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GENSYS MARINE Technical documentation page 1/128 A40 Z1 9 0020 A-EN Technical documentation

April 2009

Generator management module Technical Documentation

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 unless otherwise expressly undertaken.

CRE Technology 130 Alle Charles-Victor Naudin

Zone des Templiers - Sophia Antipolis 06410 BIOT - FRANCE

Phone: + 33 (0)4.92.38.86.82 - Fax: + 33 (0)4.92.38.86.83 www.cretechnology.com - [email protected]

SARL au Capital de 300.000 Euros - RCS Antibes: 7488 625 000 15 NTVA FR54 488 625 583

GENSYS MARINE


You can download this documentation and the different documentation relating to GENSYS on our web site: http://www.cretechnology.com/ . Documentation list on web site: GENSYS technical documentation (this manual) Complete variable list with label, units and limits GENSYS menu help file (HELP windows file) Web JAVA machine CPA technical documentation GCR technical documentation C2S/SCR technical documentation

NOTE : Bureau VERITAS marine approval : The control and monitoring functions must not be undertaken on the same module. The engine securities (min oil pressure, over speed and oil absent) must not be handled by the same module.

NOTE : Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. Contact your CRE dealer for course training.

Date Version Comments Par

1-04-2009 A Document based on GENSYS 1.0 technical documentation. JAM

http://www.cretechnology.com/


Table of contents 1 Overview ..............................................................................................................9

1.1 European Union Directive Compliance CE ............................................................ 9 1.2 Environment.............................................................................................................. 9 1.3 Characteristics.......................................................................................................... 9

2 Description.........................................................................................................10 2.1 Front panel .............................................................................................................. 10

2.1.1 Display panel ................................................................................................................... 11 2.1.2 Service panel ................................................................................................................... 11 2.1.3 Control Panel ................................................................................................................... 12 2.1.4 Upper Panel..................................................................................................................... 13

2.2 Rear panel ............................................................................................................... 14 2.2.1 Overview.......................................................................................................................... 14 2.2.2 Inputs/Outputs ................................................................................................................. 14

3 User interface ....................................................................................................18 3.1 Internal browser description ................................................................................. 18

3.1.1 Navigation Mode.............................................................................................................. 18 3.1.2 Input Mode....................................................................................................................... 19 3.1.3 Save parameters configuration........................................................................................ 19 3.1.4 Password protection ........................................................................................................ 19

3.2 PC browser.............................................................................................................. 20 3.2.1 Setting up Windows XP ................................................................................................... 21 3.2.2 View Web Pages from the GENSYS Web Server........................................................... 32 3.2.3 First level screens............................................................................................................ 32

3.3 Screensaver ............................................................................................................ 33 4 Operating modes...............................................................................................35

4.1 Manu mode.............................................................................................................. 35 4.2 Auto mode............................................................................................................... 35 4.3 Test mode................................................................................................................ 36 4.4 Semi Auto Mode ..................................................................................................... 36

5 Typical start sequence for fuel engines ..........................................................37 6 Predefined configurations ................................................................................38

6.1 Single generator in change-over mode (without paralleling) ............................. 38 6.2 Generators paralleling with inter GENSYS CANbus ........................................... 40 6.3 Generators paralleling with GENSYS and parallel line modules ....................... 41 6.4 Single generator paralleled with mains (option 2)............................................... 42

6.4.1 Mains paralleling modes:................................................................................................. 42 6.5 Power plant paralleled with mains........................................................................ 44

6.5.1 Interfacing GENSYS with GCR ....................................................................................... 45 7 Installing and commissioning a GENSYS application ...................................47

7.1 Wiring diagram ....................................................................................................... 47 7.2 Installation instructions:........................................................................................ 48

7.2.1 Panel cut-out:................................................................................................................... 48


7.2.2 Mounting: ......................................................................................................................... 48 7.2.3 Earth grounding: .............................................................................................................. 49 7.2.4 Wiring guidelines:............................................................................................................. 49 7.2.5 Vibrations: ........................................................................................................................ 50 7.2.6 Real time clock battery:.................................................................................................... 50

7.3 Before commissioning (before going on site) ..................................................... 50 7.4 During commissioning ........................................................................................... 51

8 Predefined functions ........................................................................................ 58 8.1 Water preheat / Pre-lubrication / Pre-glow functions .......................................... 58

Auto mode ...................................................................................................................................... 58 Manual mode.................................................................................................................................. 58

8.2 Crank / Fuel / Starter 2 / Starter 3 functions ......................................................... 58 8.3 Air fans..................................................................................................................... 59

Auto mode ...................................................................................................................................... 59 Manu mode..................................................................................................................................... 59

8.4 Fuel filling / Coolant filling / Oil filling................................................................... 59 Auto mode ...................................................................................................................................... 60 Manu mode..................................................................................................................................... 60

8.5 Configurable I/Os functions................................................................................... 60 8.5.1 Digital input functions....................................................................................................... 60 8.5.2 Configurable input label ................................................................................................... 60 8.5.3 Validity.............................................................................................................................. 60 8.5.4 Input functions.................................................................................................................. 60 8.5.5 Direction........................................................................................................................... 63 8.5.6 Dedicated inputs .............................................................................................................. 63

8.6 Digital output functions.......................................................................................... 63 8.6.1 Output functions............................................................................................................... 64 8.6.2 Polarity ............................................................................................................................. 67

8.7 Use spare analog input for digital input ............................................................... 67 8.7.1 Purpose:........................................................................................................................... 67 8.7.2 Configuration:................................................................................................................... 67 8.7.3 Parameters: ..................................................................................................................... 67

9 Special functions .............................................................................................. 69 9.1 Fuel crank relay function ....................................................................................... 69

9.1.1 Introduction ...................................................................................................................... 69 9.1.2 Configuration.................................................................................................................... 69

9.2 Load sharing using a central frequency (de-drooping) ...................................... 70 9.2.1 Introduction ...................................................................................................................... 70 9.2.2 Procedure......................................................................................................................... 70 9.2.3 GCR synchronization & mains paralleling ....................................................................... 71 9.2.4 INTEGRAL INHIBITION................................................................................................... 71

9.3 Pulse control calibration procedure ..................................................................... 72 Parameters ..................................................................................................................................... 74

9.4 Operator controlled return of mains ..................................................................... 74 9.5 Mains & Generator electrical fault options........................................................... 75 9.6 GENSYS with external automatic start module ................................................... 78

9.6.1 Overview .......................................................................................................................... 78 9.7 Remote start upon external pulse ......................................................................... 80

9.7.1 Setting external input ....................................................................................................... 80 9.8 Safety Inhibitions.................................................................................................... 81


9.8.1 Objective.......................................................................................................................... 81 9.8.2 Configuration ................................................................................................................... 81

9.9 GENSYS with 500Hz PWM (Cat/Perkins) .............................................................. 83 9.9.1 Schematic ........................................................................................................................ 83 9.9.2 Configuration ................................................................................................................... 84

9.10 Under voltage trip coil ........................................................................................ 85 9.11 Level -1 (counters) .............................................................................................. 85 9.12 Scada.................................................................................................................... 86 9.13 How to set a GPID ............................................................................................... 86

9.13.1 Principle ........................................................................................................................... 86 9.13.2 Empirical method settings ............................................................................................... 86

9.14 Automatic load / unload...................................................................................... 86 9.15 KVAR or Kw dependant start/stop..................................................................... 88 9.16 Heavy consumer (marine sequence)................................................................. 89

Introduction..................................................................................................................................... 89 Procedure....................................................................................................................................... 89

9.17 Non essential consumer trip (marine sequence) ............................................. 92 Introduction..................................................................................................................................... 92 Procedure....................................................................................................................................... 92

To deactivate the outputs, it is necessary to reset the alarm E2729 on the front panel................................................................................................................95 10 GENSYS PLC ..................................................................................................96

10.1 Introduction ......................................................................................................... 96 10.2 File description.................................................................................................... 96 10.3 Parameter definition block ................................................................................. 96 10.4 Label definition block ......................................................................................... 97 10.5 Unit definition block............................................................................................ 97 10.6 Initialization definition block .............................................................................. 98 10.7 Equation definition block ................................................................................... 98 10.8 End of file ............................................................................................................. 98 10.9 PLC programming language .............................................................................. 99

11 Communication ............................................................................................102 11.1 CANBUS GOOD PRACTICES ........................................................................... 102 11.2 COM1: RS232 to PC .......................................................................................... 103 11.3 COM2: CAN bus inter GENSYS........................................................................ 103

11.3.1 Wiring............................................................................................................................. 103 11.3.2 CAN bus fault................................................................................................................. 104

11.4 Broadcasting Data between GENSYS units.................................................... 104 11.4.1 Introduction: ................................................................................................................... 104 11.4.2 Procedure / Example ..................................................................................................... 105

11.5 Can Bus Inhibition............................................................................................. 108 11.5.1 How to set theses functions:.......................................................................................... 109

11.6 COM3: CANopen remote I/O............................................................................. 110 11.6.1 System configuration ..................................................................................................... 111


11.6.2 Read / write I/O .............................................................................................................. 112 11.7 COM3: J1939 ...................................................................................................... 112

11.7.1 Configuration.................................................................................................................. 113 11.7.2 J1939 fault...................................................................................................................... 113 11.7.3 Engine Speed ................................................................................................................ 113 11.7.4 Coolant temperature ...................................................................................................... 113 11.7.5 Oil pressure.................................................................................................................... 113 11.7.6 Engine diagnostic........................................................................................................... 113 11.7.7 J1939 Messages............................................................................................................ 114 11.7.8 Advanced functions........................................................................................................ 117 11.7.9 Engine notes .................................................................................................................. 118

11.8 COM4: MODBUS RTU on serial port RS485 .................................................... 118 12 Troubleshooting........................................................................................... 121 13 Variables....................................................................................................... 123 14 Precautions .................................................................................................. 124 15 References ................................................................................................... 126

15.1 Options ............................................................................................................... 126 15.2 Accessories ....................................................................................................... 126

16 Company Information.................................................................................. 128


List of illustrations Figure 1 - M121 GENSYS Front Panel ................................................................................................. 10 Figure 2 - A40 Z1 Front panel ............................................................................................................... 10 Figure 3 - Rear panel ............................................................................................................................ 14 Figure 4- Browser link description......................................................................................................... 19 Figure 5 - Contextual keys for Input Mode ............................................................................................ 19 Figure 6 - Password input mode display ............................................................................................... 19 Figure 7 - Typical menu page................................................................................................................ 20 Figure 8 - Typical configuration page.................................................................................................... 21 Figure 9 - GENSYS PC ................................................................................................................... 21 Figure 10 - Tree menu description ........................................................................................................ 33 Figure 11 - State machine ..................................................................................................................... 36 Figure 12 - Typical start sequence for fuel engines .............................................................................. 37 Figure 13 - Power plant in change over mode without paralleling ........................................................ 38 Figure 14 - Typical sequence in change over mode ............................................................................. 39 Figure 15 - Power plant with several generators................................................................................... 40 Figure 16 - Generators paralleling with parallel lines............................................................................ 41 Figure 17 - Paralleling with mains ......................................................................................................... 42 Figure 18 - Typical sequence in No Break CO mode............................................................................ 43 Figure 19 - Typical sequence in permanent mode................................................................................ 44 Figure 20 - Power plant paralleling with mains ..................................................................................... 44 Figure 21 - GCR GENSYS wiring diagram....................................................................................... 45 Figure 22 - Panel cut-out....................................................................................................................... 48 Figure 23 - Mounting kit......................................................................................................................... 48 Figure 24 - Mounting brackets on GENSYS ......................................................................................... 48 Figure 25 - Earth grounding .................................................................................................................. 49 Figure 26 - Interconnection of all battery negatives .............................................................................. 50 Figure 27 - Connecting CAN bus with isolators .................................................................................... 50 Figure 28 - Speed output....................................................................................................................... 52 Figure 29 - Voltage output..................................................................................................................... 54 Figure 30 - Synch check........................................................................................................................ 56 Figure 31 - Connections for water preheat, pre lubrication and pre glow ............................................. 58 Figure 32 - Connection for air fans........................................................................................................ 59 Figure 33 - Connections for filling.......................................................................................................... 59 Figure 34 - Fuel filling diagram.............................................................................................................. 60 Figure 35 - Pulse control ....................................................................................................................... 74 Figure 36 - Wiring GENSYS Auto Start Module............................................................................... 78 Figure 38 - Typical GPID controller ....................................................................................................... 86 Figure 39 - Automatic load/unload arbitration ....................................................................................... 87 Figure 40 - Automatic load/unload sequence........................................................................................ 88 Figure 41 - Heavy consumer validation................................................................................................. 90 Figure 42 - Heavy Consumer Control with active power analysis......................................................... 90 Figure 43 - Heavy Consumer Control with number of gensets analysis............................................... 91 Figure 44 - Configuration of the heavy consumer confirmation output ................................................. 91 Figure 45 - Non essential consumer trip settings.................................................................................. 92 Figure 46 - Non essential consumer trip alarm (1)................................................................................ 93 Figure 47 - Non essential consumer trip alarm (2)................................................................................ 93 Figure 48 - Non essential consumer trip output setting ........................................................................ 94 Figure 49 - Non essential consumer trip timers .................................................................................... 94 Figure 50 - Non essential consumer trip diagram ................................................................................. 95 Figure 51 - CAN Bus wiring................................................................................................................. 103 Figure 52 - GENSYS GENSYS ...................................................................................................... 103 Figure 53 - GENSYS GENSYS GENSYS ........................................................................ 104 Figure 54 - CAN bus inhibition schematic (example) .......................................................................... 109 Figure 55 - Modular remote I/O extension module.............................................................................. 110 Figure 56 - CANopen coupler wiring ................................................................................................... 111 Figure 57 - Wiring diagram for Volvo EMS2........................................................................................ 118 Figure 58 - GENSYS GENSYS GENSYS (MODBUS) ..................................................... 119 Figure 59 - Several generators warning.............................................................................................. 124 Figure 60 - One generator with mains warning ................................................................................... 124


Figure 61 - Standard cables ................................................................................................................ 127 Figure 62 - Access to CRE Technology in Sophia Antipolis................................................................ 128

List of tables Table 1 - LCD screen characteristics .................................................................................................... 11 Table 2 - Display Panel keys ................................................................................................................. 11 Table 3 - Service Panel keys................................................................................................................. 12 Table 4 - Control Panel keys ................................................................................................................. 13 Table 5 - M121 Control panel LEDs ...................................................................................................... 13 Table 6 A40 Z1 Control Panel LEDs .................................................................................................. 13 Table 7 - Inputs/Outputs description...................................................................................................... 17 Table 8 A40 Z1 User interface............................................................................................................ 18 Table 9 - Screensaver description......................................................................................................... 34 Table 10- Typical change over mode configuration .............................................................................. 38 Table 11 - Typical basic multi Generator configuration ......................................................................... 40 Table 12 - Typical basic configuration for GENSYS with parallel lines modules .................................. 41 Table 13 - Typical basic mains paralleling configuration....................................................................... 42 Table 14 - Paralleling with mains configuration..................................................................................... 45 Table 15 - GENSYS /GCR configuration............................................................................................... 46 Table 16 - Input functions ...................................................................................................................... 63 Table 17 - Wiring GENSYS Auto Start Module ................................................................................ 79 Table 18 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus ................................. 105 Table 19 - Variables received by BROADCAST DATA via Inter GENSYS CANbus .......................... 106 Table 20 - CAN bus inhibition parameters........................................................................................... 110 Table 21 - CANopen configuration example ....................................................................................... 112


1 Overview The version described here is the A40 Z1 GENSYS MARINE which is equivalent to the A40 Z0 but with special marine functions. The A40 Z1 M121 GENSYS MARINE has a specific front panel including a preferential button. N.B.: in this manual, all mentions of the A40 Z0 should be considered as the A40 Z1.

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 2009. This product is developed to respect harmonized norms: EN 55099:2009 EN 55099:2010 EN 55088:2008 2006/95/EC (replaced directive 73/23/EEC since January 16th 2007). SAE J1939/71, /73, /31 Other norms: EN 61326-1: 2006 (Industrial location) EN 55011 EN 61000-3-2 EN 61000-3-3 Marine certification: Bureau Veritas, Lloyds Register of shipping, DNV (pending).

1.2 Environment Operating temperature

A40Z0 0 to 55C A40Z1 -20 to 70C A40Z2(GNSS) 0 to 55C (UL certified) A40B0,B1, B2, B3, B4, B5 5 to 55 C (Bureau Veritas Marine agreement, Lloyds register) Storage temperature -30 to +70C Humidity 5 to 95% Tropic-proof circuits for normal operation in humid conditions. Front panel: IP54 protection. Back panel: IP20 protection. Altitude: 2000m

1.3 Characteristics Size 248x197x57mm (9.76x7.76x2.24in) Weight 1.9kg (4.2oz)


2 Description

2.1 Front panel

Figure 1 - M121 GENSYS Front Panel

Figure 2 - A40 Z1 Front panel


The display panel allows setting up and monitoring of the GENSYS configuration and the power plant it controls. It provides a large LCD display and a keypad. See "User interface" chapter, for more details about the functions of LEDs & Keys.

LCD characteristics Value Unit

Viewing area 240x128 dot

114x64 (4.49x2.52) mm (in)

30x16 Characters

Character size (small font) 2.7x3.6 (0.1x0.14) mm (in)

(standard font) 3.6x3.6 (0.14x0.14) mm (in)

(large font)

9.45x9.45 (0.37x0.37) mm (in)

Back light 60 cd/m

LCD mode STN

Table 1 - LCD screen characteristics

2.1.1 Display panel

M121 Keys

A40 Z1 Keys Navigation mode

Input mode (during parameter modification)

F1 F5

scroll / select menus and parameters

change parameter value

Enter

enter a menu / switch to Input mode

Validate parameter and return to Navigation mode

Shift

Used with other keys only (F1, F2, I). Shift + I saves all parameters.

Not used.

Raise

Shortcut to special function Increase speed in manual mode. Increase voltage when associated with Shift key in manual mode.

Lower

Shortcut to special function Decrease speed in manual mode. Decrease voltage when associated with Shift key in manual mode.

Esc

Return to parent menu Discard parameter changes and return to Navigation mode

Table 2 - Display Panel keys

2.1.2 Service panel The five dedicated keys of the service panel allow you to switch to special menus or functions directly. See "User interface" chapter for more details about the functions of LEDs & Keys.

M121 Keys

A40 Z1 Keys

Function

Horn off

This key will stop the buzzer and turn the associated LED off. The associated red LED indicates the status of the buzzer output.


Fault page !

Direct access to the Fault menu. An associated red LED indicates the Fault status of the generator. Pressing this key will switch to the associated menu, showing active faults. Pressing a second time on the same key will switch back to the menu displayed beforehand.

Alarm page !

Direct access to the Alarm menu. An associated orange LED indicates the Alarm status of the generator. Pressing this key will switch to the associated menu, showing active alarms. Pressing a second time on the same key will switch back to the menu displayed beforehand.

Info page

1. Direct access to global monitoring page (user configurable). 2. Save parameters in flash storage when pressed with SHIFT: this action is called SHIFT-I Pressing this key will switch to the associated menu, which is custom made and contains parameters the user wants to monitor easily. Pressing a second time on the same key will switch back to the menu displayed beforehand.

LED test

LED test: pressing this key will turn on all GENSYS LEDs. It is a simple test to check the LEDs and the keypad.

Table 3 - Service Panel keys

2.1.3 Control Panel The control panel allows the user to pilot and control the generator. See "User interface" chapter, page 18, for more details about the functions of LEDs & Keys.

M121 Keys

A40 Z1 Keys

Function

LED upper right

LED upper right

This LED is not associated with any key. It is illuminated when a key is pressed and switched off when all keys are released. This LED also stays on during a save parameters command (see SHIFT-I above).

Auto

Switches the system to automatic mode. The associated LED is ON when AUTO mode is activated.

Semi Auto

Switches the system to Semi Auto (M121) or test (A40 Z1) mode. The associated LED is ON when TEST mode is activated.

Manu

Switches the system to manual mode. The associated LED is ON when MANU mode is activated.

Start

Starts the generator (only available in manual mode).

Stop

Stops the generator (only in manual mode).

O/I

Closes/opens the generator breaker (only in manual mode).

Closes/opens the mains breaker if available (only in manual mode on the A40 Z1).

Pref. Selects preferential running (M121 only)


Table 4 - Control Panel keys

M121 LEDs Function

Engine

Shows green when engine is running

Alternator

Shows green when generator voltage is present

CB closed

Shows green when generator breaker is closed

Preference Shows green when preferential mode is selected.

Busbar Shows green when voltage is present at bus input

Table 5 - M121 Control panel LEDs

A40 Z1 LEDs Function

Engine

Shows green when engine is running

Alternator

Shows green when generator voltage is present

Genset breaker

Shows green when generator breaker is closed

Mains breaker

Shows green when mains breaker is closed

Mains / Bus

voltage

Shows green when voltage is present at Mains/bus input

Table 6 A40 Z1 Control Panel LEDs

2.1.4 Upper Panel The upper panel displays the status of the power supply. See "User interface" chapter for more details about the functions of LEDs & Keys.


2.2 Rear panel 2.2.1 Overview

Figure 3 - Rear panel

2.2.2 Inputs/Outputs

Pin nb Description Terminal capacity (mm / AWG)

Comment

A1 Crank relay out 2.5 / 12 Supplied via emergency stop input at battery positive voltage; 16 Amps.

A2 Fuel relay out 2.5 / 12 Supplied via emergency stop input at battery positive voltage; 16 Amps.

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 will calculate a virtual neutral voltage.

B2 Generator L1 2.5 / 12



100 to 480 VAC line to line. Frequency: 50 or 60 Hz. 100 mAmps / 600 VAC fuses. For UL homologation: - 100 to 230VAC line to line - Fuses must be UL 248-14 listed. - Surge protection must be UL1449 listed.

B5 Busbar L1 2.5 / 12 100 to 480 VAC line to line. Frequency: 50 or 60 Hz.


B6

Busbar L3 2.5 / 12 100 mAmps / 600 VAC fuses. For UL homologation: - 100 to 230VAC line to line - Fuses must be UL 248-14 listed. - Surge protection must be UL1449 listed.

C1 to C5

Output 1 to 5 2.5 / 12 350 mAmp. Over current protected. Reactive load. Each output can be configured with a specific function (see option list in the Z090014.chm file) or programmed with an equation.

D1 Generator I1- 2.5 / 12

D2 Generator I1+ 2.5 / 12





0 to 5 Amps. Maximum rating: 15 Amps during 10s. 1 VA consumption. Each phase is isolated from the others and from the supply voltage. For UL homologation: External current transformer must be UL506 listed.

D7 Busbar I1- 2.5 / 12

D8

Busbar I1+ 2.5 / 12

0 to 5 Amps. Maximum rating: 15 Amps during 10s. 1 VA consumption. Each phase is isolated from the others and from the supply voltage. For UL homologation: External current transformer must be UL506 listed.

E1 Busbar breaker NC 2.5 / 12

E2 Busbar breaker NO 2.5 / 12

E3 Busbar common 2.5 / 12

230 VAC, 5 Amps. Isolated relay contact.

E4 Gen breaker NC 2.5 / 12

E5 Gen breaker NO 2.5 / 12

E6 Gen common 2.5 / 12

230 VAC, 5 Amps. Isolated relay contact.

F1 Engine meas. 1- 2.5 / 12

F2 Engine meas. 1+ 2.5 / 12

0 to 10 kOhms resistive sensors with programmable gain.

F3 Engine meas. 2- 2.5 / 12

F4 Engine meas. 2+ 2.5 / 12

0 to 10 kOhms resistive sensors with programmable gain.

F5 Shield 2.5 / 12

F6 Water temp meas. - 2.5 / 12

F7 Water temp meas. + 2.5 / 12

0 to 400 Ohms resistive sensors.

F8 Oil pressure meas. - 2.5 / 12

F9 Oil pressure meas. + 2.5 / 12

0 to 400 Ohms resistive sensors.

G1 0-20 mA + 2.5 / 12

G2 Shield 2.5 / 12

G3 0-20 mA - 2.5 / 12

+/- 10 V (20 kOhms input) or +/- 20 mAmps (50 Ohms input). Used as Mains power input with single generator. Used as synchronization input from GCR (terminal 42) when several generators parallel with mains

G4 Parallel. - 2.5 / 12

G5 Shield 2.5 / 12

5V (10KOhms) Load sharing and power set level (kW only).


G6

Parallel. + 2.5 / 12 Compatibility with GCR (CRE product) and with analogue load sharing line. Compatibility with Wheatstone bridge. Only used with GCR or old ILS Isolated.

G7 Pickup - 2.5 / 12

G8 Pickup + 2.5 / 12

50 Hz to 10 kHz. Maximum voltage: 40VAC Used for speed regulation, crank drop out and over-speed (see precautions in chapter 4.2.8). If not wired, the speed measurement can be made by the alternator voltage. But pickup is recommended.

G9 Speed out + 2.5 / 12

G10 Shield 2.5 / 12

G11 Speed ref 2.5 / 12

G9: +/- 10 V analogue outputs. G11: +/-10V input from speed governor (ESG) Compatibility with most of speed regulators. Independent gain and offset software adjustment (see Z0900014.chm file).

H1 Not connected 2.5 / 12

H2 AVR out + 2.5 / 12

H3 Shield 2.5 / 12

H4 AVR out - 2.5 / 12

Analogue output. Automatic voltage regulator (AVR) set level (see Z0900014.chm file for further explanations). Stanford, AVK and Leroy Somer automatic voltage regulators already tested. For others, ask your dealer. Isolated.

J1 Mains breaker in 2.5 / 12 Digital input with 10 kOhms pull-up.

Dedicated input for mains breaker feedback. Accepts NO or NC contacts to 0V. Not isolated.

J2 Gen breaker in 2.5 / 12 Digital input with 10 kOhms pull-up.

Dedicated input for generator breaker feed back. Accepts NO or NC contacts 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 contacts to 0V. Not isolated.

J4

Oil pressure 2.5 / 12 Digital input with 10 kOhms pull-up. Dedicated input for oil pressure fault. This sensor is needed to start the engine whatever the mode. Accept s NO or NC contacts to 0V. Not isolated.

J5 Water temp 2.5 / 12 Digital input with 10 kOhms pull-up.

Dedicated input for water temperature fault. Accept s NO or NC contacts to 0V. Not isolated.

J6 to J15

Input 1 to 10 2.5 / 12 Digital inputs with 10 kOhms pull-up. 10 inputs can be configured with a specific function (see option list in the Z090014.chm file) or programmed with PLC equations. Accept s NO or NC contacts to 0V. Not isolated.

K1 Reserved 2.5 / 12 Used for 12V power supply backup during crank time. See A40U200000 documentation for more information.

K2 Power supply + 2.5 / 12 9 to 40 V, 10 Watt consumption (without actuator).


K3

Power supply - 2.5 / 12 Polarity inversion protection. Note: The "Power supply -" must be wired from the speed governor using 4 mm wires. See "state of the art" rules wiring diagram. 5 Amps / 40 VDC fuse recommended. For UL homologation: Fuse must be UL 248-14 listed.

K4 Actuator + 2.5 / 12

K5

Actuator - 2.5 / 12

200 Hz PWM output (6 Amps continuous). Power supply of actuator. Compatibility with most standard electromagnetic actuators. (Barber Colman, GAC, SynchroStart) Needed to activate an OPTION (To be ordered with the product).

COM1

RS232 to PC or modem

Female DB9

Straight cable is needed. 19200 bps, 8b, no parity, 1 stop bit. Communication with a local computer. Used for configuration, parameters, file downloading and uploading. Uses a TCP/IP protocol to communicate. Not isolated. Not to be connected while engine running.

COM2

CAN1 to other GENSYS

Male DB9 125 kbaud. Standard CAN / proprietary protocol. Used to communicate with other GENSYS units (kW, kVAR, dead bus management) and for broadcast data function. Not isolated.

COM3

CAN2 to options Male DB9 125 kbaud. Standard CAN / CANOPEN protocol. Used to communicate with remote I/O (WAGO) (see remote I/O chapter) or with engine management units (option 4). Not isolated.

COM4

RS485 / MODBUS RTU Male DB9 4800, 9600 or 19200 bps. Used to communicate with SCADA. MODBUS RTU slave. Read (04 and 03) and write (06) functions. 2 wires mode.

Table 7 - Inputs/Outputs description


3 User interface

Table 8 A40 Z1 User interface

The user interface can be controlled through two different ways: Directly on local browser using front panel LCD screen and keyboard Remotely through an internet browser running on a PC

3.1 Internal browser description GENSYS can be configured and monitored remotely with a Web browser such as Internet Explorer or Netscape Navigator.

For local usage, GENSYS has an embedded browser which is able to display the same information pages as the remote Web browser.

The user can navigate through the different menus with the navigation bar and the / keys.

3.1.1 Navigation Mode The navigation bar provides 5 contextual keys. Depending on the menu displayed, different icons may appear above these keys, allowing the user to scroll up/down the pages or to select a link to a new menu or parameter.

When the user selects a parameter and presses the key, the browser switches to the Input mode.

The 5 icons above contextual keys will change appearance depending on the type of parameter to change (list of choice, label, numerical value, password...).

When in Input mode, the key will discard the parameter changes and return to the Navigation

mode. The key will confirm the parameter changes and return to the Navigation mode.

The browser displays a white pointer in front of each link or parameter of a menu. A black pointer will indicate the active link or parameter. Figure 4- Browser link description shows these two pointers:


Figure 4- Browser link description

3.1.2 Input Mode

To change a parameter, first select it with contextual keys and press to switch to Input mode. New icons will appear above the contextual keys, depending on the kind of parameter selected.

Label modification:

Digital value modification:

List of options modification :

Figure 5 - Contextual keys for Input Mode

When the new parameter value is input, the user must press key to store and confirm the new value.

3.1.3 Save parameters configuration All GENSYS 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. This new value will be effective as soon as it is entered, but it will be lost if the GENSYS power supply is cut or too low. To save the new

parameters in FLASH, you must use SHIFT-I. The user must press both + 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.

3.1.4 Password protection The GENSYS has different password levels, allowing access to more or less critical parameters or

menus. When the password page is shown on the LCD display, the user must first press on the key (like for other parameters) to switch to the Password Input mode.

Figure 6 - Password input mode display

Three lines of characters (upper case and lower case letters and 0 to 9 characters) will appear along with 5 icons above the contextual keys.

NOTE:

Due to the great 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 at the same time on both + keys on the GENSYS front panel. Otherwise, the new parameters will be lost when shutting down the GENSYS.


The first four contextual keys allow the user to move the cursor up, down left or right onto the desired character. The last key (OK icon) will validate the selected character and write it in the password line (a * will appear).

When all characters are entered, another press on the key will validate the password. If it is correct, the main menu will appear on the LCD display. Otherwise, the password page will be displayed again.

Default settings for the password are:

Level 0: no password entered, just press "Enter" key. Level 1: 1. Level 2: Only for distributors.

The password of your level and those lower can be changed in the system menu.

Note: the menus might differ according to the security level of the password entered.

3.2 PC browser GENSYS provides an efficient way of configuring your application thanks to its embedded Web server.

It is thus possible to access the different menus with a simple Web browser such as Netscape Navigator or Internet Explorer. However, it is not recommended to be connected with the PC while the engine is running.

Before connecting with the GENSYS you have to configure your computer as described in the next chapter ". The next figure show a typical GENSYS menu accessed from a PC Web browser.

Figure 7 - Typical menu page

In this page, the user can choose from among 6 submenus (Generator electrical meters for example). It is also possible to scroll up/down the other pages of the menu with the page up > links. The ESC link acts in the same way as the GENSYS ESC key: it will display the parent menu.

The last 3 links are identical to the Fault / Alarm / Information key on the GENSYS 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 using the [Save] button. Clicking on the [Save] button changes the parameter immediately.


Figure 8 - Typical configuration page

3.2.1 Setting up Windows XP Connecting a GENSYS with a PC is similar to connecting to Internet with a modem. GENSYS works as a modem and the integrated software works as an Internet provider. GENSYS also provides 1 web server. This web server sends HTML pages to your PC, and your PC browser is used to display it. Live data is refreshed with the JAVA applet.

A40W0

Figure 9 - GENSYS PC

Data transfer takes place through a straight serial cable (with 9 wire DB9 connectors), as shown on the figure above.

A few steps are required to configure a PC before controlling a GENSYS:

Install the modem. Create a Dial-Up Networking Connection. Check the network properties. Set-up the internet security properties.

Communication between the GENSYS and the PC is carried out via a Dial-Up Network.

NOTE :

The user must press on both + keys at the same time on the GENSYS front panel to save the parameters permanently. Otherwise, the new parameters will be lost when shutting down the GENSYS.


The PC must be configured to communicate with a 19.2K bps modem with TCP/IP networking enabled.

3.2.1.1 Check the network properties

Click Start, Settings, and Network Connection.

Dial-Up Adapter and TCP/IP -> Dial-Up Adapter protocols must be present in the list. If they are not there, create a new connection using the new connection wizard.

In the New Connection Wizard, select connect to the network at my work place. Then, click Next.


Select Dial-up connection. Click on Next

In the next page, select a 19 200 bps modem. Then, click Next.

In the connection name dialog box, in the Company name field write GENSYS. Click on Next

In the Phone number to dial dialog box, in the Phone number field, write: 123. Then click Next.


The new connection is now installed. Select Add a shortcut to this connection to my desktop. Then click on Finish.

3.2.1.2 Install the Modem Click Start, Settings, and Control Panel.

In the Control Panel, double-click the Modems icon.

In the Modems Properties dialog box, click Add.

Double click on Add hardware icon.


Click on Next.

Choose the Modem icon.

Then, choose Add a new hardware device, and click Next.

Select Yes, I have already installed the hardware, and click Next.


Select install the hardware that I manually select from a list (Advanced). Then, click Next.

The following dialog box will appear: select option dont detect my modem; I will select it from a list. Then, click Next.

In the next dialog box, under Manufacturers, Standard Model Types should be selected. Under Models, select Standard 19200 bps Modem, then click Next.

In the next dialog box, select the Communications Port where GENSYS is connected as the port, and then click Next.


After Windows installs the modem, click Finish.

3.2.1.3 Set the Modem Properties Back in the Modem Properties dialog box, select the new modem (Standard 19200 bps Modem) and then click Properties.

In the General tab, check that the port speed is: 19 200 and the flow control is hardware.

In the Advanced parameters, in the advanced options tab, ensure that the modem is configured for 8 data bits, no parity, and one stop bit. Then click OK.

Click OK until you exit this dialog box.

Create a Dial-Up Networking Connection.

In the Control Panel, select Network Connection.

Double click on the GENSYS icon.


In the Connection to GENSYS dialog box, click on Properties.

In the General tab, ensure that the selected modem is the modem installed in the previous step.

In the Option tab, in the dialling option, select Display progress while connecting.


In the Security tab, select Typical (recommended settings).

In the Networking tab, select PPP Windows 95/98/NT4/2000, Internet. Select Internet Protocol. Click on Install.

In the General tab, select Use the following IP address and write: 192.168.11.2. Then select Advanced.


In the General tab, disable every tick box.

In the DNS tab, select Append primary and connection specific DNS suffixes and Append parent suffixes of the primary DNS suffix.

In the WINS tab, select enable LMHOSTS lookup and in the NetBIOS setting, select enable NetBIOS over TCP/IP. Then, click OK.


Back in the GENSYS properties dialog box, click on Advanced tab. In this tab, ensure that every option is disabled. Then, click OK.

3.2.1.4 Setting the internet security properties In the Control panel, double-click the Add/Remove program icon. If present, uninstall the Java sun program. Click OK. Run the msjavwu_.exe program provided in the CD Rom. Click Start, Settings, and Control Panel. In the Control Panel, double-click the Internet Options icon. Under the Security tab, select Trusted Sites and click on Add Sites. Check that Require server

verification (https :) for all sites in the zone is disabled. In the Zone field write "http://GENSYS" and click on Add. Click OK.

Under the Security tab, select trusted sites, click on Customize. In Java (or Java VM for 95, or Microsoft VM for ME) and Java permissions, select Custom. Click on the Java Custom Settings button. Under the Edit permissions tab, enable the Access to all Network Addresses in the Run Unsigned Content part. Click OK. Click OK. If a dialog box appears, click YES.

In the Connection tab, click on Never establish connection. Select GENSYS modem in the modem list Click on Settings, Use a proxy server must be disabled. Click OK.

Under the Advanced tab, in the Java VM field (Microsoft VM for ME); check that Java JIT enabled is selected. Click OK.

Close Control panel. Copy the file named hosts from the GENSYS CD Rom C:\WINDOWS\system32\drivers\etc


3.2.1.5 Connect the GENSYS Connect one end of a DB-9 serial cable to the COM1 port of the PC. Connect the other end of the cable to the connector labelled "RS232 to PC or modem" on the GENSYS.

Double-click on the Shortcut to GENSYS icon. In the Connect to dialog box, click CONNECT. Click close.

If the connection is OK, an icon (2 small computers) in the bottom right of the screen appears.

3.2.2 View Web Pages from the GENSYS Web Server After the TCP/IP connection has been established with GENSYS, you can view GENSYS menus with any standard Web browser such as Firefox or Internet Explorer.

Start the web browser (Internet explorer, Firefox ).

In the Location or Address field of the web browser, enter the URL of the GENSYS: http://gensys (CAUTION: host file must be present in C:\WINDOWS\system32\drivers\etc and must contain a line such as: 192.168.11.1 GENSYS The GENSYS password page should appear in the browser window. Enter your password.

You can now browse through the different GENSYS menus.

To close the connection, double-click on the connection icon in the status bar of Windows. In the Connected to GENSYS dialog box, click Disconnect. Close your web browser.

3.2.3 First level screens Upon power up, GENSYS displays the genset status (if EMERGENCY STOP not connected) or WELCOME SCREEN. The first level menu contains three entries: Display Configuration System

You can access it with next KEY sequence:

=> => => You then have access to the top level menu:

=> =>

http://gensys/


Figure 10 - Tree menu description

See the Help file for the complete description of the tree menus.

3.3 Screensaver GENSYS has automatic screensavers. They only appear on the GENSYS LCD screen when you press "Esc" in the password page or after an adjustable delay (GENSYS variable 1266). There are four screensavers and the display depends on the mode and state of GENSYS:

Screensaver Description Display in Auto mode Display in Manu mode

Customized screen

4 customized lines Customer Logo Date and time

In Wait state (engine stopped). In other cases.

Generator overview

KW (in large font) Voltage (in large font) Frequency (in big font) Running hours (in large font)

When the generator breaker is closed.

When the generator breaker is closed.

Engine overview

Crank Relay Output Fuel Relay Output Water Temp Digital Input Oil Pressure Digital Input Emergency Stop Remote start Nb of start attempts Battery voltage (bar graph) Engine speed (bar graph)

In Start state and fault state. When you press Start or when in fault state.

Synchronization column

Frequency difference (bar graph) Voltage difference (bar graph)

In Synchronization state.

When the generator is ready and the generator breaker is opened.


Phase difference (column) Frequency match (OK / NOK) Voltage match (OK / NOK) Phase match (OK / NOK)

Table 9 - Screensaver description


4 Operating modes With the GENSYS unit, three main operating modes and one special mode are available to allow you to control your generator.

Modes are:

Manual Automatic Test Mode (A40 Z1) Semi Automatic (M121)

4.1 Manu mode In manual mode, it is possible to control the generator with the front panel of the GENSYS. 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 regulator is connected to GENSYS, it is possible to increase the speed with the F1 key, and decrease it with the F2 key.

If a voltage regulator is connected to GENSYS, it is possible to increase and decrease the voltage with the SHIFT+F1 keys and SHIFT+F2 keys.

When the generator is synchronized, it is possible to 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 met.

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 is switched to droop mode for speed and voltage, i.e. the speed and the voltage will decrease when the load increases.

To stop the engine, push the Stop key.

4.2 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:

The generator starts with a remote start or in the case of mains failure. When the generator is ready (voltage, frequency), the mains breaker is opened and the generator breaker is closed. Should the mains return to normal conditions or remote start is off, after a programmed delay the generator breaker is opened, the mains breaker is closed and the generator set is stopped.

One generator paralleling with the mains (option 2):

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, or PERMANENT Load sharing can be on a "base load" or "peak shaving" 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:


The generator starts with a remote start signal, and parallels with the bus. If there is a dead bus, GENSYS will check with the other GENSYS 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 or via the parallel lines. The generators stop with a remote stop signal.

Power plant with several generators with automatic load/unload:

The communication between GENSYS units is via the inter GENSYS CANbus 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).

4.3 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 will carry out the standard Auto mode sequence. To exit TEST MODE, push the [AUTO] key.

4.4 Semi Auto Mode Similar to Auto Mode, except that to pass from one state to another you press a button. The following illustration shows the various states.

Figure 11 - State machine


5 Typical start sequence for fuel engines 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.

SpeedNominal speed (1080 or 1081)

Idle speed (1079)

Startrequest

Crank drop out (1325 or 1326 or 1327)

Prelub1145

Preglow1157

Crank1135

Crank rest1136

Preglow1157

Crank1135

Warm up1139

RPM stab1140

Volt stab1141

Safety on1514

Stoprequest

Cooling1142

Rest1144

Running timers

Engine state (2057) 0 1 12 0109866543212112

Crank relay out (2018) (Terminal A1)

Fuel relay out (2019) (Terminal A2)

Warm up (2214) (Terminal J6 to J15)

Validation protection (2192)

Gen. readyEngineready

Figure 12 - Typical start sequence for fuel engines


6 Predefined configurations In marine applications, the "mains" can be either a busbar or the shore voltage.

6.1 Single generator in change-over mode (without paralleling)

Functions:- Manual mode- Auto mode- Test mode- Nb of running hoursAnalog / logical inputs :- Oil Pressure- Water temp- remote start- Emergency stop- Genset breaker aux- Mains breaker aux- Pickup frequency- Spares ...Logical outputs:- Crank- Fuel solenoid- Mains breaker- Genset breaker- SparesAnalog output:- analog signal to speed regulator

Start/stop

Alarms ...

Mains

- RMS reasurements (three or single phase)- Electrical protections (>V,f,Q, >P,>I, ...)

Breakersmanagement

Utility

LVor

HV(100-

480Vac)

GENSYS

LVor

HV(100-

480Vac)

LOA

DC

onso

t

OU

GEN

SET

Pow

er

t

LOA

DC

onso

t

GEN

SET

Pow

er

t

MA

INS

Pow

er

t

MA

INS

Pow

er

t

Figure 13 - Power plant in change over mode without paralleling

Variable number Variable label Variable value

1179 Gen. number 1

1147 Nb of gen. 1

1148 Mains parallel ChangeOver

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 10- Typical change over mode configuration


In Change over mode, as shown in Table 10- Typical change over mode configuration, 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 opens the mains breaker, then closes the generator breaker and takes the load.

400 V

Mains electrical fault

Mains voltage

Fastest mainselectrical fault

E2201

E1085

Remote start onterminal J3

400 V

Genset voltageGenset ready

E1142CooldownGenerator CB

Switchover delayE1459

Mains CB E1459Swithover delay

First black

Second black

First black

Second black

There are 2 blacks

START FOR EMERGENCYwill only start if a mains protection or a digital input is programmed as

"Mains electrical Fault".

START FOR TESTor switch load from mains to genset

There are 2 blacks

E0022

E2002

E0003

E2001

E2000

triggered by a protection ordigital input set as "Mainselectrical fault"

Mains backtimer

E1459Swithover

delay

E1459Switchover

delay

E1142Cooldown

Figure 14 - Typical sequence in change over mode

Note: in "No change over" mode (1148) GENSYS only starts upon a remote start demand and doesn't manage the mains breaker.


6.2 Generators paralleling with inter GENSYS CANbus

GENSYS 1 GENSYS nGENSYS 2

CAN BusKW, KVAR, COS (f), ...

Utility Figure 15 - Power plant with several generators


1179 Gen. number 1 to n

1147 Nb of gen. N (>=2)

1148 Mains parallel No ch.over

1153 Mains regul X



1515 Deadbus manag. Yes

1258 Load/Unl. mode X

1020 MA kW 20mA 0

1021 MA 0kW setting 0

Table 11 - Typical basic multi Generator configuration


6.3 Generators paralleling with GENSYS and parallel line modules

GENSYS 1 GENSYS nGENSYS 2

CAN BusKW, KVAR, COS (f), ...

Utility

Analog load sharing lines

ILS PowRcon

Figure 16 - Generators paralleling with parallel lines



1147 Nb of gen. n (>=2)


1153 Mains regul X

1158 ILS compatible Yes


1515 Deadbus manag. No


Table 12 - Typical basic configuration for GENSYS with parallel lines modules

When GENSYS 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...).


6.4 Single generator paralleled with mains (option 2)

GENSYS

Mains

CPA2

Utility Figure 17 - Paralleling with mains

In permanent mode (1148) and peak shaving mode (1153), a mains power measurement is required. Internal via D7-D8 inputs (Mains I1) or external via G1-G3 inputs (0-20 mA).


1179 Gen. number 1

1147 Nb of gen. 1

1148 Mains parallel NoBreak CO / Permanent

1153 Mains regul Base load / Peak shav.



1515 Deadbus manag. X


Table 13 - 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.

6.4.1 Mains paralleling modes: Choice of mains paralleling mode is configured through parameter E1178.


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 opens the mains breaker. When remote start is off, the mains takes the load in the same way as the generator did previously. If the generator started for a mains failure, when mains power returns the GENSYS synchronizes the load transfer (ramps down), opens the breaker and then stops the generator.



START FOR TEST or to transfert load from mains to GE.

Triggered byfastest "Mainselectrical fault"

E1142Cooldown

E1152Unloadramp

E1151Load ramp

Syn

chro

bac

k

Sho

rt tra

nsfe

rt fro

m G

Eto

Mai

ns

Sho

rt tra

nsfe

rt fro

mm

ains

to G

E

Syn

chro

bac

k

Sho

rt tra

nsfe

rt fro

m G

Eto

mai

ns

E1085Mains back

timer

400 V


Mains voltage

E2201


400 V

Genset voltage

Generator CB

Mains CB

E0022

E2002

E0003

E2001

E2000

Syn

chro

E1152Unloadramp

E1142Cooldown

There is only 1 black No black

E1459Swithover

delay

GE

read

y

GE

read

y

Firs

t Bla

ck

Figure 18 - Typical sequence in No Break CO mode

Permanent:

When the remote start is on, GENSYS 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.


Cooldown

Syn

chro

Load

ram

p

Bas

e lo

ad o

r pea

ksh

avin

g (C

HP

for

exam

ple)

Unl

oad

ram

p



START FOR PRODUCTION /base load or peak shaving

Triggered byfastest "Mainselectrical fault"

E1142Cooldown

E1152Unloadramp

Syn

chro

bac

k

Tran

sfer

t loa

d fro

m G

Eto

Mai

ns

E1085Mains back

timer

400 V


Mains voltage

E2201


400 V

Genset voltage

Generator CB

Mains CB

E0022

E2002

E0003

E2001

E2000

There is only one black

E1459Swithover

delay

E1152Unloadramp

E1151Load ramp

GE

read

yFi

rst B

lack

No black. Mains CB is always closed

GE

read

y

Figure 19 - Typical sequence in permanent mode

6.5 Power plant paralleled with mains

CAN busKW, KVAR, COS (phi), ...

CPA2

GENSYS nGENSYS 2GENSYS 1 GCR

Mains kW

Utility

Analog load sharing lines

PLC

Synchronization bus

Rseau

Figure 20 - Power plant paralleling with mains

In this configuration, base load or peak shaving regulation can be selected, depending on GCR configuration. In base load mode, GCR doesn't need CPA.



1147 Nb of gen. n (>=2)



1153 Mains regul X

1158 ILS compatible Yes


1515 Deadbus manag. Yes

1258 Load/Unl. mode X

1020 MA kW 20mA 18000


1461 Ext kW measure +/- 10V

Table 14 - Paralleling with mains configuration

To allow Power Factor regulation, the "Mains breaker in" (J1) information to GENSYS must be wired. Power Factor regulation is not an option.

6.5.1 Interfacing GENSYS with GCR

Figure 21 - GCR GENSYS wiring diagram

GCR (39-40) GENSYS (G4-G6): parallel lines (0-3V) to control active power. GCR (42-43) GENSYS (G1-G3): mains synchronization bus (+/- 3V). GENSYS (K3): -VBat from speed governor.



1464 Mains kW Meas. External

1461 Ext kW measure +/- 10V

1020 MA kW 20mA 20000


Table 15 - GENSYS /GCR configuration


7 Installing and commissioning a GENSYS application

7.1 Wiring diagram


7.2 Installation instructions: The GENSYS module has been designed for front panel mounting.

Indoor or outdoor installation is possible as long as the following requirements are met:

The chosen cabinet must meet the standard safety rules of the workplace. The chosen cabinet must be closed during normal use to prevent the user from coming into

contact with power cables. Only the front panel must be accessible during normal use. In accordance with the Bureau VERITAS marine agreement, the module must not be installed in

areas which are exposed to the weather.

7.2.1 Panel cut-out:

Figure 22 - Panel cut-out

Note: Cut-out must be cleaned of any metal dust before mounting.

7.2.2 Mounting: To secure the GENSYS onto the panel, use the special kit provided with the module. The kit contains 4 screws, 2 brackets and 1 mounting tool.

Figure 23 - Mounting kit

1. Remove the connectors.

2. Pass the module through the panel cut-out. Ensure that the gasket is properly positioned on the panel and that it is flat.

3. On the rear side of the module, insert the first bracket into the two holes on the upper edge of the module and push it to the left.

Figure 24 - Mounting brackets on GENSYS

4. Use the tool which is provided to screw the bracket gently onto the panel (just to hold the module in place)

228 mm /8.98 in

177 mm / 6.97 in


5. Insert the second bracket into the two holes on the lower edge of the module and push it to the right.

6. Use the tool to screw the bracket gently onto the panel.

7. Tighten brackets gradually until the module is firmly secured.

8. Plug in the connectors.

7.2.3 Earth grounding: Earth grounding of the GENSYS must be made with two M5 screws & fan washers. Use a short 4mm cable to connect the unit to earth (see below).

Figure 25 - Earth grounding

For UL homologation, the screw must be hexagonal with green head.

7.2.4 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 are used, all the power supply 0V (pin K3) must connected together with mini 10mm.

WARNING :

Please read the following recommendations to avoid any hardware damage to the GENSYS CANBUS Driver (not isolated).

Power supply to 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,

there is the risk of getting AC voltage on the CANBUS terminals.


Interconnection of all battery negatives

Figure 26 - Interconnection of all battery negatives

Marine generating sets CANBUS isolators are recommended for generating sets used for Marine switchboards.

Figure 27 - Connecting CAN bus with isolators

Note: These isolators are fitted to prevent any damage due to a disconnection of any K3 terminal from the inter-negative connection. These isolators can be supplied by CRE Technology with the reference A40M0.

7.2.5 Vibrations: In case of excessive vibration, the module must be mounted on suitable anti-vibration mountings.

7.2.6 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 unit.

7.3 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 Interface Automatic Voltage Regulator / GENSYS Interface (droop current transformer must be removed) CAN Bus GCR


Check the list of inputs/outputs

How?

Check if the required function is present in the list of preset functions. If 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).

7.4 During commissioning

Start with safe condition

How?

Disconnect the GENSYS connector labelled as E (breaker control). Disconnect the wires between GENSYS and the speed governor (G9 / G11). Disconnect the wires between GENSYS and the AVR (H2 / H4). Check important GENSYS parameters (See chapter 4.2). Ask the technician who wired the power plant to lock the generator breaker open.

Why?

So as to be sure not to cause a false paralleling during commissioning.

Download the text file from the GENSYS.

How?

With a PC and Internet explorer. Why?

To store all parameters before starting the commissioning.

Check speed detection.

How?

Press on manual key. Lock the fuel closed. Access the information menu. Press and hold the start button during 5 sec. While the starter turns over, check that GENSYS RPM is close to 200RPM.

Why?

To be sure that the GENSYS 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). In the information menu check that Frequency= 50.00 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 P

gensys marine - cre technology · 3.3 screensaver ... figure 24 - mounting brackets ... gensys...

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