed [E0033]. 2/ Engine meters (2/2) The two spare analogue resistive sensors: [E0031], [E0032] Total number of starts [E0041], Hours run and User meters 1 & 2 [E0027, E0065, E0066] Digital inputs/outputs 1/ Digital inputs This menu shows the status of the 5 dedicated and 10 configurable digital inputs connected on the "J" terminal, and the status of the emergency stop input. [E2000, E2001, E2002, E2003, E2004, E2005, E2006, E2007, E2008, E2009, E2010, E2011, E2012, E2013, E2014, E2015] The name of each input is displayed. Input active =1, Input inactive = 0. 2/ Relay outputs & Digital transistor output This menu shows the status of the 4 dedicated relay outputs (fuel, crank, genset and mains breakers) and the 5 configurable digital transistor outputs. [2016, E2017, E2018, E2019, E2020, E2021, E2022, 2023, E2024] Timers This menu shows the timer values running in real time. To change timer values, you should go to Configuration Menu. 150

151 Chapter : Menu overview Timers 1/3 Crank timer [E2060]: shows the time before crank relay is energized. Warm up timer [E2061]: shows the time genset has to wait to warm up before taking the load. Speed stab [E2062]: shows the time genset has to wait to allow engine speed stabilization before taking the load. Volt stab [E2063]: shows the time the genset has to wait to allow voltage stabilization of the engine before taking the load. Cooling timer [E2064]: shows the time the genset has to run without load before stopping the engine. Fail to stop [E2065]: shows the time of the current stop sequence. If engine does not stop when this timer expires, an alarm will appear. Stop rest time: [E2066] shows the time the engine has been waiting since being put at rest. Crank rest [E2067]: shows the time between crank attempts. Prelub timer [E2084]: shows the pre-lubrication time before cranking. Preglow timer [E2083]: shows the preheating time before cranking. TM exct restrt [E2256]: shows the time before giving the AVR a command to supply excitation after a generator electrical fault Timers 2/3 No O/C ma. br. [E2073]: shows the time GENSYS 2.0 Core must wait after a start before having any action on mains breaker. No O/C gen br. [E2074]: shows the time GENSYS 2.0 Core must wait after a start before having any action on genset breaker. Fail to synchr [E2075]: when synchronizing in auto mode, this timer defines the time to determine if synchronization has failed. Ramp up timer [E2081]: shows the time to take the load with a load ramp. Ramp dwn timer [E2082]: shows the time to lose the load with an unload ramp. Bef power down [E2239]: shows the time to stop other gensets when low load level is reached (see configuration / automatic load / unload) Bef power up [E2240]: shows the time to start other gensets when high load level is reached (see configuration / automatic load / unload) MA back timer [E2091]: In changeover configuration, shows the time to wait when mains returns Timers 3/3 This menu gives all user meters, 1 to 5, hours and days Serial number / Soft version This information screen will display the serial number of the GENSYS 2.0 Core you are currently using and its software version. This information is useful for firmware information CONFIGURATION Menu This menu will allow parameter configuration. The Basic configuration is accessible to everybody and must be configured for each application. The Enhanced configuration is accessible to confirmed engineers and gives access to advanced parameter configuration. 151

152 Chapter : Menu overview 13.4 Basic Configuration Menu Will give access to the following menus where parameters can be modified: Power plant overview 1/ Power plant Parameter [var. num.] Gen. number [E1179]: Nb of gen. [E1147]: Nb of Masters [E4006]: Mains paralel. [E1148]: only use if nb of gen. [1147] is 1 Mains regul. [E1153] only available with mains paralleling option only use if nb of gen. [E1147] is 1 ILS compatible [E1158] Synchro mode [E1177] Deadbus manag. [E1515] possible value ChangeOver/ 0 Fugitive/1 Permanent/2 No ch.over/3 Peak shav./1 Base load/2 comment Is the number given to this particular GENSYS 2.0 Core on the power plant. Is the total number of GENSYS 2.0 Core installed on the power plant. Is the total number of Masters (module for mains control) installed on the power plant. On mains failure, engine starts and takes the load by opening mains breaker and closing genset breaker with interlocking. On mains return, unload genset by opening genset breaker and closing mains breaker with interlocking, and stop engine. Only available with mains paralleling option Same as changeover mode but loading/unloading is made without black, with ramps after synchronization with mains. Only available with mains paralleling option after a start demand, GENSYS 2.0 Core will synchronize genset to mains and keep both breakers closed. GENSYS 2.0 Core must receive a start demand and will not manage mains breaker output. There will be no synchronization with the bus bar or the mains. GENSYS 2.0 Core will permanently vary genset power to maintain constant power supply from mains. GENSYS 2.0 Core will permanently maintain genset power. Yes/0 Load sharing will be done via analogue bus (pins G4 and G6). No/1 Load sharing will be done via inter GENSYS digital CAN bus (Com 2 port). Dynamic/0 Standard synchronization: will be carried out by adjusting engine speed and generator voltage. Static/1 Is to be selected if breakers are closed before engine starting and generator excitation. Yes/0 Dead bus management will be done via inter GENSYS digital CAN bus (Com 2 port). No/1 External logic controls dead bus management. Table 43 - Power plant configuration 152

153 Chapter : Menu overview 2/ Mains electrical fault Open breaker [E1846]: Open breaker: you select the breaker that will be opened upon a "Mains electrical fault". You can select the "Mains" breaker or the "Generator" breaker or "both". Start on fault [E1841]: Fault start: will allow the engine to start on a "Mains electrical fault". You can select "Yes" to start the engine or "No". Start delay [E1840]: is the delay between the "Mains electrical fault" and the engine start. It will delay a digital or virtual input. For an internal detection, this delay overrides the delay of the protection. No load delay [E1842]: No load delay (60.0): is the delay during which the engine runs without load, when the generator breaker is open. If the delay is 0, the generator will never stop. 3/ Generator electrical fault TM re-synch. [E1843]: is the delay before the generator tries to re-synchronize with Mains after a "Generator electrical fault". Nb re-synch. [E1844]: is the number of attempts to re-synchronize. In case of a generator electrical fault, the generator breaker is opened and the GENSYS 2.0 Core 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 Core tries to re-synchronize Gen/Mains electrical settings 1/ Mains/Bus This page describes the parameters used to configure the Mains or the bus bar voltage connected to the GENSYS 2.0 Core MA kw <-> 20mA[1020]: is the power measured by an external transducer delivering 20 ma (or 10V if a voltage output transducer is used) to the power input of GENSYS 2.0 Core (pins G1 and G3). MA 0kW setting [E1021]: is the current to the power input of GENSYS 2.0 Core (pins G1 and G3) delivered by an external transducer measuring 0 kw. Ex: a 4-20ma transducer is used. 20ma corresponds to 500KW --> E1020=500; E1021=4; MA PT ratio [E1016]: is the ratio of your voltage transformer on the mains/busbar side (E.g. 20 kv to 100 V: type in 200). MA back timer [E1085]: if genset is in Change Over configuration, this is the time GENSYS 2.0 Core will wait to ensure a stable mains return. Mains KW Meas.[E1464]: External: measurement of mains power by external power transducer (pins G1 and G3); Internal: calculation of mains power from the single phase measurement of GENSYS 2.0 Core. Ext kw measure[e1461]: choose 10V for voltage output external transducer, 20mA for current output external transducer. Mains voltage [E4008]: is the nominal Mains voltage (used for protection %). Mains freq. [E4009]: is the nominal Mains frequency (used for protection %) 2/ Generator This page describes the parameters used to configure the generator. Gen nominal kw [E1006]: is the nominal power of your genset. kw nominal 2 [E1607]: is a second nominal power for your genset, activated with logical input or 153

154 Chapter : Menu overview equations. Gen PT ratio [E1007]: is the ratio of your voltage transformers (E.g. 20 kv to 100 V: type in 200). Gen CT1 ratio [E1008]: is the ratio of your phase 1 current transformer (E.g. 100A to 5A: type in 20). Gen CT2 ratio [E1009]: is the ratio of your phase 2 current transformer. Gen CT3 ratio [E1010]: is the ratio of your phase 3 current transformer. Gen nom kvar [E1015]: is the nominal reactive power of your genset. kvar nominal 2[E1636]: is a second nominal reactive power for your genset, activated with logical input or equations Speed control settings 1/ Speed common settings Speed measure [E1078]: Magnetic recommended if a magnetic pickup can be wired to G7 and G8 pins of GENSYS 2.0 Core; otherwise, choose Alternator for speed measurement on generator frequency. Nb of teeth [E1106]: number of teeth on the fly wheel (necessary if "magnetic" has been chosen as speed measurement source). Pole pair nb [E1109]: number of pairs of poles on the generator (necessary if "alternator" has been chosen as speed measurement source). Load pulse [E1074]: is the percentage of correction sent to speed governing system to anticipate a sudden load demand and prevent a decreasing speed in island mode or a too slow kw variation. Speed droop [E1075]: droop of the internal speed controller. Idle speed [E1079]: engine idle speed of the internal speed controller; this should be set to speed 1 value if the internal speed controller option is not used. If this feature is used, the engine will accelerate from crank disconnect value to idle speed; then the speed will increase, following a ramp from idle speed to nominal speed during the time set in "speed ramp up". Speed 1 [E1080]: first (default) speed set point Speed 2 [E1081]: second speed set point (if required for PLC programming or use with digital input). TM sensor lost [E1458]: time after which GENSYS 2.0 Core will trigger a "sensor lost" security fault if no signal is read from speed measurement input. 2/ External speed governor ESG amplitude [E1076]: to be set between -100 % for +10V to -10V output to external speed controller, and 100 % for -10V to +10V output. This value must be set to have a GENSYS 2.0 Core control speed deviation of +/- 3Hz on the engine. You can test it in Manual mode, by pressing [+] or [-]. To apply the maximum correction signal to the output, you must press as long as the variable E2058 equals +/ ESG offset [E1077]: voltage on output to external speed controller without correction: between -100 % for -10V and +100% for +10V. The offset E1077 sets the voltage output of SpeedOut G11 when the GENSYS 2.0 Core applies no correction. You can find pre calibration tips in the application note (Z pdf). However, these settings have to be adjusted during commissioning to match the physical requirements of your genset. 3/ Super Droop settings In this mode the load sharing is managed between Droop Max frequency [E1972] (0% load) and the Droop Min Frequency [E1973] (100% load). The Speed droop [E1075] (droop of the internal speed controller is always active and added to the Super Droop). Factory setting for GPID should work for most power plants. Take care before modification. 154

155 Chapter : Menu overview Figure 73 GPID factory setting Excitation control settings 1/ AVR control Volt droop [E1105]: is the droop sent to AVR if reactive load sharing is undertaken with droop (if not using inter GENSYS 2.0 CAN bus or in manual mode). Volt setpoint1 [E1107]: first (default) voltage set point. Volt setpoint2 [E1108]: second voltage set point (if required for PLC programming or use with digital input). cos(φ)setpoint [E1110]: power factor set point when running parallel to the mains. AVR gain [E1103]: to be set between 0 and 255 to set the AVR trip. AVR offset [E1104]: output voltage to AVR, to be set between 0 and 255. You can find pre calibration tips in the corresponding chapter. However, these settings have to be adjusted while commissioning to match the physical requirements of your genset. Manual colt [E2038]: shows the percentage of correction sent to the AVR after manual modification of voltage (shift+[+] and shift+[-] keys on the front panel); this value equals zero in auto and test modes. Generator V1 [E0000]: is the voltage measurement between neutral and phase 1. 2/ cos(φ) PID This screen lets you adjust the PID settings of the power factor control when parallel to the mains: G= overall gain [E1119](multiplies the sum of the following settings), P= proportional gain [E1120], I= integral [E1121], D= derivative [E1122]. Figure 74 Cos phi PID While you adjust the PID settings of the power factor control, the following parameters are displayed: Generator active and reactive power (P and Q), engine speed, pf set point, pf phase 1, 2 and 3, global pf. 155

156 Chapter : Menu overview 3/ kvar shar. gain When reactive load sharing is active: set the gain (G) for kvar sharing [E1123]. Figure 75 kvar shar. gain While you adjust the PID settings of reactive power control, the following parameters are displayed: Generator active and reactive power (P and Q), engine speed, generator Voltage (phase 1), reactive power set point, 3 phase reactive load Protections For each of the following protections, you can set a level LV, a timer TM, and an Action CT. The action CT will be activated if the Level LV is reached after the timer TM. Please refer to the protection configuration page or the table bellow for more details. 1/ Generator Protections On the generator side, the following protections are available: Protection function [Level, Timer, Function] Gen. under freq. protection [E1025,E1026,E1027] Gen. over freq protection[e1022,e1023,e1024] Gen. under volt protection [E1028,E1029,E1030] Gen. over volt protection[e1031,e1032,e1033] Gen. mini kvar protection[e1034,e1035,e1036] Gen. maxi kvar protection[e1037,e1038,e1039] Gen. reverse kw protection[e1040,e1041,e1042] Gen. reverse kvar protection[e1043,e1044,e1045] Generator mini kw protection[e1046,e1047,e1048] Generator maxi kw protection[e1049,e1050,e1051] Gen. max current protection[e1052,e1053,e1054] Gen. max neutral I protection[e1055,e1056,e1057] 156

157 Chapter : Menu overview 2/ Mains Protections On the Mains side, the following protections are available: Protection function [Level, Timer, Function] Gen. under freq. protection [E1058,E1059,E1060] Gen. over freq protection[e1061,e1062,e1063] Gen. under volt protection [E1064,E1065,E1066] Gen. over volt protection[e1067,e1068,e1069] 3/ Engine / battery Protections Miscellaneous protections: Under speed protection [E1163,E1164,E1165] Over speed protection[e1160,e1161,e1162] Min. oil pressure protection [E1166,E1167,E1168] Max. water temp. protection [E1169,E1170,E1171] Engine measure 1 protection [E1180,E1181,E1182] Engine measure 2 protection [E1184,E1185,E1186] Battery min voltage [E1172,E1173,E1174] Battery max voltage [E1086,E1095,E1098] Thresholds of measures 1 to 4: Oil threshold [E1175] Oil hysteresis [E1176] Water temp. threshold [E1426] Water temp. hysteresis [E1427] Measure 1 threshold [E1428] Measure 1 hysteresis [E1429] Measure 2 threshold [E1430] Measure 2 hysteresis [E1431] 13.5 Enhanced Configuration Menu Will give access to the following menus where parameters can be modified: Power plant overview Same menu as «Basic configuration» Start / Stop sequence 1/ Timers This page describes the parameters used to set the start sequence of the engine Prelub time [E1145]: is the time GENSYS 2.0 Core will energize a prelube output for a lubrication pump before cranking. Preglow time [E1157]: is the time GENSYS 2.0 Core will energize a preglow output for preheat plugs before cranking. Crank time [E1135]: is the maximum time for which the crank relay is energized during a start attempt. 157

158 Chapter : Menu overview Crank RestTime [E1136]: is the time GENSYS 2.0 Core will wait between two cranking attempts. Warm up time [E1139]: is the time the genset will wait before taking the load to allow the engine to warm up. RPM stab. time [E1140]: when genset is started, this is the time GENSYS 2.0 Core will wait before triggering an alarm because of an unstable speed. Volt stab time [E1141]: when genset is started, this is the time GENSYS 2.0 Core will wait before triggering an alarm because of an unstable voltage. Safety ON time [E1514]: is the time during which GENSYS 2.0 Core will not activate protections (e.g. oil pressure, under-speed...) when starting the engine. Cooling time [E1142]: is the time the engine will run without load before stopping. Rest time [E1144]: is the minimum time the engine will wait before re-starting after being put at rest. Eng. Stop time [E1143]: is the time after which the engine is considered to be not stopped. RemStart delay [E1190]: is the remote start latency time. Figure 76 Timers 2/ Crank settings Start attempts [E1134]: is the minimum number of start attempts. Nb. Of starter [E1138]: is the minimum time the engine will wait before re-start after being put at rest. Cra.1 drop out [E1325]: is the speed (RPM) above which the engine is considered to be started for crank 1. Cra.2 drop out [E1326]: is the speed (RPM) above which the engine is considered to be started for crank 2. Cra.3 drop out [E1327]: is the speed (RPM) above which the engine is considered to be started for crank 3. 3/ Checks before starting Water temp. [E1154]: Pre-heat is activated if J6 is closed and if temperature is under the preset threshold (E0030 < E1154). Oil prelub [E1155]: Pre-lubrication will be activated when engine state is pre-start (E2057 = 1) and if pressure is under the threshold (E0029 < E1155). If the threshold (E1155) is 0, then pre-lubrication is active while the engine state is pre-start (E2057 = 1). In this last case, an oil pressure sensor isn t required. Max time [E1146]: is the longest acceptable delay for engine start. Cooling thresh [E1178]: AIR FAN is activated when temperature is over the preset threshold (E1178) and deactivated when water temperature is lower than 80% of the threshold. AIR FAN is not active when engine is stopped (E2057=0) Gen/Mains electrical settings Same as "Basic configuration/gen/mains electrical settings" menu. 158

159 Chapter : Menu overview Protections Same as "Basic configuration/protections" menu Breaker settings This menu is used for breaker configuration. Each of the 2 breakers (Generator and Mains) can be configured with 5 different values from table below: 0 = open contact close pulse 1 = open contact close contact 2 = open MXcoil close pulse 3 = open MXcoil close pulse 4 = open pulse close pulse 5 = open pulse close contact Table 44 - Breaker settings Mains brk ctrl [E1992]: This is the mains breaker control. Gen brk ctrl [E1993]: This is the generator breaker control. It is also possible to change the pulse timer: UV coil rst TM [E1994]: Timer for the negative impulsion of the low voltage coil. UV coil pre TM [E1995]: Safety timer for the low voltage coil Speed control settings Same as "Basic configuration/ Speed control settings" menu Excitation control settings Same as "Basic configuration/excitation control settings" menu Active power regulation 1/ Generator kw settings Gen low lim [E1091]: is the lower power limit of the genset; enter a value (in kw) that will prevent reverse power protection triggering. Gen high lim [E1092]: is the upper power limit of the genset; enter a value (in kw). Ge kwsetpoint1[e1093]: is the genset kw set point in constant production mode. Ge kwsetpoint2[e1094]: is a second genset kw set point in constant production mode. Can be used in association with digital inputs. Optional. Load ramp [E1151]: time to ramp up from lower limit to required power output. Unload ramp [E1152]: time to ramp down from required power output to lower power limit. 159

160 Chapter : Menu overview 2/ Mains kw settings (only available with mains paralleling option) MA kwsetpoint1[e1096]: is the mains power set point in peak shaving mode. MA kwsetpoint2[e1097]: is a second mains kw set point in peak shaving mode. Optional. 3/ kw sharing GPI When genset is sharing the load with other gensets: G= overall gain (multiplies the sum of the following settings)[e1102], P= proportional gain,[e1900] I= integral [E1901]. The Global Gain for the central Frequency is [E1902]. The right hand side of the table only displays values that allow easy setting. Figure 77 - kw sharing GPI P= Constant (Gen//mains), (only available with mains paralleling option) This screen lets you adjust the Proportional and Integral power management settings when a single genset is running parallel to the mains: G= overall gain (multiplies the sum of the following settings[e1099]), P= proportional gain[e1100], I= integral[e1101]. Figure 78 P=const PI While you adjust the PID settings of active power control, the following parameters are displayed: Generator active and reactive power (P and Q), engine speed, generator Voltage (phase 1), frequency, sum of the speed signals (in %). 160

161 Chapter : Menu overview Synchronization 1/ Synch check relay Voltage match [E1127]: is the maximum difference (in percent) between genset and busbar voltage that allows the synch check relay to operate. Freq. match [E1128]: is the maximum frequency difference between genset and busbar that allows the synch check relay to operate. Phase match [E1129]: is the maximum phase angle difference allowed between genset and busbar for the sync check relay to operate. Min volt [E1432]: is the minimal percentage of nominal voltage on both sides of the breaker to allow sync check relay to operate. Max volt [E1433]: is the maximal percentage of nominal voltage allowed on both sides of the breaker for the sync check relay to operate. Min frequency [E1434]: is the minimal percentage of nominal frequency allowed on both sides of the breaker for the sync check relay to operate. Max frequency [E1435]: is the maximal percentage of nominal frequency allowed on both sides of the breaker for the sync check relay to operate. Fail to synchr[e1150]: this timer will trigger a fail to synchronize protection if genset has not synchronized within the time you enter. CT Fail synchr[e1928]: this selects the course of action in case of impossible synchronization; Please refer to the protection configuration for details 2/ Voltage synchronization PID This screen lets you adjust the PID settings of the output to AVR: G= overall gain (multiplies the sum of the following settings) [E1130], P= proportional gain[e1131], I= integral[e1132], D= derivative[e1133]. Figure 79 Synchro volt PID While you adjust the PID settings, the following parameters are displayed: Generator active and reactive power (P and Q), frequency, generator phase to phase Voltages (U 12, U 23, U 31 ), Bus phase to phase voltage (U 13 ), Bus frequency. 3/ Synchroscope for frequency and phase PID settings This screen lets you adjust the PID settings for faster frequency and phase matching: Frequency PID G= overall gain (multiplies the sum of the following settings [E1111]), P= proportional gain [E1112], I= integral [E1113], D= derivative [E1114]. 161

162 Chapter : Menu overview Phase PID G= overall gain (multiplies the sum of the following settings)[e1307], P= proportional gain[e1308], I= integral[e1309], D= derivative [E1310]. Figure 80 Synchroscope frequency & phase PID The internal GENSYS 2.0 Core synchroscope is displayed and lets you monitor in real time the changes you make on these parameters Digital outputs Outputs 1 to 5: [E1260, E1261, E1262, E1262, E1264], function and polarity have to be defined. The relays "Crank" and "Fuel" can be set for other functions. See 3 below. 1/ Possible output functions: Detailed list of useable output functions is given in chapter / Polarity: For each of the five outputs, two options are possible: NE: normally energised; the output will de-energize when required, depending on its function. ND: normally de-energized; the output will energize when required. 3/ Fuel Crank Special functions: The relays "Crank" and "Fuel" can be set for other functions. The initial settings are for Crank and Fuel. Polarity cannot be changed on these relay outputs. Crank output function is settable with [E1989]; Fuel output function settable with [E1916]. For Fuel: If E1916= "Unused" the initial settings apply, with E2019 to the A2output (fuel). Other functions for this output can be selected in the list. For Crank: If E1989= "Unused" the initial settings apply, with E2018 to the A1output (crank). Other functions for this output can be selected in the list Virtual digital 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 (CAN Open linked) inputs. For virtual digital inputs 1 to 40: label, validity, direction, and function have to be defined. Variable numbers: [E2283 to E2302 and E2565 to E2584] 162

163 Chapter : Menu overview 1/ Label: The name you give to the virtual input. This will be displayed in the info, alarm, and fault screens if so programmed. 2/ Validity: Virtual input validity variable numbers: [E1348 to E1357 / E1388 to E1397 / E1640 to E1659] can be set as: Never [E2329]: never active: should be selected if you do not use the input. Always [E2330]: always active: input will be monitored as long as GENSYS 2.0 Core has power supply. Post-Starting [E2192]: the input will be monitored at the end of the "safety on" timer. Stabilized [E2331]: The input will be monitored when genset frequency and voltage are stable. Spare scenario: [E2332]: input will be monitored as programmed in equations. 3/ Direction: Virtual input direction variable numbers: [E1358 to E1367 / E1398 to E1407 / E1659 to E1679]. Can be set as: NO [0]: normally open; should be selected unless the input is used for protection. NC [1]: normally closed. This should be selected if the input is normally connected to 0V and opens when active. 4/ Accuracy This parameter sets accuracy (number of digits after decimal point). Possible values are: / Functions: Virtual input function variable numbers: [E1328 to E1337 / E1368 to E1377 / E1680 to E1699] can be set as described in chapter Note that both virtual and real inputs use the same functions Digital inputs They are split into dedicated and configurable inputs. For Digital inputs 1 to 10 [E2006, E2007, E2008, E2009, E2010, E2011, E2012, E2013, E2014, E2015]: label, validity, direction and function have to be defined, as for dedicated inputs. Polarity must also be defined on input variable numbers: [E2000, E2001, E2002, E2003, E2004]. 1/ Configurable input labels: It is the name you give to the input, and will be displayed in the info, alarm, and fault screens if so programmed. 2/ Validity Input validity variable numbers: [E1287 to E1296] can be set as: Never: [E2329]: never active: should be selected if you do not use the input. Always: [E2330]: always active: input will be monitored as long as GENSYS 2.0 Core has power supply. Post-Starting: [E2192]: input will be monitored at the end of the "safety on" timer. 163

164 Chapter : Menu overview Stabilized: [E2331]: the input will be monitored when genset frequency and voltage are stable. Spare scenario: [E2332]: input will be monitored as programmed in equations. 3/ Direction: Input direction variable numbers: [E1297 to E1306]. For each of the ten inputs, two options are possible: NO [0]: normally open; should be selected unless the input is used for protection. NC [1]: normally closed. This should be selected if the input is normally connected to 0V and is open when active. 4/ Delays: Delays for input variable numbers are: [E1277 to E1286 ] 5/ Possible functions: Input function variable numbers: [E1267 to E1286] can be set as described in chapter Note that virtual and real inputs use the same functions. 6/ Dedicated inputs In the menu list each input is named after its pin number on the wiring of GENSYS 2.0 Core. Polarity can be normally open or normally closed. Program this according to the wiring you will have on site. As a reminder: J1 is Mains breaker position, J2 is Genset breaker position, J3 is remote start input, J4 is oil pressure switch and J5 is coolant temperature switch. [E2000, E2001, E2002, E2003, E2004] Configuration of analogue inputs 1/ 1/ Units Oil pressure measure (O. P. Input) unit should be chosen between mbar, kpa, PSI. Water temperature measure (W. T. Input) unit should be chosen between C, F. Spare Analogue measures 1 and 2: you should give them a name, and decide which unit shall be displayed 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. 2/ 2/ Calibration A/ Ohms sensor calibration: 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 calibration table. Oil Temperature calibration points are [E1188 to E1198], which correspond to 0 to 400 Ohms Water Temp. calibration points are [E1199 to E1209], which correspond to 0 to 400 Ohms. B/ Engine measurements 1 and 2: Spare engine measure 1 calibration points are [E1210 to E1220]. Spare engine measure 1 impedance points are [E1188 to E1198]. Spare engine measure 2 calibration points are [E1232 to E1242]. Spare engine measure 2 impedance points are [ E1199 to E1209]. 164

165 Chapter : Menu overview For each of the two spare sensors, please indicate on the right hand side (min and max boxes) the operating range of each of your sensors; then, give the value to be displayed for each tenth of difference between min and max values. 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. You can find a calibration graph for different sensors in application note Z pdf CANopen 1/ Input message configuration Input messages 1 to 13: For each message transmitted from the external block to GENSYS 2.0 Core, please specify: mod_id_inx: For message number X (1 to 13), the ID number of the remote inputs module. [E1518 to E1530] type_in_messx: For message number X (1 to 13), whether the inputs are "digital" [1]or "analogue"[2] if not used, choose "Unused"[0]. [E1531 to E1543] nb_in_messx: For message number X (1 to 13), the number of inputs received from the remote inputs module. [E1544 to E1556] 2/ Output message configuration Output messages 1 to 19. For each message transmitted from GENSYS 2.0 Core to the external block, please specify: mod_id_out_x: For message number X (1 to 19), the ID number of remote outputs module. [E1557 to E1569] & [E1875 to E1880] type_out_messx: For message number X (1 to 19), whether the outputs are "digital" or "analogue"; if not used, choose "Unused".[E1570 to E1582] & [E1881 to E1886] nb_out_messx: for message number X (1 to 19), the number of outputs sent to the remote outputs module.[e1583 to E1596] & [E1887 to E1892] 3/ Launch modules configuration Launch modules configuration *E1603+: this is not really a menu, but a GO BUTTON. This variable is always set to NO by default. When you force it to YES, GENSYS 2.0 Core restarts configuration of all external CANopen modules. Afterwards, GENSYS 2.0 Core resets to NO. It is good practice to use this after a CANopen configuration modification. 165

166 Chapter : Menu overview Modification by variable number 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. Please refer to GENSYS 2.0 Core technical documentation for list of parameter or variable numbers. Note: You can only change the parameters (settings), from E1006 to E1999. Some of these settings are not accessible from other menus. The second field in this page allows you to 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. Figure 81 Modification by variable number Special functions Will give access to the following menus where parameters can be modified: 1/ Automatic load/unload 2/ Heavy consumer control 3/ Non essential consumer trip 4/ Phase Offset Refer to corresponding Chapters Inhibit variables In these pages you can change the Inhibit variables value. 1/ Inhibit variables 1/2 Inhibit variable 1: [E1608] = Auto start sequence. This is used when the engine has got is own automatic start module. The start sequence is redundant in the system. Inhibit variable 2: [E1609] = BV Option This option is used for Marine Bureau VERITAS applications. Inhibit variable 3: [E1610] = Custom option Used to set mains meter / used for G59 setting. Inhibit variable 4: [E1611] = I/O swapped on COM 2. COM 2 is the standard port for transmission, the inhibit variable switches transmission to COM 1. Inhibit variable 5: [E1612] =Inhibition E2071 Used to inhibit E2071 (Machine status): No Power management. Inhibit variable 6: [E1613] =Front face without keys and LEDs. 166

167 Chapter : Menu overview Inhibits LEDs and keys of the lower part of the front panel. Inhibit variable 7: [E1614] = IMTECH option. Activates the SEMI AUTO mode instead of the TEST mode. Inhibit variable 8: [E1615] = Modification for SEDNI application. Specific application for SEDNI (Spain). Inhibit variable 9: [E1616] = InterGENSYS CAN on COM3 (Can2). Inhibit variable 10: [E1617] =Number of priority with "custom" load/unload sequence (E1258=3) Used to set the priority number for load/unload application. (E1258=3) 2/ Inhibit variables 2/2 Inhibit variable 11: [E1618] = Synchronization for low response time engine. Frequency synchronization window is set at 0.1 Hz instead of 1 HZ (before activating the phase synchronization). Inhibit variable 12: [E1619] = KVAR auto start and stop. Used to set the Stop/start request with Kvar and Kw threshold, instead of Kw only. Inhibit variable 13: [E1620] = Operator controlled return of mains (+ E2584). With E1620=1, when the mains voltage returns, GENSYS 2.0 Core waits for a command (E2584=1) before re-synchronizing (Engine to mains). Inhibit variable 14: [E1621] =NOT USED YET Inhibit variable 15: [E1622] =NOT USED YET Inhibit variable 16: [E1623] =NOT USED YET Inhibit variable 17: [E1624] =NOT USED YET Inhibit variable 18: [E1625] =NOT USED YET Inhibit variable 19: [E1626] =NOT USED YET Inhibit variable 20: [E1627] =NOT USED YET Maintenance cycles This page is for the selection for maintenance cycles, on hour or in days. 5 hour cycles and 5 day counters are available. Label: Name of the alarm displayed when the counter matches the cycle time. Cycle time: [E1442 to E1451]. Number of hours or days for the timer. When these parameters are different from zero, the variables E2304 to E2313 are automatically incremented (in hours / days in) and saved on memory. When the variable E23nn is greater or equal to the variable E14nn, an alarm is set on. Meter: [E2304 to E2313]. Counter which starts after selecting the corresponding "cycle time". Reset: When pressed, resets the corresponding counter Fifo data logger Log on/off: [E1988] is set to "On" to enable the data logger. Log Var 1 to Log Var 10: Set here the variable value you want to watch. When set to "-1" the Log Var is disabled. These values are displayed in the Data logging display page. 167

168 Chapter : Menu overview J1939/MDEC 1/ CAN Protocol Com2 protocol: [E1855]: Select 0 for CANopen protocol, 1 for MTU MDEC engine, and 2 for CANopen + J1939 communication engine. J1939 Engine selection: [E4034]: select the J1939 Engine you want in the list. 1=Scania 2=Volvo 3=Perkins 4=Iveco 5= Standard 6= Custom 7= Cummins This automatically sets the internal configuration of the GENSYS 2.0 Core for the requested engine type. Contact CRE technical support for more information on GENSYS 2.0 Core J1939 communication and other J1939 engine types available. 2/ Configuration Depending on the CAN protocol selected, the navigation arrow selects the correct configuration page: 3/ J1939 J1939 Address [E1856]: this is the address of the GENSYS 2.0 Core unit on the J1939 bus. Engine Speed [E1854] Coolant temp [E1853] Oil Pressure [E1852] Select the associated function for each protection displayed. If you chose an engine in the previous list some values are automatically set and you cannot modify them. If you want to modify all values please select "none": E4034=0. For more details please contact CRE support. 4/ MTU This menu is used to choose actions for each of the MTU protocol parameters. Select the associated function for each protection displayed. CT speed [E1857] CT Oil Pres [E1858] CT Cool Temp + [E1859] CT Oil Pres [E1860] CT Cool Temp++ [E1861] CT speed ++ [E1862] CT Malfunction [E1863] CT Protection [E1864] CT Orange [E1865] CT Red [E1866] 168

169 Chapter : Menu overview Opt4Param12 [E1867] Opt4Param13 [E1868] Opt4Param14 [E1869] Opt4Param15 [E1870] Opt4Param16 [E1871] 13.6 SYSTEM Menu This will give access to the following menus which display system parameters; some of them can be modified: Date / Time / Meters 1/ Date / Time Here you can choose Date format (dd/mm/year or mm/dd/year) and set Date and Time. 2/ Meters reset You can reset the meters using the software on your PC or via the front panel by selecting "reset". The following meters are set to zero: Gen. kw sum [E0025]; Gen. kvar sum [E0125]; Mains kw sum [E0061]; Mains kvar sum[e0063]; Hours run [E0065]; Nb of starts [E0027]; User meter 1 [E2657] : settable in the following page User meter 2 [E2659] : settable in the following page Data logging [E1988]: 3/ Dedicated meter settings For the two dedicated meters [E2657] and [E2659] you can chose: The name of the meter The unit of the meter. 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 The accuracy of the meter Password / Options 1/ Passwords This screen allows you to change passwords, from level 0 to the currently connected level. Passwords are limited to 8 characters maximum. 169

170 Chapter : Menu overview 2/ Options Displays only the options active on your GENSYS 2.0 Core. 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: Enable the coupling function. 6: Master 2. This is a "factory only" configurable option. This option is set to OFF on GENSYS 2.0 Core, and set to ON in the Master2. 8: Phase offset option. This option is generally used with HIGH VOLTAGE transformer applications GENSYS 2.0 Core screen saver 1/ Introduction The screen displayed when user does not interact with GENSYS 2.0 Core (keys not used) is called SCREEN SAVER. Information displayed on this screen is automatically chosen depending on GENSYS 2.0 Core status, as described in table below. Some parameters can also be used to customize this behaviour. Screensaver Description Display in auto mode Synchronization Frequency difference (bar graph) In synchronization column Voltage difference (bar graph) state Phase difference (column) Frequency match (OK/NOK) Voltage match (OK/NOK) Phase match (OK/NOK) Generator overview Engine overview Customized screen KW (in large font) Voltage (in large font) Running hours (in large font) Crank relay output Fuel relay output Water temp digital output Oil pressure digital output Emergency stop Remote start Nb of start attempts Battery voltage (bar graph) Engine speed (bar graph) 4 custom lines Customer logo Current date and time When the generator breaker is closed In start and fault state In wait state (engine stopped) Display in Manu mode When the generator is ready and the generator breaker is open When the generator breaker is closed When you press start, or when in fault state In other cases 2/ Menu Table 45 - Screensaver modes TM scr saver [1266]: set the time (in minutes) after which the front panel display will exit menus and show the screen saver. Line 1 to Line 4: 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. 170

171 Chapter : Menu overview 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; for more information, refer to the next chapter Back light timer / Languages 1/ Back light timer Horn delay [1991]: Time (in seconds) after which the horn goes off. TM back light [1014]: This sets the time (in minutes) after which the front panel display backlight will be switched off. The light will be switched on again as soon as a key is pressed on the front panel. PC language: Allows you to choose the language of the menus displayed on your computer. Local language: Allows you to choose the language of the menus displayed on your GENSYS 2.0 Core front panel Serial port configuration This menu is mainly for informative purposes: 1/ COM1 This bus allows synchronization, load sharing (active and reactive), dead bus management, automatic load/unload, Broadcast data... This isolated communication port is also used for MASTER 2.0 communication. GENSYS 2.0 Core uses a proprietary protocol. 2/ COM2 This bus is used for communication with CANopen remote I/O modules (Beckhoff, Wago...) or J1939 engine communication. 3/ COM3 On GENSYS 2.0 Core with firmware v1.xx, this port is used for computer connection (USB). On GENSYS 2.0 Core with firmware v2.00 or later, this port is not used anymore. It is replaced by Ethernet communication. Figure 82 Com ports 171

172 Chapter : Menu overview 4/ COM4 The modules are designed to work with independent remote display module RDM 2.0 screens which are connected by Ethernet. Ethernet connection to GENSYS 2.0 Core with firmware v2.00 or later. Not used on GENSYS 2.0 Core with firmware v1.xx. 5/ COM5 MODBUS speed [E1441]: the following speeds are available: 4800, 9600, 19200, bps. 8 data bits. No parity. 1 stop bit. Isolated. 2 wires. Modbus address [E1634]: this parameter is used to define the GENSYS 2.0 Core Modbus SLAVE (RTU) address. 6/ COM6 COM6 is the memory card port. No settings on this com port Serial number/software version This is the same item as Display in the first level menu Level -1 password menu Option select *E1610+: this can be Meters preset, G59, or None (default). See chapter 9.10 for details GENSYS 2.0 to PC file This menu is only displayed on the computer and not on the GENSYS 2.0 Core front panel. Download. By selecting Download GENSYS 2.0Core _file.txt, the current configuration file will be displayed in your internet browser. 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 GENSYS 2.0 Core, modify it, and download this new text file to the GENSYS 2.0 Core. Always use a text file compatible with the installed firmware version. Warning: File transfer is only possible when engine is stopped. Use the File / Save as... menu of your browser to save this file. 172

173 Chapter : Menu overview PC to GENSYS 2.0 Core file This menu is only displayed on the computer and not on the GENSYS 2.0 Core front panel. NOTE: We recommend you first save the current configuration using the GENSYS 2.0 Core to PC file menu before making changes. File transfer is only possible when engine is stopped. Use the "browse" button to select your file, then choose the "Save" button. When the operation is completed, a screen will appear showing: Figure 83 Compilation result screen Download logo This menu is only displayed on the computer and not on the GENSYS 2.0 Core front panel. This menu allows you to change the screen saver logo on the GENSYS 2.0 Core front panel. NOTE: File transfer is only possible when engine is stopped. The picture must be a monochromatic BMP file of 74*52 pixels. Use the "browse" button to select your file, then choose the "Save" button. When the operation is completed, a screen will appear showing: Figure 84 Download screen 13.7 Dedicated screens Access to the Information page. Access to the Alarms page. Access to the Faults page. Click BACK on your internet browser or press the button a second time to return to your previous screen. 173

174 Chapter : Menu overview Alarms At any time and any level, you can click on the "Alarms" link in your browser or press the [ALARM] key on the front panel. By pressing "<<" or ">>", you can change between 1 st to 10 th alarms and 11 th to 20 th alarms...etc. 50 alarms are visible. Pressing "Refresh" will update the screen with last occurred alarm(s). Pressing "Reset" 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 Alarm archive can be deleted in the System/ Date Time meter/. Data logging --reset menu 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. This will automatically change the display and show the faults screen. The last 50 faults are displayed as follows: dd/mm/yy hh:mn:ss protec. label XXXX=On (or Off). XXXX stands for the variable number. The Faults archive can be deleted in the System/ Date Time meter/. Data logging --reset menu. Figure 85 Fault screen 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. 174

175 Chapter : Menu overview Figure 86 Information screen Power [E2071]: This will display the current status of the GENSYS 2.0 Core regarding power management. It will also display a state code which is dedicated to the technical support team of your local GENSYS 2.0 Core Distributor. Engine [E2057]: This will display the current status of GENSYS 2.0 Core regarding the engine. It will also display a state code which is dedicated to the technical support team of your local GENSYS 2.0 Core Distributor. Parameter information: You can display any parameter by simply 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. 175

176 Chapter : Useful Information 14 Useful Information This page gives access to useful information concerning different areas of the GENSYS 2.0 Core unit's functioning Speed Regulation details Figure 87 Speed regulation details 176

177 Chapter : Useful Information Voltage Regulation details Figure 88 Voltage regulation details 177

178 15 Variables All GENSYS 2.0 Core variables are listed in an EXCEL file ( A53 Z x.xls ) available on CRE technology Web site ( ). This file contains all defined parameters and labels in all languages handled by GENSYS 2.0 Core. The file also contains the history of all different versions of GENSYS 2.0 Core firmware.

179 Chapter : Precautions 16 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 89 - Several generators warning and Figure 90 - One generator with mains warning. +24V +24V G1 G2 SYN SYN GENSYS E5-E6 Gen. ref volt SYNCH CHECK RELAY GENSYS E5-E6 Gen. ref volt SYNCH CHECK RELAY Bus ref volt Bus ref volt Figure 89 - Several generators warning Mains G +24V +24V GENSYS E2-E3 Mains ref volt SYNCH CHECK RELAY Gen. ref volt GENSYS E5-E6 Generator breaker NC feedback SYN SYN Mains breaker NC feedback C2S product is the good solution as SYNC CHECK RELAY (see accessories below) Figure 90 - One generator with mains warning GENSYS 2.0 Core CRE Technology Official Technical documentation 179

180 Chapter : Precautions Warning: When you use the virtual digital input in this way: "Generator electrical fault", "Mains electrical Fault", "External alarm", "External fault (Soft shut down)" or "External security (Hard shut down)", NEVER use the "Normally Open" or "Normally Close" directions but ALWAYS "Normally Open Wired Or" or "Normally Close Wired Or". Warning: Manual breaker opening. When an external security device opens the breaker, the order has to be latched. GENSYS 2.0 Core needs the feedback. Warning: When a power plant has several generators, even if only one generator has a GENSYS 2.0 Core, the number of generators (E1147) must be equal or above 2. If it is 1, you may seriously damage your generator. Warning: 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 operates independently from the prime mover control device. CAUTION: When a power plant has several generators, each GENSYS 2.0 Core 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. GENSYS 2.0 Core CRE Technology Official Technical documentation 180

181 Chapter : References 17 References A53Z1 Standard product reference. Full reference follows this format: A53Z1-L00xx with xx depending on factory installed options. Standard product is A53Z1-L0001. Consult your dealer for complete reference Options Each of the following options can be selected and is password activated: contact your dealer for procedure. OPT2: Mains paralleling option for single generator paralleled with the mains. The most important paralleling functions are: Phase shift ROCOF power management (command mode, peak shaving ) OPT5: OPT8: Disable paralleling function. Transformer phase shift compensation (HV, Dyn11 ) A watchdog option is also available using the C5 output. This option must be specified upon ordering your unit so that CRE Technology can activate it. GENSYS 2.0 Core CRE Technology Official Technical documentation 181

182 Chapter : References 17.2 Accessories A53W0 USB/B GENSYS 2.0 Core to PC cable 3 m. A40W8 DB9/DB9 - CAN inter GENSYS 2.0 cable for 2 generators - 7m. A40W6 DB9/free wires - CAN inter GENSYS 2.0 cable for more than 2 generators or CANopen I/O modules - 7m. A40W3 screws). A40W4 request. A53X0 DB9/Terminals connector to be used with more than 2 generators for double connection (with Free wire both sides - Communication cable (RS485, CAN, RS232) - Price per meter. Length on Manual GENSYS 2.0 Core test bench. A09Tx GCR: digital mains controller (ref A09T0 for 100 VAC, A09T1 for 230 VAC, and A09T2 for 400 VAC). A24Zx CPA: active power converter (A24Z0 for 100 VAC / 5 A, A24Z1 for 230 VAC / 5 A, A24Z2 for 400 VAC / 5 A, A24Z3 for 100 VAC / 1 A, A24Z4 for 230 VAC / 1 A, A24Z5 for 400 VAC / 1 A). A61Y1 BSDPlus: remote management box (GPRS, , SMS ) A25Z0 C2S is an Auto Synchronizer and Safety Column to control the paralleling of two alternating power sources. Figure 91 - Standard cables GENSYS 2.0 Core CRE Technology Official Technical documentation 182

183 Chapter : CRE TECHNOLOGY 18 CRE TECHNOLOGY 130, Allée Victor Naudin Zone des Templiers Sophia-Antipolis Biot FRANCE Phone: +33 (0) Fax: +33 (0) Website: info@cretechnology.com Technical support: +33 (0) (office hours: 8.30AM-12AM / 2PM-6PM) support@cretechnology.com SKYPE: support-cretechnology.com SARL au Capital de Euros - RCS Antibes: N TVA FR Figure 92 - Access to CRE Technology GENSYS 2.0 Core CRE Technology Official Technical documentation 183

184 Chapter : CRE TECHNOLOGY Found our entire distributors list into the world, tab DISTRIBUTEURS Head Office: FRANCE Official Distributors Agents Figure 93 - 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. GENSYS 2.0 Core CRE Technology Official Technical documentation 184