Vous êtes sur la page 1sur 97

The GENCONII pro System Manual

The controller is made of three parts:


GENCON PRO
This is the main unit that performs all computations, measurements,
paralleling and communication. Standard models nominal line to neutral Vac: 120, 127,
220, 240 and 277.

IOB1 This is an auxiliary 16 input and 8 output relay board that is mounted on a DIN rail
inside the control cubicle. It takes care of engine management (eg fuel-solenoid), handles
external alarms (eg low oil pressure), etc. Standard models nominal battery Vdc: 12 and
24.
IOB2 The IOB2 has all the facilities of the IOB1 but also has 4 multi-range programmable
analogue inputs for reading such things as oil pressure, water temperature, charger rate
etc. All readings can be displayed on the LCD display of the Gencon and also read remotely
via the communicator.

AVRx This is a small interface circuit between the main unit and the generator's
(alternator) automatic voltage regulator (AVR). It is required for voltage matching during
synchronization and for reactive power (kVAr) control when in parallel.

Frostechnic Rev 9.00 June 2004

Outlook
There are many situations that can be handled best by operating two or more generator
sets in parallel on a common bus. Typical reasons are -Reliability: In a standby system, when there is a mains failure, all generators in the
system are started. The probability of having a generator start and achieve nominal voltage
and frequency is increased according to the number of sets available.
Flexibility: Maintenance operations can be performed without having to shut down the
whole system.
Economy:
When the loads are expected to expand substantially, the initial investment is
minimized by installing one smaller generator set, and then adding more sets in parallel as
the loads increase. The number of generator sets running can change according to the
load. In contrast, having one large genset run under light load conditions accelerates
engine wear.
There are reasons to let a single generator set also have switch gear for paralleling with
the mains -Reliability: A standby generator set with a paralleling switch gear, when the mains supply
is restored, can transfer the load back to the mains smoothly without the consumers having
to undergo a (second) power cut.
Flexibility: Exercising standby generator sets under load does not interrupt the
consumers supply.
Economy:
Exporting to the mains lines can reduce the peak kilowatt demand of a
facility at high tariff hours. Also, when an engine heat recovery system is installed
(Combined Heat & Power), the generator set can export power through the mains lines to a
local community and reach high overall efficiency.
With all these good reasons to use paralleling, for a given project kW requirements, the
decision whether to opt for paralleling depends to a large extent on the following costs'
ratio:
Control Equipment + Design/Installation/Commissioning Man-Hours
kW Generating Set

The GENCON II is designed to bring this ratio as low as possible with present day
electronics.
Each numerator factor is carefully optimised:
Equipment: The generator set controller takes complete care of measurement, engine
management, protection and paralleling. Virtually nothing but an electric governor and an
AVR is additionally required.
Design: Numerous delays, set points and options (parameters) adapt the controller's
software to suit any application. Software programming skills are not necessary.
Installation: Compact design and unprecedented integration of functions, which are
"interconnected" by software, makes wiring extremely simple (see the installation
diagram).
Commissioning: With a built in measurement system, one can find wiring mistakes easily,
eg incorrect phasing of a CT. As fault messages are logged in memory in plain language,
marked with the time of their arrival, one does not confuse a "cause" with a "result". The
large stock of parameters is edited using the controller's own LCD and keypad. Each
parameter value is displayed with a short explanation -- no need to consult the manual
each step.
The result: Paralleling is no longer the realm of heavy kW genset

projects.
Frostechnic Rev 9.00 June 2004

GENCON PRO -- The main unit


Attention!
The system supports three phase Wye (star) connected generators (alternators). There are
several controller models to choose from according to the phase (line to neutral) voltage
and current to measure#1. Be sure that you are using the correct model!
The following models are standard#2:
Nominal AC phase voltage: 120, 127, 220, 240, 277.
Nominal AC phase current: 5 amps.
Note! The maximum voltage or current value that can be measured is approximately 120%
times the nominal. For example, a 220 nominal phase volts model can measure 260.4 volts
maximum.

Front panel
LED's
The green LED should always blink. Fast blinking rate indicates existence of one or more of
the following conditions:
1.
Normal engine oil pressure (ie In#5 OIL PRESS SHUT = OFF),
2.
Engine speed greater than 60 RPM,
3.
Gen frequency greater than 15 Hz.
Blinking red LED indicates detection of a shutdown fault.
Blinking yellow LED indicates detection of a warning fault.
Press RESET to clear fleeting faults.

STOP and RESET push buttons

To stop the genset press the red STOP push-button. Shutdown fault is declared.

To silence the audible alarm press the yellow RESET push-button once.

To clear fleeting faults, if the audible alarm was silenced, press the RESET pushbutton again.
Pending faults cannot be cleared. If you press RESET, the faults will be re declared.

Liquid Crystal Display navigation primer


A user function can display on the LCD a set of measurements, it can execute a command
or it can examine the system status. To select a particular function, the LCD presents a
multilevel menu of options: Each option designates a function
The root menu
or it leads to a lower, more detailed, menu.
OVERVIEW REPORT

A selected option is indicated by .


COMMAND
MEASURE

Use the left and right arrow push buttons to select


SET-UP
HELP
another option.
Select
Enter

Press the ENTER push-button to call a selected


Esc
option.

Press ESC to return to a higher menu level.

Press any push-button to return from a measurement display function back to the
menu mode.
#1

Model variations affect one low cost PCB (A50-3). Re-calibration must follow its
replacement.
#2 Contact factory for special requirements.

Frostechnic Rev 9.00 June 2004

Short-cuts:
1.
Enter any menu. The option that is selected by default is the one that was selected
before leaving the menu by Esc . Example: You are using a function from the MEASURE
menu and need to call a function from COMMAND. Go up to the root (by Esc s) and down
to COMMAND... To return to the MEASURE function, go up to the root, select MEASURE and
make a series of blind ENTER s.
2.
When a fault is detected, if no push-button is pressed for 20 seconds or if ESC is
pressed, REPORT is automatically called. Quit REPORT and you are back at the previous
location.
Key

Description

Generator-set activity overview

Messages log

Generator 3 phase L-N measurements

Generator 3 phase L-N and L-L voltage measurements

Generator total power and power factors

Mains/Bus phase measurement

Synchroscope

Control system overview

Basic engine measurements

IOB1: Activity counters


IOB2: Extended engine measurements

The numeric keypad also acts as a fast navigator of the Most popular menus (see table)
The normal screen to leave the Gencon showing is Overview as this informs the user of the
gencons actions as they happen.
In this manual, references to functions are preceded with the path leading to them,
beginning from the top most menu level, the root. For example,
MEASURE\GENERATOR\POWER+PF shows how to call the function that displays the genset
power output and the power factors (cos). Ie starting from the root call MEASURE, call
GENERATOR and finally call POWER+PF.

Frostechnic Rev 9.00 June 2004

OVERVIEW

OVERVIEW is a useful display function. It explains what the controller is doing at any
moment. Hence, in addition to reaching OVERVIEW through the menu, you can call
OVERVIEW by:
1.
Pressing the 0 push-button at any menu level,
2.
Pressing the ESC push-button at the highest (root) menu level. The following are a
few OVERVIEW "snapshots" taken during the operation of a Euro standby generator-set
installation with soft load transfer. See configuration #5 in applications.
Snapshot 1

Snapshot 2

Mode=Auto Tue 22:35


GenSet Stationary
Mains OK
Stand-by!
Power Source: Mains

Mode=Auto Tue 22:37


GenSet Stationary
Mains Fail Run: 0'05
Power Source: None!

Snapshot 3

Snapshot 4

Mode=Auto Tue 22:40


Set Runs with Load
Mains Failure
Run!
Power Source: GenSet

Mode=Auto Tue 22:41


Set Runs with Load *
Mains OK Stop: 0'24
Power Source: GenSet

Snapshot 5

Snapshot 6

Mode=Auto Tue 22:42


kW Down Ramp: 0'04 *
Mains OK
Stand-by!
Parallel Connection!

Mode=Auto Tue 22:43


Cooling-off: 2'45 *
Mains OK
Stand-by!
Power Source: Mains

Line 1 shows the controller operating mode and the clock. The clock appears only if
the operator initialised the clock by the COMMAND\SET-CLOCK.

Line 2 shows the genset current activity and the remaining time to its end. Asterisk
(*) indicates that the genset is running in sync with the auxiliary phase V4, ie the mains
phase A.

Frostechnic Rev 9.00 June 2004

Mode=Auto Sat 22:15


Set Runs w/o Load
Test w/o Load: 2'38
Press any key...

Line 3 shows the genset command or countdown to the command start.

Line 4 shows the automatic transfer switch status.


On the left is an OVERVIEW display of a generator-set test run triggered by In#2. Line 3
indicates that the genset will stop in 2 minutes and 38 seconds.

On the right is an OVERVIEW display of a #3


Mode=Auto Sat 22:11
configured controller serving in multiple
Set Runs with Load
generator-set "random access paralleling" system.
In#01 Run with Load!
Line 3 shows that the controller IOB1 input
Parallel on Gen Bus
number 1 are active.
Line 4 shows that other gensets are connected to the bus too.
This OVERVIEW displays a controller in multiple
generator-set parallel systems. Line 3 indicates
that a system condition initiated the run
command, eg response to increase in the system
load.

Frostechnic Rev 9.00 June 2004

Mode=Auto Sat 22:26


Set Runs with Load
System Run With Load
Parallel on Gen Bus

REPORT
REPORT examines the log of messages. Each message includes the time it entered the log.
If the clock was not running, "time ???" will appear.
Most messages report some fault such as the
HIGH WATER TEMP SHUT
Logged -- Sat 17:06
example on the left.
Clear message by
Earlier Later Esc

Press the ENTER button to remove the


displayed message from the log.

Press the left arrow button () to examine earlier logged messages.

Press the right arrow button () to examine later logged messages.

Press ESC to leave the REPORT function.


Note!
1.
Every new message automatically calls REPORT.
2.
Clearing a fault message does not "accept" or "clear" the fault. Use the RESET button
to accept faults.
3.
REPORT opens the log of messages showing the most recent message first.
The log keeps the last 8 messages.

COMMAND
OFF mode
When in OFF mode, the monitoring system is active except for the relays R#3
AUDIBLE ALARM and K#4 AIR DAMPER. If Mains Standby ATS = 1, the mains contactor,
irrespective of the mains (V4) status is closed (ie K#8 MAINS CONTACTOR relay is
off). It is possible to define the OFF mode as a warning fault.
OFFAUTO
This function changes the operating mode to AUTO. User password may be required.
OFFMAN
This function changes the operating mode to MAN. The genset immediately starts
unless a shutdown fault exists.
Manual mode
When in MAN mode, the genset runs unless a shutdown fault exists. It is possible to
define the MAN mode as a warning fault.
MANOFF
This function changes the operating mode to OFF. The genset stops after cooling
down if necessary.
LOAD-GEN

This function instructs the genset to take the load. User password may be required.

OFF-LOAD

This function instructs the genset running in MAN mode to remove the load.

Frostechnic Rev 9.00 June 2004

Automatic mode
When in AUTO mode, unless a shutdown fault exists, the genset
Starts immediately on active In#1 RUN WITH LOAD signal.
Starts immediately on active In#2 TEST W/O LOAD signal. Stops after a time delay
following In#2 deactivation.
3.
Starts after delay following a mains failure (ie abnormal V4 voltage). Stops after
delay following the mains return. All this is provided that SET-UP\OPTIONS Mains
Standby ATS = 1.
4.
SLEEP is a special AUTO mode where genset start is disabled. It is selected by
active In#3 SLEEP signal.
AUTOOFF
This function changes the operating mode to OFF. User password may be required.
1.
2.

EXPORT
This function examines and changes the amount of active (kW) and reactive (kVAr) power
that is exported to the mains in configurations #4, #5 and #6.
The user may be required to enter a password to change the
/ kVA
genset p.f. = cos = kW
export quotas. In configurations #4 and #6, export to the mains
is continuous. In configuration #5, export to the mains is
kVA
kVAr
maintained until ramp up brings the genset power output to

the defined export quotas, the mains contactor opens, and the
load is completely transferred to the genset. See Applications
kW
for further details. The export quotas must be within the
genset kW and kVA ratings, which are defined in SET-UP\BASICS. The user should be
familiar with the power right triangle relationship and with the generator derating
characteristics at low power factors (below 0.8 p.f.).
In configuration #4 it is possible to control dynamically the kW export quota through In#16.
See Applications for further details.
SEQUENCE
IDs 2 1 3
This function examines and changes the order in which
This Gen-Set ID No=1
controllers start and stop their gensets in response to an
Exchange Command 2,3
increase or decrease in their common load. If any genset
Initial Sequence 0,0
in the sequence cannot run, the next one is called. This
function is applicable to controllers in configuration #3 (random access paralleling) that
have the option Parall Auto Start set. In this example three controllers are connected to
the RS-485 network. The genset whose Controller ID No is 2 runs all the time. As the load
increases genset 1 and later genset 3 join the bus. When the load decreases genset 3 is
disconnected from the bus first.
The exchange command propagates to all the network controllers. It is called up by the
ENTER key (cancelled by ESC ) followed by pressing 0. Entering the 2,3 exchange
example results in the 3 1 2 sequence.

Entering 0,0 followed by the user password, selects the 1 2 3 4 5 6 7 8 sequence.


The sequence is stored in the EEPROM memory, ie it is not lost when disconnecting the
battery.
SET-CLOCK
The clock has no memory. Set it up after switching on the battery to have messages
logged with time.

Frostechnic Rev 9.00 June 2004

MEASURE
ENGINE
Battery Volts: 13.8
MPU: 1513rpm 50.39Hz
kW Hours: 00,001,234
HoursRun: 000,150:10

Maximum reading is 40 volts


Pickup reading. See SET-UP\BASICS Pick-up Teeth.
Non-volatile count! See COMMAND\SET-kWH
Non-volatile count! See COMMAND\SET-HOURS

GENERATOR
OVERVIEW
Gen Volts Amps
Hz
A
221 115 50.07
B
222 117
kW
C
220 125 69.9

Phase-A RMS voltage, current and frequency


Phase-B
Phase-C+ total 3-phase TRUE power

POWER+PF
Total-Power
kVA: 78.9
kW:
69.9
kVAr: 36.4

COS(PF)
A: 0.91
B: 0.88
C: 0.87

Generator
Total apparent power, Phase-A power factor
Total true power, Phase-B power factor
Total reactive power, Phase-C power factor

GEN A, GEN B and GEN C


Phase-A (L-N) display example. Phase-B and phase-C are similarly displayed.
Phase-A frequency
Gen A
Hz: 50.07
RMS voltage, % Total Harmonic Distortion
Volt: 221 %THD: 0.1
Amps: 115 kVAr: 10.5
RMS current, Reactive Power
kVA: 25.4 kW:
23.1
Apparent Power, True power
Note!
1.
%THD is a measure of how "pure" the generator sine wave is. Consider Total
Harmonic Distortion (THD) above 2% as inappropriate for modern office equipment. Nonlinear loads and ground faults at the generator stator windings are major sources of
harmonics.
2.
Positive kVAr means that the current is lagging after the voltage. Normal.
3.
Negative kVAr means that the current is leading the voltage. Abnormal!
GEN
Gen Volts Hz: 50.07
A:
221 AB:
384
B:
222 BC:
383
C:
220 CA:
382

Generator phase-A frequency


L-N voltage, L-L voltage

MAINS or BUS
This function displays V4 phase measurements.
The caption is MAINS or BUS according to SETMains A
UP\OPTIONS Mains Standby ATS
Frequency Hz: 50.14
Voltage Vrms:
223
Distortion %THD: 0.1

Frostechnic Rev 9.00 June 2004

SYNCscope
Synchroscope display example:
Gen A v Mains A
Freq Slip Hz: -0.07
Phase Shift :
11
Voltage Match:
-2

V1 gen phase-A vs V4 mains phase-A


V1 frequency - V4 frequency
V4 to V1 angles: -180..180
V1 volts - V4 volts

IN 1..16
This function shows which IOB1 input channels are active. Use the left and right push
buttons to move the LCD cursor to any input channel column to find its name. The input
channel type, "normally open" or "normally closed", is defined by SET-UP\IN 1..16.

SYSTEM
This display function provides general system
information.

Function:
Master
Network IDs 12-----ANALOG OUT (V): 1.50
PWM OUT (%):
50.0

A "Master" function indicates that the genset, when


in parallel with other gensets, determines the bus
voltage and frequency.
A "Slave" function indicates that the genset, when in parallel with other gensets, changes
its governor speed and AVR voltage settings to make its active and reactive load-Share
match those of the "Master" set.
Up to eight controllers can be connected to the RS-485 network. Each has a unique ID
number (See SET-UP\BASICS) in the range of 1..8. "Network IDs" identifies the controllers
that are connected to the network.
ANALOG OUT and PWM OUT respectively control the governor speed/fuel and the AVR
voltage/excitation.

SET-UP

This menu defines the systems parameters: set points, delays, etc. The parameters are
non-volatile (unaffected by battery disconnection). You need to know the installation
engineer password to enter the menu. See Set-up menu options for further details.

HELP

This function displays useful information.

Press ENTER to browse through the display pages.

Press ESC to exit.


The first line of display, "Standby Vx.xx", identifies the controller's operating software.

Frostechnic Rev 9.00 June 2004 10

SET-UP MENU
You can set-up the system parameters from the front panel keypad or from the remote PC
console (running the program REMOTE.EXE). The parameters are organized in several lists
according to their type: Time-delays, set-points, yes/no options, N/O or N/C definitions of
the IOB1 inputs, basic definitions and factory calibration data. Each parameter is
presented with a brief text prompt. The parameters are stored on a non-volatile memory.
They are not affected by battery voltage disconnection.
Select a list and enter :

The marker points to the parameter last examined.

Use the left and the right arrow push buttons to get to the parameter that you
want to edit.

Press ESC to return to the SET-UP menu.

Press ENTER to begin the parameter value editing. A cursor starts blinking at the
value field. If you come across the "Remove Write Protect" response, refer to the next
paragraph ("Attention!").

Press the left and the right arrow push buttons to move the LCD cursor across
the value digits.

Type any digit over a sign to invert it.

Press ESC to quit parameter editing (this leaves the parameter value unchanged).

Press ENTER to replace the parameter value with a new one. Choose different
parameter value if you come across the Value Outside Range! message.
Important! Begin the first SET-UP session with a careful review of the SET-UP\ BASICS
parameters.

Attention!
There are two methods the installation engineer can protect the system parameters:
LEVEL 1:
SET-UP entry password is 1993. After typing the password you can leave and
enter the SET-UP menu for 15 minutes without being asked for the password again.
LEVEL 2:
Parameters can be made "read-only" by SET-UP\OPTIONS Write Protect. This
protection is implemented in hardware -- IT IS RECOMMENDED TO USE THIS OPTION! To
inhibit write protect temporarily (ie effective until the battery voltage is removed) press
the push-button 0 while switching on GENCON II battery volts.

Frostechnic Rev 9.00 June 2004 11

Parameters

The following definitions correspond to the parameters of the current software


version.
The default password to enter the SET-UP menu is 1993. It is possible to change this
password through the program NED.

Basics:
Adjust the following parameters first as the set-points depend on them!
Controller ID No
Each controller that is connected to the RS485 network should have a unique ID
number, a number between 1 to 8 (use smaller ID numbers first). The ID numbers of
all the controllers that are connected to the network can be examined by the
MEASURE > SYSTEM menu function (note though that "exclude rules" can hide other
controllers from view).
Number of Poles
The number of rotor poles, a value between 2 to 20 is expected. 4 is the common
number of poles where then RPM = 30 * Hz. See the magnetic pick-up formulas page
64. The {Number of Poles } can be an odd number for cases where the engine drives
the generator through a frequency converter.
Pick-up Teeth
The number of pulses generated by the magnetic pick-up per one revolution of the
engine. See the magnetic pick-up formulas page 64. Enter 0 if the engine has no
magnetic pick-up.
CT Ratio
The current transformers ratio. The standard GENCON model is suitable for CTs with
5A secondary current, a current level that typically corresponds to 100% gen-set
load. GENCON's maximal reading is 5.9A for overcurrent implementation. The largest
{CT Ratio} value is 1023, admitting 5000/5A current transformers.
PT Ratio
Potential transformers ratio. Enter 0 or 1 if the voltage channels, V1 to V4, are
directly connected. 127 is the highest acceptable ratio but since the displayed
voltage cannot exceed 16383 a lower limit may exist. For example, a 120V model
whose full-scale {Vx Volt Max} value is 143.5V imposes a limit of 114 on the {PT
Ratio}.
Xap: Rated kVA
The generator-set maximal continuous kVA (apparent) load.
Xre: Rated kW
The generator-set maximal continuous kW (real) load. Usually Xre=0.8*Xap.
Double-up WYE Gen
This option makes it easier to reconnect a rental generator-set for low and for high
WYE (star) operation. In both cases the V1/V2/V3 channels measure the voltage of a
single (internal) alternator coil. This coil has another one in parallel when operating
in low WYE or another one in series when operating in high WYE. The generator
current is externally measured, just as usual. The use of this option is preferred to
assigning a {PT Ratio} of 2 for the high WYE case as here all the other parameters
are automatically adjusted -- the {Gen OvCurrent} is halved and all the kW/kVAr
related parameters keep their value, e.g., the {Gen Revrse kW} set-point, etc.
Ideal Voltage
The desired bus voltage. Changes to this set-point automatically pass to the
overvoltage and undervoltage set-points.
Frostechnic Rev 9.00 June 2004 12

Ideal Freq Hz
The desired bus frequency, usually 50 or 60 Hz. It is the nominal frequency that the
software for hydraulic/mechanical govnernors establishes. Changes to this set-point
automatically pass to the overfrequency and underfrequency set-points.

Options:
WRITE PROTECT...!
1 locks the parameters to prevent change of values by end users. To unlock the
parameters switch on the DC supply of the controller while pressing and holding the
0 key.
The following 4 options -- Generic, Parallel, ATS and Cogen -- select the fundamental
operating mode of GENCON software, the configurations:
Config

Application

#0

Complex projects, usually cooperating with an external PLC

#1

Prime power, Standby

#2

Mains failure standby with delayed transition ATS

#3

Multiple generator-set load-sharing

#4

Peak lopping (shaving) and CHP (combined heat and power)

#5

Mains failure with soft transfer ATS

#6

Combined mains failure with soft transfer ATS and peak-lopping

Generic Configure
In configuration #0 GENCON cooperates with an external PLC: Through In#15 and
In#16 the PLC tells GENCON what parallelling function to activate: sync, load-sharing
or export... Through K#7 and K#8 GENCON reports back to the PLC its status: ready
for load, in-sync,... Detailed documentation is available in another section.
The following three options select software configurations #1 to #6 as shown above.
In these configurations GENCON controls the generator contactor/breaker via the
normally open contact of relay K#7 and, if applicable, it controls the mains
contactor/breaker via the normally closed contact of relay K#8:
Frostechnic Rev 9.00 June 2004 13

Parallelin System
Is the parallelling system active or not. This option is ignored when selecting the
generic configuration.
Mains Standby ATS
Does relay K#8 control the mains contactor/breaker or not. This option introduces a
European style AMF (automatic mains failure) standby logic: channel V4 serves as a
single phase mains failure detector, etc.
Cogeneration Mode
This parameter tells GENCON if it used for continuous parallelling with the mains or
not.

Software configuration enhancements


System Auto Start
Breaking news: This option is a modifier to the basic six closed configurations.
This option applies to the load-sharing configuration #3 when having equal size
engines, i.e., having the same {Xre: Rated kW} parameter in BASICS. The generatorsets start and stop automatically according to the total bus load following a user
supplied priority sequence, see the COMMAND > SEQUENCE. The set-points
{+%kW/XreStart} and {+%kW/Xre Stop} determine the critical load levels at
which one generator-set needs to be added or subtracted. You can see the effect of
these set-points using the program astart.exe. Detailed documentation is available
in another section.
Load-Sharing AMF
This option brings load-sharing capability to configs #2 #5 and #6. One GENCON
controller, that is the bus master, operates almost as usual. All the other controllers
become load-sharing config #3 like slaves of that master. Should the master genset
fail one of the slaves will immediately take its place including responsibility over the
mains breaker. This new class of applications is described in the work in progresss
pages.
Sync Timeout S|W
This option applies to config #3 only. If set to one it turns the SYNCHRONIZER
TIMEOUT fault from its default shutdown behaviour into a warning fault where the
genset tries to synchronise indefinitely. This is NOT the recommended behaviour yet
one large company insists on this...
Engine Diesel|Gas
Enter 1 for gas engines. These engines require one "purging" cycle before starting
them up in order to clear gas residues. "Purging" is one {Engine Crank}, {CrankFail
Rest} cycle done with the fuel supply blocked.

Frostechnic Rev 9.00 June 2004 14

Generator Syn|Asy
Enter 1 for induction generators. This option is mainly used with config#4. Note:
1. V1, V2 and V3 connect to the mains, i.e., before the generator breaker. V4 is
not used.
2. The synchronizer matches the engine speed as read by the magnetic pick-up
with the frequency of the mains as read by V1. Only the {SY stability V/Hz}
setpoint is effective. The synchronizer does not work in test run (active In#2)
and its ANALOG-OUT is then fixed at {Gov Volt Bias}. When running the set by
In#1 and the engine speed stays within 0.4Hz from the mains frequency for
{Sync Dwell Time} the generator breaker (K#7) energises, the synchronizer
loop then stops and the load-sharing closed-loop control takes over.
3. Since in induction generators there is no control over the reactive power
(kVAr), disable the GEN EXCITATION LOSS shutdown by selecting a high {Gen
Rvrs kVAr} value and disable the AVR CONTROL FAILURE warning by selecting
zero {LSgain%P/Xap} and {LSstbl%P/Xap} values.
Disable AUTOOFF
1 tells to controller to lock the software operating mode in "auto" mode.
NOT IN AUTO Warn
1 tells the controller to declare a warning fault when the operating mode is taken
out of "Auto" by an AUTOOFF command or an active In#3 SLEEP line.
Energize Run|Stop
This option defines the fuel solenoid type as either (0) energize to run or (1)
energize to stop.
Cool After NoLoad
1 tells the controller to enter the {Coolin Down} delay before stopping the engine
even if the genset ran without load earlier, i.e., with the relay K#7 de-energized.
Bat OverVolts S|W:
HIGH BATTERY VOLTAGE alarm is declared when the DC voltage at terminal C11 is
{Bat OvVoltage} or higher for 1 second. This typically happens when the battery is
disconnected while the engine is running. The DC voltage rises due to the engine
charging alternator. It is recommended to shut down the genset immediately, i.e.
choose option 0, as this high DC voltage can damage the electric governor, etc.
Gen UnderVolt S|W :
0 = gen undervoltage fault is shutdown.
1 = gen undervoltage fault is warning.
Gen UnderFreq S|W :
0 = gen phase A under frequency fault is shutdown.
1 = gen phase A under frequency fault is warning.
LowWaterLevel S|W
In#10 LOW WATER LEVEL fault is: 0 = shutdown, 1 = warning
Ext. Overload S|W
0 would cause the generator breaker to open (by de-energizing K#7) immediately
when In#14 becomes active. A shutdown fault is then declared and the engine stops
after a cooling off period. If the option is 1 active In#14 would just cause a fault
message to be logged.

Frostechnic Rev 9.00 June 2004 15

GENCON LOW DC S|W


GENCON has a large internal capacitor that can power its microprocessor circuits
briefly while it starts to crank the engine (the voltage of 12V batteries drops to
around 5V during the initial stage of engine cranking). The DC voltage on this
internal capacitor is monitored by a special circuit to determine if its level is
sufficiently high. If the capacitor voltage gets too low a GENCON LOW DC DANGER
message is logged and GENCON writes the kWH and run-time counters to its EEPROM
memory for safekeeping. The GENCON LOW DC DANGER event can be defined as a
shutdown or as a warning fault. For 12V batteries serving emergency power systems
it may be considered better to define this condition as a warning only (if the engine
battery is old).
SleepClearsFaults
In#3 SLEEP can be used for "remote faults reset". If this option is 1 pending warning
and shutdown faults are accepted when In#3 is activated (i.e., on In#3 OFF to ON
transition).
Check Contactors
When this option is 1 (recommended!), GENCON reads the status of the generator
breaker and the mains breaker (if applicable) and compares it with the status of the
respective K#7 and K#8 command relays. Conflict between the status of the
command relays and the status of the breakers, as their auxiliary switches indicate,
will cause "CONTACTOR(s) FAILURE" and "BUS CB FAILS TO OPEN" shutdown faults to
be declared, as appropriate.
Motor Contactors
This option complements the earlier one ({Check Contactors}=1). Entering 1 tells
GENCON that without any A.C. source it is possible for a breaker to remain closed
even though its command relay tells it to open.
R#1 Shunt|kW Load
This option defines the function of Relay#1 as follows:
0
Relay#1 energizes when detecting a shutdown fault while the engine is running.
1
Relay#1 functions as a programmable load relay according to the bus load:
It energizes on light load when the {%kW/XreR#1 On} set-point is smaller than the
{%kW/XreR#1 Off} set-point.
It energizes on high load when the {%kW/XreR#1 On} set-point is larger than the
{%kW/XreR#1 Off} set-point.
Relay#1 is held de-energized when no generator-set is under load.
Relay#1 can introduce an artificial load to a lightly loaded gen-set or shed load from
a heavily loaded gen-set. Example:
Requirement: A #3 configured 1MW gen-set (the slave) is required to start and share
the load with another #2 configured 1MW standby gen-set (the master) when the
total load reaches 800kW. The slave should stop when the load drops below 700kW.
Solution: In the #3 configured GENCON connect DC- through the normally closed
contact of Relay#1 (C21-C22) to In#16. Set set-points {%kW/XreR#1 On} to 80% and
{%kW/XreR#1 Off} to 35%. Set the delays {R#1 OffOn } {R#1 OnOff} are set as
needed.

Frostechnic Rev 9.00 June 2004 16

R#2 Alarm|Usable
With the "0" option relay #2 serves as a visual alarm relay, energized when the
genset has a shutdown or a warning fault.
When this option is "1", an energized relay #2 state indicates that the genset can be
used. I.e., if the genset has a shutdown fault, if the operating mode of GENCON is
Off or Sleep (see In#3) and, of-course, if GENCON has no DC supply, relay #2 will
NOT be energized. This status is important for supervisory systems (PLCs) having to
know if a certain genset is available for work or if another one has to be chosen.
K#6 Engine|Gen On
With the 0 (default) option, K#6 energises when the engine speed is higher than 60
RPM. With 1, K#6 energises only when the generator voltage is normal.
K#8 Delay|Neutral
This option concerns the load-sharing config#3:
"0" tells GENCON to use the relay K#8 as a delayed K#7 follower, with a {K#7
On K#8 On} time delay. I.e., K#8 energizes a programmable number of seconds
after the generator breaker closes. However, K#8 de-energizes immediately when
K#7, the generator breaker, de-energizes. Typically all the K#8 N/O contacts of the
load-sharing gensets are strung together in series to create a common bus breaker
command.
"1" tells GENCON to use the relay K#8 for neutral breaker switching when paralleling
generators with star windings. Only one generator, whose GENCON is the bus
master, will have its neutral connected to the bus to prevent circulating harmonic
currents through the neurtals.
The neutrals of generators of dissimilar construction and differing output and
power factor ratings should ... never be interconnected (LLJ MAHON, DIESEL
GENERATOR HANDBOOK, page 227)
kW Drop=LoadSurge
This option tells GENCON when paralleling with the mains to consider a sudden load
decrease, where the measured load falls by {Mains kW Surge} or more, also as a
PARALLEL LOAD SURGE, i.e., loss of mains during paralleling. We recommend to set
this option.
Smooth MainsGen
This option concerns config#5, i.e., standby with soft transfer. It tells GENCON not
to log PARALLEL MAINS FAIL messages.
When one activates In#1 for testing the genset, the mains breaker opens when the
genset power reaches the EXPORT QUOTA level. In some cases it is desired to open
the mains breaker exactly when the genset power reaches the plant demand. This is
done by installing a reverse power relay on the plant mains input and the EXPORT
QUOTA is set at its highest. The reverse power relay then disconnects AC from V4
exactly when the genset power reaches the plant demand. GENCON's immediate
response in config#5 is to log a PARALLEL MAINS FAIL message and open the mains
breaker. Since in our case (*) disconnection of the V4 is normal, it is desired to
suppress the PARALLEL MAINS FAIL message.
(*) Loss of mains during paralleling is detected by the built-in PARALLEL LOAD SURGE
mechanism. If a secondary (external) means for loss of mains detection is required it
should, when it activates, disconnect the AC input from channel V4. GENCON then
immediately isolates the plant from the mains through the appropriate breaker and
it logs a PARALLEL MAINS FAIL message.
Frostechnic Rev 9.00 June 2004 17

In#06 Aux Shutdn


If this option is 1, In#06 becomes a general purpose shutdown input.
In#08 Aux Shutdn
If this option is 1, In#08 becomes a general purpose shutdown input.
In#09 Aux Shutdn
If this option is 1, In#09 becomes a general purpose shutdown input.
In#12 Aux Shutdn
If this option is 1, In#12 becomes a general purpose shutdown input.
Sndr1 OpenCircuit
The IOB2 analogue channels measure senders resistance from 20 to 512 ohms. Any
resistance from approximately 1K it considers as an open circuit state. This option
defines the open circuit state as an alarm condition for sender 1. It is a shutdown
alarm if either {Sender1 loOHM S|W:} or {Sender1 hiOHM S|W:} are 0 (shutdown).
Otherwise, if the sender setpoints serve for warning only, open circuit is a warning
alarm only too.
Sndr2 OpenCircuit
This option defines the open circuit state as an alarm condition for sender 2.
Sndr3 OpenCircuit
This option defines the open circuit state as an alarm condition for sender 3.
Sndr4 OpenCircuit
This option defines the open circuit state as an alarm condition for sender 4.
Sender1 loOHM S|W
&ONLY IF Set Runs
Sender2 loOHM S|W
&ONLY IF Set Runs
Sender3 loOHM S|W
&ONLY IF Set Runs
Sender4 loOHM S|W
&ONLY IF Set Runs
Sender1 hiOHM S|W
&ONLY IF Set Runs
Sender2 hiOHM S|W
&ONLY IF Set Runs
Sender3 hiOHM S|W
&ONLY IF Set Runs
Sender4 hiOHM S|W
&ONLY IF Set Runs

Frostechnic Rev 9.00 June 2004 18

Setpoints:
User Password
This is a four digit password that is needed for changing the operating mode
(AUTO/OFF), the export quota levels and for erasing alarms from the report log (*).
If you don't require this password mechanism enter a 0000 value.
(*) To protect erasure of alarms from the report log you also have to enable the
{WRITE PROTECT...!} option.
Cranking Attempts
The number of starter motor cranking attempts (through the relay K#3) before
ENGINE OVERCRANK or ENGINE SLOW CRANK shutdown is declared. This limit does
not apply if the {In#3 Sleep|Bypass} option is 1 and In#3 is active (when powering
fire pumps).
Overspeed RPM
This threshold applies to the speed read from the magnetic pickup. Make sure that
a correct number of teeth is defined in SET-UP\BASICS.
CrankStop RPM
Engine "firing" speed. This threshold applies to the speed read from the magnetic
pickup. Make sure that a correct number of teeth is defined in SET-UP\BASICS.
Bat OvVoltage
Battery over voltage threshold. Note, the battery equalize/recharge voltage, per
cell is for lead-antimony 2.35, for lead-calcium 2.40 and for nickel-cadmium=1.65.
Fault is declared after a 1 sec delay.
Bat UnVoltage
Battery under voltage threshold. The battery cell final voltage is dependent on the
discharge rate. For a lead-acid type at high discharge rate it may even be 1.0V.
Typical value is 1.75V. Battery undervoltage is ignored during engine cranking. Fault
is declared after a 1 sec delay.
Gen OvVoltage
Over voltage threshold. Applies to each gen phase to neutral voltage
Gen UnVoltage
Under voltage threshold. Applies to each gen phase to neutral voltage.
Gen OvFrequen
Generator phase A (V1) over frequency threshold.
Gen UnFrequen
Generator phase A (V1) under frequency threshold.
Gen OvCurrent
The overcurrent protection applies to each phase. This value (denoted Is) should be
the maximal allowable current. The time delay (denoted t) before shutdown follows
the "very inverse" curve, t = T*Is/(I-Is), where T denotes the {G 2x OvCurr} timedelay value and I denotes the measured phase current.
Gen Revrse kW
The smallest total negative kW load that would cause, if it exists for {G Revrse kW}
time, a GEN REVERSE POWER shutdown.
Gen Rvrs kVAr
The smallest total negative kVAr load that would cause, if it exists for {G Rvrs kVAr}
time, a GEN EXCITATION LOSS shutdown.

Frostechnic Rev 9.00 June 2004 19

Gen Over %THD


IEC55 standard for clean AC power suggests 2% as the maximal harmonics percentage
acceptable.
V4 Ov Voltage
Over voltage threshold for the mains/bus phase A (V4) input. If SET-UP\OPTIONS
enables Mains Standby ATS, voltage above this threshold is a mains failure condition.
V4 Un Voltage
Under voltage threshold for the mains phase A (V4) input. If SET-UP\OPTIONS
enables Mains Standby ATS, voltage below this threshold is a mains failure condition.
V4 Ov Frequen
Over frequency threshold for the mains phase A (V4) input. If SET-UP\OPTIONS
enables Mains Standby ATS, frequency above this threshold is a mains failure
condition.
V4 Un Frequen
V4 is the reference phase for synchronisation and for mains failure detection. Note
that the synchroniser will not work if the measured V4 bus/mains value is outside
the acceptable range that these four setpoints define.
Mains kW Surge
If the controller is running the generator-set in parallel with the mains and it
suddenly senses that the generator-set load dropped by more than this value (or
increased by more than this value if the option {kW Drop=LoadSurge} is set;
recommended!) it decides that loss of mains during paralleling had occurred. Its
response then is configuration dependent: In config#4 it would open the generatorset breaker, in config#5 and #6 it would open the mains breaker and would continue
to carry the load. In the generic configuration (config#0) it would report this event
to the PLC by de-energizing its K#8 relay.
When using multiple asynchronous- (induction-) generators it is not recommended to
use this protection as it was found that one generator can cause on parallel
connection another already paralleling running generator-set to trip on PARALLEL
LOAD SURGE. This is due to the random angle at which the asynchronous-generator
comes in. Another reason to hate this type of generator
Bus kW Surge
This setpoint is designed to speed up the load-sharing process when connecting or
disconnecting a large load to or from the bus. A slave generator-set introduces a
special load-sharing method once it senses that its load suddenly changed by more
than this value. Give this setpoint a value that is larger than "normal" KW
fluctuations as otherwise it would decrease the overall system stability.
SYNC Window
For successful synchronisation the phase-shift between the genset (as measured by
V1) and the bus/mains (as measured by V4) should not exceed this value for {Sync
Dwell Time}. For soft parallel connection, especially when parallelling with the
mains, it is recommended to reduce this value from the 10 default to, say, 7. The
OVERVIEW display shows an asterisk (*) on line 2 whenever sync conditions exist.
SYNC Window V
For successful synchronisation the voltage between the genset (as measured by V1)
and the bus/mains (as measured by V4) should not exceed this value for {Sync Dwell
Time}.

Frostechnic Rev 9.00 June 2004 20

Mains Offset
This set-point is subtracted from the Phase Shift that is measured by the
Gen A v Mains A Synchroscope. It is useful for LV generators that need to
synchronize across a breaker on the HV side of a step-up power transformer (power
transformers typically introduce a 30 phase shift due to their delta to star wiring).
The set-point is not applied in the generic and in the load-sharing AMF
configurations when the generator is synchronizing as a slave without load
assunming that it is then synchronizing to the LV generator bus. Here is a typical 1line diagram of such installation:

Gov Volt Bias


This is the B21 D/A voltage that GENCON applies to run the engine at the nominal 50
or 60 Hz.
SYgainV/180
This is the synchroniser phase matching gain "trimmer". It adjusts the ANALOG-OUT
reaction to the phase shift error that exists between the generator phase that is
measured by V1 and the mains/bus reference phase that is measured by V4.
ANALOG-OUT, through an appropriate interface method, controls the governor speed
setting. For fastest synchronisation aim at max-gain min-stability parameter
settings.
>>SYg V/180
This alternative synchronizer phase matching gain value is only used by a "master"
GENCON when it has one or more "slaves" running in parallel. The synchronization
process of a group of generators (bus dragging) requires a smaller than the usual
{SYgainV/180} value.
SYstbl V/Hz
This is the synchronizer phase matching stability "trimmer". In addition, the leading
plus or minus sign tells GENCON how to increase the engine speed: Select '+' if by
raising the ANALOG-OUT voltage the engine speed increases. Select '-' if by raising
the ANALOG-OUT voltage the engine speed decreases (see the GAC governors case).
>>SYs V/Hz
This alternative synchronizer phase matching stability "trimmer" is only used when
dragging a number of load-sharing slaves.
SYgain %P/V
This is the synchronizer voltage matching gain "trimmer". Note that no stability
trimmer is needed.
>>SYg %P/V
This alternative synchronizer voltage matching gain "trimmer" is only used when
dragging a number of load-sharing slaves.

Frostechnic Rev 9.00 June 2004 21

LSgain V/Xre
This is the active (kW) load-sharing loop gain "trimmer".
LSstbl V/Xre
This is the active (kW) load-sharing stability "trimmer".
LSgain%P/Xap
This is the reactive (kVAr) load-sharing gain "trimmer".
LSstbl%P/Xap
This is the reactive (kVAr) load-sharing stability "trimmer".
Ramp +kW/Sec
This is the kW loading rate of a paralleling generator-set.
Ramp -kW/Sec
This is the kW unloading rate of a paralleling generator-set.
Ramp+kVAr/Sec
This is the kVAr loading rate of a paralleling generator-set.
Ramp-kVAr/Sec
This is the kVAr unloading rate of a paralleling generator-set.
kW Quota++
When paralleling with the mains this is the individual active (kW) increment that the
dynamic export quota controls can introduce. Note that the actual generator-set
output power only gradually changes at the {Ramp +kW/Sec} rate and the effective
(cumulative) quota level is its target. Also note that after parallel connection the
effective quota levels always start from zero. The effective quotas can be displayed,
for debugging purposes, through the COMMAND / EXPORT menu function. The
EXPORT command itself sets a limit on the quota level.
kW Quota-When paralleling with the mains this is the individual active (kW) decrement that
the dynamic export quota controls can introduce...
In#00 kW Quota++
Determines which free input channel from the available 06, 08, 09, 12, 15 and 16
increases the kW export quota level in configurations #0, #4 and #6. To increase the
kVA exoprt level select the same channel in {In#00 kVAr Quota++}.
In#00 kW Quota-Determines which free input channel from the available 06, 08, 09, 12, 15 and 16
decreases the kW export quota level in configurations #0, #4 and #6. To decrease
the kVA exoprt level select the same channel in {In#00 kVAr Quota--}.
kVAr Quota++
kVAr Quota-In#00 kVAr Quota++
In#00 kVAr Quota-%kW/XreR#1 On
%kW/XreR#1 Off
+%kW/Xre Start
This set-point applies to the {System Auto Start} option of configuration #3 which
applies to equal-size generator-sets. It is the percentage of spare capacity under
which the next generator-set on the priority list is started.
+%kW/Xre Stop
Likewise... this set-point determines when one generator-set with the least priority
can be stopped.

Frostechnic Rev 9.00 June 2004 22

Exclude Net IDs


Unconditional RS485 LAN splitting: There can be 8 GENCON controllers connected
to the RS485 communication bus (LAN). If these GENCON controllers serve
generators that are on different electrically isolated bus segments, it is necessary to
tell the GENCONs on one bus segment to ignore the communications of GENCONs on
another segment (for example, to prevent load-sharing of unrelated loads). Since we
want the generators at the site to be monitored by a single PC or COMMUNICATOR
we cannot physically dissect the RS485 LAN cable. Rather, through this set-point we
tell each GENCON which other GENCON controllers to ignore. For example, if the
GENCON ID no. is 3 and it has to ignore the communication of GENCONs 1 and 2
enter {Exclude Net IDs}=1-2.
In#06 Excludes
Conditional RS485 LAN splitting: The listed controller IDs are logically excluded
from our GENCON view when input #06 becomes active. Typically In#06 is active
when a bus tie breaker (a.k.a. bus coupler) that connects to the listed gen-sets
opens. Note that the MEASURE > SYSTEM menu function shows which other
controllers our GENCON is logically RS485 LAN connected to.
In#08 Excludes
Ditto but conditional on In#08 state instead.
In#09 Excludes
Ditto ...
In#12 Excludes
Ditto ...
In#00Bypass Shutdn
When the selected input is activated a "SHUTDOWNS BYPASS ON!" warning is logged
and the genset operates in an emergency mode where most shutdown faults become
warning only. This mode of operation is required when powering fire pumps. In
accordance with the behaviour of several dedicated diesel fire pump controllers the
following faults cannot be bypassed: "REMOT EMERGENCY STOP", "OIL PRESS NOT
BUILT", "LOW OIL PRESS SHUTDN" and "RPM OVERSPEED SHUTDN".
Sender1 loOHM
Each sender has two alarm setpoints that are originally called "loOHM" and "hiOHM".
If the sender table is properly set up (see BASICS), the alarm set-points take
engineering units -- degrees, litres, etc. Hence, it is recommended to change the
"loOHM", "hiOHM" texts to the appropriate engineering units. You can change the
alarm range by moving the cursor on the '>' or '<' symbol and pressing and digit.
Hence, you can use one setpoint, for example, for {Temp Warning}>85 and one setpoint for {Temp Shutdown}>95.
Sender2 loOHM
Sender3 loOHM
Sender4 loOHM
Sender1 hiOHM
Sender2 hiOHM
Sender3 hiOHM
Sender4 hiOHM

Frostechnic Rev 9.00 June 2004 23

Delays:
Set Overspeed
The time delay from detecting engine overspeed to the declaration of fault.
Gen OverVolts
The time delay from detecting over-voltage in any gen phase (V1,V2,V3) to the
declaration of fault.
Gen UnderVolts
The time delay from detecting under-voltage in any gen phase (V1,V2,V3) to the
declaration of fault.
Gen OverFreq
The time delay from detecting over-frequency in gen phase A (V1) to the declaration
of fault
Gen UnderFreq
The time delay from detecting under-frequency in gen phase A (V1) to the
declaration of fault
G 2x OvCurr
The time delay before declaring an over-current fault in each channel I1, I2 or I3 is inversely
proportional to the phase current I:

Time-Delay =
Is is the current level that is defined in SET-UP\SET-POINTS.

Is
I Is

T, this parameter, is the time-delay that corresponds to I = 2As (substitute0in the


formula and check).
However, note that this formula is correct only for currents within the controller
measurable range, which is approximately 5.9 Amps CT RATIO maximum.
This resulting time-delay vs. current relationship is called "very inverse" and is
widely in use.
G Revrse kW
The time delay from detecting reverse active power in any gen phase (V1,V2,V3) to
the declaration of fault.
G Rvrs kVAr
The time delay from detecting reverse reactive power in any gen phase (V1,V2,V3)
to the declaration of fault, ie generator loss of excitation.
G Over %THD
The time delay from detecting "percentage of harmonic distortion" higher than the
set-point level in any gen phase (V1,V2,V3), to the declaration of fault.
SyncTimeout
Limit on the time it should take the genset to reach synchronization with the mains
or the bus (ie match V1 with V4 in phase and in voltage). When this time delay
expires, a warning fault is declared. Where load transfer is required (Mains Standby
ATS = 1, etc.), after this time delay expires transfer through paralleling is discarded
and "breakdelaymake" transfer is made.

Frostechnic Rev 9.00 June 2004 24

Sync Dwell Time


This is the minimum time that is required for the generator phase A (V1) and the bus
or mains phase A (V4) to stay within the phase and voltage match windows to
recognize synchronization.
At least 1/2 sec Sync Dwell Time is recommended.
The contactor parameters that are relevant to the
2 w
w + Tw Tc < c
synchronizer are its worst case closure time, Tc, and the
maximal phase-shift it allows at the moment of closure,
c.
Denote Sync Dwell Time by Tw and SYNC Window by w. You should make sure
that Tw is large enough and w is small enough to satisfy the above relation.
Example: Given a contactor with Tc=0.2 sec and c=20.
The default parameter values w=10 and Tw=0.5 sec mean that the worst phase
shift that the contactor will be subject to at the moment of closure is 18, which is
acceptable.
kW Surge Enable
This parameter delays the introduction of the PARALLEL LOAD SURGE protection
which detects loss of mains during parallelling. Connecting the generator-set to the
mains, because of the slight frequency and phase difference, is inevitably involved
with sudden changes in the generator-set load. Without this delay these load
changes can mistakenly be considered as an indication of loss of mains. See the
{Mains kW Surge} setpoint.
Test Delay
The time delay from In#2 TEST W/O LOAD deactivation to genset stop.
V4phase Status
This time delay concerns the AMF software configurations (#2, #5 and #6) where V4
measures the mains voltage and frequency. It is used to ignore transient mains
conditions: The mains has to be continuously "abnormal" for this time duration to
declare mains failure. The mains has to be "normal" again for this duration to
declare mains return.
Standby On
How long after mains failure (in configs #2, #5 and #6) to start the generator-set.
Standby Off
How long after mains return (in configs #2, #5 and #6) to stop the generator-set.
Eng Preglow
How long relay K#1 should energize before the first cranking attempt.
Engine Crank
Cranking (K#3) time limit. Note also that K#3 de-energizes also before this time limit
expires if two seconds after stating to crank the engine speed does not reach 60
RPM.
CrankFail Rest
The time delay between cranking attemps.
Set Stabil Max
This is the longest time that is allowed from the moment engine firing is detected
during cranking to having normal genset voltage, frequency and oil pressure. If this
time limit is not met the appropriate VOLTAGE NOT BUILT, FREQUENCY NOT BUILT
or OIL PRESS NOT BUILT alarm is raised.
Set Stabil Min
This is the minimal time that should pass from the moment engine firing is detected
during cranking to the moment when the generator breaker is closed to pick up the
load. Since software V2.8j the synchronizer is enabled only after this time delay
expires.
Frostechnic Rev 9.00 June 2004 25

Coolin Down
The genset run on time, without load, to cool off the engine
Stoppin Max
The limit on the time from blocking fuel supply (through IOB1 K#2 FUEL SOLENOID
relay) to reaching genset standstill conditions The genset run time, without load, to
cool off the engine.
AlarmOn Max
This parameter sets a time limit on the audible alarm (Relay#3) activity. There is no
time limit if the value zero.
LubPump On
K#5 lubrication Pump cycle: on time
LubPump Off
K#5 lubrication Pump cycle: off time
LoadBreakMake
This delay applies to the closed configurations, #1-#6, where GENCON controls the
breakers. It forces the load to stay cut off this minimal length of time from any
power source (mains or generator) once disconnected. By delaying the reconnection
of motor loads overloading of the power source to which the load is transferred or
reconnected is prevented. When using an air breaker with a motor charged spring
enter a long enough time delay to make sure that the spring gets fully charged
before the breaker close command is allowed to go through.
Contactor Delay
In the closed configurations, #1-#6, when the option {Check Contactors} is 1,
GENCON compares the open/closed status of the generator breaker, as it reads
through In#15, with the state of its command relay, K#7 N/O. The breaker status
must follow the state of the command relay within this time delay or the
CONTACTOR(s) FAILURE shutdown is declared. Similarly, if the software
configuration also includes control over the the mains breaker, the state of the N/C
contact of relay K#8 is compared with the mains breaker status as read through
in#16. It should be noted that when the option {Motor Contactors} is 1, conflicts
between K#7/K#8 state and In#15/In#16 status are tolerated in the absence of a
power source.
In the generic configuration #0, where the breakers are controlled by an external
PLC, this delay sets the maximal time that is allowed for GENCON to be in modes 2-4
though its K#7 is de-energized, indicating that it cannot take load. A GENERIC
CONFIG ERROR shutdown is otherwise declared. In most cases this indicates having a
bug in the controlling PLC program.
K#7 On K#8 On
This time delay is associated with the {K#8 Delay|Neutral} = 0 option and applies to
configurations #1 and #3. It marks the time delay between closure of the generator
breaker through relay K#7 to the moment when relay K#8 energizes too. K#8 deenergizes immediately when the relay K#7 de-energizes, i.e., when the generator
breaker opens. Thus, K#8 can be used in logic circuits which ensure that the loadsharing gen-sets run without load a few seconds before closing their common bus
breaker.
kW Quota++
kW Quota-kVArQuota++
kVArQuota

Frostechnic Rev 9.00 June 2004 26

R#1 OffOn
When R#1: Trip|kW Load option is 1, this is the time delay before RELAY#1 is
energized.
See Basic load control in Applications.
R#1 On->Off
When R#1: Trip|kW Load option is 1, this is the time delay before RELAY#1 is deenergized.
See Basic load control in Applications.
Parll Start
When the Parall Auto Start option is active, in parallel genset systems, as the
system load increases this is the time delay before starting the next genset in the
COMMAND\SEQUENCE. See Applications.
Parll Stop
When the Parall Auto Start option is active, in parallel genset systems, as the
system load decreases this is the time delay before removing and stopping one
genset. See Applications.
LS Settling
When the Parall Auto Start option is active, in parallel genset systems, this is the
minimal time between consecutive gensets start/stop in response to load changes.
The load-sharing feedback loops should re-distribute the load evenly within this
time. See Applications.
Sndr1 loOHM
Sndr2 loOHM
Sndr3 loOHM
Sndr4 loOHM
Sndr1 hiOHM
Sndr2 hiOHM
Sndr3 hiOHM
Sndr4 hiOHM

Frostechnic Rev 9.00 June 2004 27

FACTORY
Access to this menu is protected by the password 311794. It is possible to change this
password through the program NED. This menu allows access to two sensitive lists:
1. SET-COUNT
Adjusts the following activity counters: kW Hours, HoursRun, Engine Cranks and
GenSet Runs.
2. CALIBRATE
Vx Volt Max
This is the full scale AC volts reading of channels V1 to V4. This value is selected
according to GENCON model. To calibrate the voltage channels (if this is really
required!) adjust the first four trimmers on GENCON side (V1 trimmer is topmost). It
is recommended to restore the weak glue (or use a common nail polish) that
prevents trimmers position changes due to vibrations.
Ix Amps Max
This is the full scale AC amps reading of channels I1 to I3. It is 5.9 Amps for the
standard models. To calibrate the current channels adjust the lower three trimmers
on GENCON side. Restore the weak trimmers glue...
B+ Volt Max
Full scale reading of the battery DC volts. This value is used for calibration. Its
nominal value is 40V.
D/A VoltMax
Full scale DC volts of ANALOG OUT. This value is used for calibration. Its nominal
value is 7.5V.
Adj Sec/Week
This parameter calibrates the clock and the frequency metres. A positive value
accelerates the clock, a negative value slows it down. The required value is 0 for all
the new controllers as marked on their rear panel. Unmarked old controllers require
slowing down of their clocks by 399 seconds per week, i.e. -399 (which is the default
value). As computer clocks slightly "drift" due to "aging" and different operating
temperatures you may wish to adjust the clock in the future.
Ignore PhaseOrder
Phase input V2 is expected to lag after V1. Otherwise an ILL GEN PHASE ORDER
warning is issued. When GENCON is used for single phase applications this warning
has to be disabled. We hide this option in the FACTORY list to discourage its use in
normal 3-phase projects...
RMS use Harmonics
This option tells the controller how to compute the electrical parameters, VAC's,
etc. With the 0 option the computed values are based on the fundamental frequency
only, with 1 the 3rd, 5th and 7th harmonics are included too.

Frostechnic Rev 9.00 June 2004 28

Software Code
If the displayed number is not 0, the installed software has some non standard
operating rules in effect. Also in this case the HELP screen shows the software
version with a capital letter, for example, 2.8M rather than 2.8m. The software
code is a hexadecimal number. For example, when the special options 10 and 11 are
effective the software code is 0600 ( = 29 + 210). Contact Wexler if you need any one
from the following special options:
1. Don't cool off the engine when stopping it by In#3.
2. Don't add up the measured V3xI3 power components to the total kW and kVAR
values which the closed-loop load-sharing and export controls use. See the
page on measuring 3 wire systems.
3. Skip the test for 20 RPM after 2 seconds of cranking. This may be required
when using compressed air starters.
4. Work in 1 phase 3-wire applications (where there is 180 degrees phase shift).
5. Apply 10 seconds to the GOV CONTROL FAILURE alarm. In the standard
software the delay is 0.5 sec.
6. Apply the generator over/under voltage/frequency alarms to the induction
(asynchronous) generator case too. In the standard software abnormal voltage
and frequency condition just stops the induction generator.
7. 10 second AVR CONTROL FAILURE delay. In the standard software the delay is
0.5 sec.
8. De-energize the fuel solenoid K#2 during the {CrankFail Rest} time delay. This
is required for MTU's MDEC engine controller.
9. In non-paralleling applications this option turns the ANALOG-OUT and the
PWM-OUT ports into kW and kVAR load monitors, respectively. This option is
available from version 2.9I. It can also be identified on the first HELP display
line as IOB1:M or IOB2:M. The following two adjustable set-points define the
monitoring full-scale:
{Monitor V/Xre} which defines the ANALOG-OUT voltage level when the
engine runs with full load, i.e., when it carries {Xre: Rated kW}
kilowatts.
{Monitor %/Xap} which defines the PWM-OUT duty cycle when the
generator carries {Xap: Rated kVA} kilovars.
This special option is required by modern gas powered engine
governors.
10. Relay#1 under the option {R#1 Shunt|kW Load} = 0 energizes on any shutdown
fault. In the standard software, as a shunt trip driver, it energizes only if the
generator-set was running when shutdown was declared.
11. Relay#1 under the option {R#1 Shunt|kW Load} = 1 energizes when the
generator load is between the {R#1 Lowest kW} set-point to the {R#1 Highest
kW} set-point (set-points included). The {R#1 Off->On} and {R#1 On->Off}
delays apply here too. This behaviour is required for dual fuel engines where
R#1 tells when to switch on the gas supply.
12. Disables the warning COMM2 TIMEOUT ERROR. When the MODBUS master is a
non-critical SCADA system it may be difficult to comply with the requirement
to repeat the run/test commands...
13. Turns In#7 (HIGH TEMP SHUT) and In#13 (AIR DAMPER SHUT) into general
purpose warning inputs.
14. Modifications:
Energize K#6 immediately past cranking.
Shut down the genset immediately upon In#14 OVERLOAD and not after
cooling off.
Frostechnic Rev 9.00 June 2004 29

15. Turns the set-point {In#00Bypass Shutdn} into {In#00Disable Parll}. Any
spare input, #6 #8 #9 or #12, can be used to disable the paralleling system. An
active input logs a PARALLELING DISABLED warning and the system replaces
soft transfer (configs #5 and #6) with delayed transition (effectively
config#2), etc. In addition, the relay K#4 (usually the air-flap relay) is used to
indicate activity of the synchronizer. This option also applies to the generic
configuration only that instead of resetting the ANALOG/PWM controls they
freeze at the levels existing immediately before the spare channel of choice
became active.
16. Disables the RPM v FREQUENCY ERROR warning. This was required for a
generator-set whose 1500 RPM engine drove (through frequency conversion
gear) a 60Hz alternator.
17. Turns In#07 into a general purpose, non-bypass-able shutdown (ned the "HIGH
TEMP SHUT" and the "HIGH WATER TEMP SHUT" text messages). Turns In#13
into a general purpose warning (ned the "AIR DAMPER SHUT" and the "AIR
DAMPER CLOSED" text messages).
18. Include harmonics in the RMS computation.
19. Immediate COMM2(phone) command execution. By default GENCON has to be
told the same command twice for any genset start/stop or power
increase/decrease command takes effect. We need however an immediate
response when managing a group of config#4 peak-shavers where the
Communicator has also the onus of (proportional) load-sharing to manage
through GENCON's export quota mechanism.
20. Paralleling with analog gensets: The KW load is read by Sender1 of the IOB2
rather than from GENCON's own three phase inputs. With Sender1 reading the
analog paralleling line of an old/existing genset systems we can parallel them
with new GENCON based gensets. More information is available.
21. Based on the IOB2 Sender4 readings and after a one second filtering delay the
relay K#4 switches on and off according to the set-points {Sndr4K#4 On} and
{Sndr4K#4 Off}. A typical use is for fuel pump control based on the fuel
sender readings. Note that like the sender alarm set-points the greater-than
(>) and the less-than (<) signs can be changed by placing the cursor on the
sign and pressing any number key. The K#4 relay resets on any immediate
type generator-set shutdown.
22. In#07, normally the high coolant temperature shutdown, becomes a general
purpose warning channel.
In#14, under the option {Ext. Overload S|W}=0, becomes an immediate
shutdown alarm (normal "overload behavior" is to shut down the genset after
the cooling off interval).

Frostechnic Rev 9.00 June 2004 30

Applications
It is obvious that a switchboard design depends on the
generator-set use: prime, standby, mains peak demand
lopping (shaving), etc. However, the difference in the
scope of the switchboard design between the continents is
less known. Here is a block diagram of a classic standby
set:

Transfer

Normal Source

Switch
Loads

G
Emergency Source

In the USA, the transfer switch function is normally


implemented by an independent device, the Automatic Transfer Switch (ATS): Detecting
power failure, triggering the engine to start, transfer of load to the generator after build
up of voltage and frequency, re transfer to normal source when power is restored and
engine shutdown, are all handled by the ATS. The genset switchboard does not include
these functions.

However, particularly in Europe, all these functions are normally included in the
genset switchboard. Typically the switchboard with two contactors directly implements the
load transfer (called the changeover contactors).
The Americans claim that their approach is more reliable
The Europeans claim that their approach is more economical
GENCON II does not take sides -- It supports both traditions and its large number of
parameters (delays, set points,), all adjustable from the front panel, make it easy to
adapt to any application.

Abbreviation

SET-UP\OPTIONS

Description

GENERIC

Generic Configure?

Is contactors' switching under


external control?

PARALLEL

Parallelin System?

Are the synchronizer and the


load-sharing functions active?

ATS

Mains Standby ATS?

Does the relay K#8 control the


mains contactor?

COGEN

Cogeneration Mode?

Will the genset parallel with the


mains continuously?

Genset applications are built around the following seven configurations:


YES

NO

GENERIC?

NO

#0

NO

#1

ATS?

YES

PARALLEL?

NO

YES
#2 NO
#3

Frostechnic Rev 9.00 June 2004 31

COGEN?

ATS?

YES

NO

#4

#5

YES

COGEN?

YES

#6

The generic configuration, #0, is designed for the "special projects" department. Access is
given to all the GENCON II functions, but the "glue logic", particularly control over the
contactors (breakers), is handled by an external logic device, a PLC usually.
The configurations #1..#6, however, constitute complete solutions, including control of the
contactors.
The following description of the applications assumes that the controller is in AUTO mode
and that no shutdown fault is pending.

Single generator-set applications


#1 American standby
The controller starts the genset immediately when its
K#7
In#1 input becomes active. When the genset is ready for
load the relay K#7 is energized, the contactor is closed
ATS or LOAD
G
In#1
and the genset takes the load. When In#1 is deactivated,
K#7 is de energized and the genset stops after a cooling
off period. Momentary activation of In#2 starts the genset for a test without load session
(ie K#7 is not energized).

#2 Euro standby

K#8
The controller monitors the voltage and frequency of one
phase of the mains by its V4 input (for 3 phase protection the
Mains Contactor
external relay should disconnect V4 input on a mains failure).
K#7
On a mains failure the controller energizes relay K#8 which,
LOAD
V4
through a normally closed#1 contact, opens the mains
In#1
G
contactor. After a predetermined time delay the genset is
Gen Contactor
started. When the genset is ready for load, the relay K#7 is
energized and its normally open contact closes the generator contactor. When the mains
power is restored, after a predetermined time, the load is transferred back to the mains.
To protect the load (eg synchronous motors), a time delay is introduced between the load
power cut and load power re connection. In this configuration the two contactors are
electrically interlocked (and sometimes mechanically interlocked) to prevent simultaneous
engagement.
An active In#1 input starts the genset. When the genset is ready for load the relay K#8 is
energized and the mains contactor opens, there is a time delay and then the relay K#7 is
energized and the genset takes the load.
Momentary activation of the In#2 input starts the genset for a test without load session.

#4 Paralleling with the mains


Note: This configuration also supports induction (asynchronous)
generators. See in SET-UP\OPTIONS the parameter Generator
Syn|Asy.

LOAD
K#7

In#1
G
The genset starts immediately on an active In#1 input. The
genset is synchronized with the mains. When the voltage and
phase of V1 (generator) are sufficiently close to the voltage and phase of V4 (the mains),
the relay K#7 is energized and parallel connection begins. The genset raises the amount of
active (kW) and reactive (kVAr) power it exports to the mains at a predetermined rate,
until the export quotas are met. When the In#1 input is deactivated, power export is
reduced at a predetermined rate. When reaching zero the relay K#7 is de energized, the
generator contactor opens and the genset stops after a cooling off period:

#1

In this way the mains is connected to the load when GENCON II is without DC supply.

Frostechnic Rev 9.00 June 2004 32

Engine Active Power Output

Generator Reactive Power Output

+ kW/Sec Ramp

- kW/Sec Ramp

+ kVAr/Sec Ramp

kW Export Quota

- kVAr/Sec Ramp

kVAr Export Quota

Time
Sync with Mains

Parallel Connection

In#1 ON

Time

Cooling-off

Sync with Mains

In#1 OFF

Parallel Connection

In#1 ON

Cooling-off

In#1 OFF

Momentary activation of the In#2 input starts the genset for a test without load session -the genset is synchronized with the mains but the relay K#7 is not energized.
When detecting loss of mains during paralleling, the relay K#7 is de energized and the
generator contactor opens. Loss of mains is detected within 100 ms, as follows:
1.
PARALLEL LOAD SURGE: Built-in protection mechanism: A sudden load change is
measured, larger than the Parll kW Surge set-point. Response to load decrease is optional,
see kW Drop=LoadSurge?.
2.
PARALLEL MAINS FAIL:
External protection: Low voltage is measured by V4 -- an
external relay disconnects V4 input.
The user can select export quotas within the genset ratings, ie Export-kW Rating-kW and
(Export-kW) + (Export-kVAr) (Rating-kVA). See SET-UP\BASICS Xre and Xap.
In this configuration the genset is used to parallel and export power to the mains in order
to reduce the electricity supply tariff for peak loads. The electricity companies also
surcharge consumers with low power factor (PF). The user should know that improper
choice of the export quotas can worsen the mains supply PF: Suppose a plant load is
444 kVA at 0.9 PF, ie 400 kW & 193.7 kVAr. If the genset exports 200 kW only, ie the mains
still carries the full 193.7 kVAr load, it turns that the mains is supplying power at an
uneconomic 0.72 PF. However, if the genset export quotas are 200 kW and 150 kVAr (using
a 250kVA genset at 0.8 PF) the mains is supplying power at an excellent 0.98 PF.
K#8

#5 Euro standby with soft load transfer

Mains Contactor

Unlike the configuration "#2 Euro Standby" here the


K#7
changeover contactors must not be interlocked. On the mains
LOAD
V4
return, the genset is synchronized and goes into paralleling
In#1
G
with the mains. The genset power is reduced at a
Gen Contactor
predetermined rate, gradually transferring the load back to
the mains. When reaching zero genset power output, the relay K#7 is de-energized, the
generator contactor opens and the genset stops after a cooling off period. The diagram on
the left describes the mains vailure and return cycle for the genset kW output (the kVAr
case is similar).
Engine Active Power Output

Engine Active Power Output

+ kW/Sec Ramp

- kW/Sec Ramp

- kW/Sec Ramp

Unknown Plant Load

Unknown Plant Load

kW Export Quota
Time

Time
Isochronous
Governor
Operation
Mains Failure

Sync
Cooling-off
Parallel
Connection
with
Mains
Mains Return

Frostechnic Rev 9.00 June 2004 33

Sync with Mains Parallel


Connection
In#1 ON

Isochronous
Governor
Operation

Cooling-off
Parallel
Connection
In#1 OFF

When the mains is available, an active In#1 input starts the genset immediately. Before the
genset takes the full plant load it reaches through paralleling a user selected export power
quotas.
Momentary activation of the In#2 input starts the genset for a test without load session -The genset is continuously synchronized with the mains but there is no load transfer.
In this configuration the genset stays in parallel with the mains only for the brief time it
takes to perform a smooth power transfer (called "occasional paralleling"). Most electricity
boards are more lenient in approving an installation of this sort than approving continuous
paralleling with the mains.

#6 Euro standby with soft mains return & paralleling with the mains
K#8
This configuration provides an automatic mains failure standby
operation with one power cut only as in configuration #5.
Mains Contactor
Active In#1 input starts the genset for continuous paralleling
K#7
with the mains as in configuration #4.
LOAD
V4
When detecting loss of mains during paralleling, the relay K#8
In#1
G
is energized, the mains contactor opens and the genset
Gen Contactor
remains with the load. Loss of mains is detected within 100
ms, as follows:
1.
PARALLEL LOAD SURGE: Built-in protection mechanism: A sudden load change is
measured, larger than the Parll kW Surge set-point. Response to load decrease is optional,
see kW Drop=LoadSurge?.
2.
PARALLEL MAINS FAIL:
External protection: Low voltage is measured by V4 -- an
external relay disconnects V4 input.

Multiple generator-set applications


Up to 8 generator-sets can operate in parallel on a common bus. Their ratings need not be
equal.
The controllers coordinate their operation by communicating through their RS485 local
area network (LAN).
The LAN maximal length, end to end, is 1,200 meters.
An IBM compatible PC can be connected to the LAN: The program, REMOTE.EXE, creates
virtual duplicates to all the controllers' front panels, display and keys, simultaneously on
the PC screen.

#3 Random access paralleling


All the controllers use configuration #3. The controllers synchronize the genset phase,
measured by V1 input, with the bus phase, measured by V4 input.
The gensets start by activating their In#1 inputs. If the bus is dead, the first genset is
connected without delay. Other gensets are synchronized with the bus before connecting
them, one by one, to the bus. The K#7 relays control the generator to bus contactors. The
K#8 relays follow K#7 with a time delay and can be used to ensure some time of paralleling
on the bus without load. The gensets share the load active (kW) and reactive (kVAr)
components proportionally, ie each genset contributes an equal share of its kW and kVAr
ratings. The genset connecting first to the (dead) bus is called the "master" genset. Other
genset's that are in parallel on the bus are called the "slave" gensets. If the "master" genset
is disconnected from the bus, immediately one of the "slave" gensets becomes a "master"
genset. The voltage and frequency of the bus are determined by the "master" genset
governor and AVR independent characteristics. The "slave" gensets however by continuously
varying the governor and AVR external controls make the "slave" gensets load share exactly
match the load share of the "master".
Frostechnic Rev 9.00 June 2004 34

A.K#7

The figure describes a three-genset system with


controllers A, B and C. The bus to load contactor is
closed only if the bus is powered by at least two
gensets.

#3 Load dependent start/stop sequencing


1 General

A.In#1

G1
A.V4
B.K#7

B.In#1

F= (A.K#8 and B.K#8) or


(B.K#8 and C.K#8) or
(C.K#8 and A.K#8)
LOAD

G2
B.V4

GENERATORs

C.K#7
GENCON (R) controllers, in a multiple generator-set
BUS
plant with equal size engines, can automatically
G3
start and stop their generator-sets according to the C.In#1
plant active (kW) load. The operator can change
C.V4
the sequence in which the generator-sets start and stop from any controller panel.
The sequencing logic is designed for plants with a slowly varying load level. Hotels,
hospitals and large residential and office blocks fall into this category. The objective of the
sequencing logic is to keep the number of parallel running generator-sets to the minimum.
In this application all the controllers are in configuration #3 and the{ Parall Auto Start}
option is 1.

2 Starting and stopping rules


2.1 General
The plant operator through the SEQUENCE command determines the order in which
generator-sets start when the load in-creases and stop when the load decreases. With a
2 3 1 sequence the generator-set whose controller ID no. is 2 has the highest running
priority. If a generator-set cannot start, the next one from the sequence automatically
starts.
The sequencing logic skips generator-sets with a pending shutdown fault and generator-sets
whose controllers are not in auto mode (for example, where the controller has an active
In#3 SLEEP command). In addition, be-ginning from software version 2.5n, also an active
In#16 command disables the participation of the generator-set in the sequencing logic. Yet,
with an active In#16 line the controller can be started for testing through In#2 or forced to
run in parallel with the other generator-sets through an active In#1 command.

Frostechnic Rev 9.00 June 2004 35

2.2 Definitions
N : Denotes the number of generator-sets that currently run in parallel.
Unity : The engine { Xre: Rated kW} parameter in BASICS is defined as one unit of power.
The following , and _ variables use this unit. For example, if Xre is 800kW then a 50% _
level represents a 400kW load.
: Denotes the generator-set load. Note that (1- ) is the spare generator-set power and N
* (1- ) is the total spare power in the parallel running generator-sets, i.e., how much extra
load the running generator-sets can safely take.
: Denotes the set-point { +%kW/Xre ! Start}. is the total spare power threshold that
requires an increase in the number of parallel running generator-sets. can be larger than
100% and its value must be the same in all the controllers.
: Denotes the set-point { +%kW/Xre ! Stop}. 1 + is the total spare power threshold that
requires a de-crease in the number of parallel running generator-sets. can be larger than
100% and its value must be the same in all the controllers. Make sure that < or
otherwise one generator-set will start and
stop incessantly.
T1 : Denotes the { Parll Start } time delay for the threshold. Its value must be the same
in all the controllers.
To : Denotes the { Parll Stop } time delay for the threshold. Its value must be the same in
all the controllers.
2.3 The rules
1. One generator-set should start and take load immediately when the condition N * (1- )
0 is true.
This condition exists when:
(a)
(b)
too high.

N = 0, i.e., the plant must have at least one generator-set powering the load.
_ 1, i.e., the load on the current number of parallel running generator-sets is

2. A generator-set should start and join the parallel running generator-sets T1 time after
the condition
N * (1- ) becomes true. I.e., when the total spare power in the parallel running
generator-sets
is or lower.
3. A generator-set should stop To time after the condition N* (1 - ) 1 + becomes true.
I.e., even after stopping one generator-set the total spare power in the remaining
generator-sets, N * (1- ) - 1, is or higher.
4. When a generator-set connects to the bus or when a generator-set disconnects from the
bus, rules 1-3 are suspended for { LS Settling } seconds. These rules are suspended to avoid
false decisions while the load is re-distributed among the new number of generator-sets.

Frostechnic Rev 9.00 June 2004 36

5. Black start:
Before software version 2.5n
When the generator-set controllers mode changes from Sleep to Auto by simultaneously
deactivating their In#3 command lines, all the generator-sets start and connect to the bus.
The generator-sets run in parallel for T0 time and then, according to the bus load level
(rule 3), some of the generator-sets stop.
From software version 2.5n
When all the In#16 command lines are simultaneously released all the generator-sets start
and connect to the bus. The generator-sets run in parallel for T0 time
and then, according to the bus load level (rule 3), some of the generator-sets stop.
6. When the generator set controllers mode changes from Auto to Manual by simultaneous
activation of
their In#1 terminals, all the generator-sets connect to the bus. When the controllers mode
changes back to Auto by simultaneous deactivation of their In#1 terminals, according to
the bus load level (rule 3) some of the generator-sets stop without delay.

3 Start/stop rules example


A power plant has five generator-sets, each has the following set-points:{ Xre: Rated kW }
=400, = 25% and = 30%. Assume that N generator-sets currently run in parallel. As the
load increases the following table shows the load levels when the (N + 1)-th generator-set
starts:
N
Total bus load
Generator-set load
1
300
300
2
700
350
3
1100
367
4
1500
375
As the load decreases the following table shows the load levels when the N-th generatorset stops:
N Total bus load
Genset load
2
280
140
3
680
227
4
1080
270
5
1480
296

4 A Real Application
A, B and C denote the controllers of three equal size generator-sets that serve for mains
failure standby; The sequence is 1 2 3; The Automatic Transfer Switch (ATS) logic
is external.
Let the signal x = A.In#16 = B.In#16 = C.In#16 (version 2.5n onward).
When the mains is healthy the ATS should hold x active.
Upon mains failure the ATS releases the signal x 1 .All the generator-sets start
together according to rule 5; the generator-set that has stabilized first connects to the
(dead) bus without delay and becomes the bus master 2. The other slave generatorsets connect to the bus after synchronization 3 . The generator-sets run in parallel for T0
= { Parll Stop} time and then, if the load is low enough, generator-sets 3 and 2 stop (no. 2
stops { LS Settling} time after no. 3)
1 The expected plant load is unknown. Probably it will be at its peak because of the need to recharge the UPS.
2 The
3 If

generator-set whose governor and AVR determine the bus frequency and voltage.
the master stops, the remaining set with the lowest ID number becomes the new bus master.

Frostechnic Rev 9.00 June 2004 37

Hybrids
A hybrid paralleling system is made of one (but only one) controller in configuration #1,
#2, #4, #5 or #6 and a number of controllers in configuration #3. The controllers in
configuration #3 are said to be "permanent slaves" -- the different controller is said to be a
"permanent master". The use of the hybrid system is similar to the use of the master
controller. The slave gensets constitute an auxiliary power generation capacity that
augments the capacity of the master genset. The following operating rules are common to
all hybrids:
1.
2.
3.
4.
5.

When the master genset starts, all the slave gensets start#1,
When the master genset is taken off load, all the slave gensets are taken off load,
When the master genset stops, all the slave gensets stop,
The master genset is always first to be connected to the bus,
The slave gensets maintain the same load share of the master genset.

Hybrids will be demonstrated by a few practical examples:


A.K#7

CONFIG.#1
Augmented American standby
ESSENTIAL
When A.In#1 starts genset G1, controller B
G1
A.In#1
LOAD
automatically starts up genset G2. G1 takes the
essential load first. Controller B, sensing the bus
phase through V4, synchronizes G2 with the bus
B.K#7
B.K#8
and the two gensets share the essential load. After
NON ESSENTIAL
G2
CONFIG.#3
a certain time, through B.K#8 the non essential
LOAD
load is also introduced and the two gensets share
B.V4
GEN BUS
both loads proportionally. Since controller A does
not use the auto synchronizer function,
G1 does not require an electric governor, nor an AVR with external voltage control.
A.K#8

Augmented Euro standby


MAINS CONTACTOR
In this example only the combined power of gensets
LOAD
G1 and G2 can supply the load:
A.V4
Genset G1 is started either by a mains failure,
A.K#7
CONFIG.#2
detected by A.V4, or by an active A.In#1 input.
B.K#8
G1
A.In#1
Controller B automatically starts up the genset G2
B.K#7
too. When G1 is ready for load it is connected to the
GENs CONTACTOR
generators bus. Controller B then synchronizes the G2 CONFIG.#3 G2
phase it measures by V1 with the bus phase it
B.V4
GENs BUS
measures by V4. After a certain time of running in
parallel without load, the relay B.K#8 is energized and the plant load is taken and shared
proportionally between the gensets. The Euro standby changeover delay between A.K#7
and A.K#8 driven contactors exists also between B.K#8 and A.K#8 since as soon as A.K#7 is
de energized, according to the hybrids operating rules, B.K#7 and B.K#8 are also de
energized. Since controller A does not use the auto synchronizer function,
G1 does not require an electric governor, nor an AVR with external voltage control.

#1

Unless it is not in AUTO mode or faulty.

Frostechnic Rev 9.00 June 2004 38

Augmented Euro standby with soft mains return


A.K#8
In this example only the combined power of gensets
MAINS CONTACTOR
G1 and G2 can supply the load: Automatic mains
LOAD
failure standby is provided as in the previous
example. When the mains returns, G1 synchronizes
A.V4
A.K#7
with the mains and in doing so "drags" G2 into
B.K#8
synchronism with the mains. This works as follows:
G1
CONFIG.#5
When G1 slightly increases its speed, it increases its
B.K#7
load share. G2, being G1's slave, in trying to match
GENs CONTACTOR
G2
CONFIG.#3
his load share with his master, raises its governor
B.V4
speed setting and so forth. When synchronism is
GENs BUS
reached, controller A de energizes the relay K#8 and
the "hybrid" enters into paralleling with the mains. As G1 gradually reduces its active and
reactive export, smoothly transferring the load back to the mains, G2 does the same and at
the same rate. When controller A de energizes the relay K#7, controller B does the same,
the two gensets cool down and stop.

#0 Generic configuration
This configuration provides
maximal flexibility in the
design of parallel systems. The
controller operates under the
command of a PLC
(Programmable Logic
Controller) that also controls
the system contactors.

GEN

BUS OR MAINS
V1

RUN WITH LOAD

V4

In#1

GENCON II
TEST W/O LOAD

In#2

SLEEP (BYPASS)

In#3

In#15

K#7

n
o
p
q

MODE

OFF OFF

SYNC W/O LOAD

OFF ON

EXPORT

ON

OFF

LOAD-SHARE

ON

ON

SYNC WITH LOAD

READY FOR LOAD

The controller starts the


B
IN SYNC
In#16
K#8
genset when activating its
RS485
In#1 RUN or In#2 TEST
command lines. An active
In#3 SLEEP command overrides In#1 RUN and In#2 TEST and stops the genset.
When the controller starts the genset following an In#1 RUN command, after build up of
the genset oil-pressure, frequency and voltage and waiting the Set Stabil Min time delay, it
energizes the relay K#7 to indicate that it is ready to accept load.
Note: The controller does not energize the relay K#7 following an In#2 TEST command!
When removing the In#2 TEST command the genset stops after a Test Delay.
MODE

The controller's operating mode is selected by In#15 and In#16 according to the above
table. If the genset is not ready for load, ie the relay K#7 is not enerwized, mode n must
be selected by the PLC within a Contactor Delay time or the GENERIC CONFIG ERROR
shutdown is declared.
In modes n and q the synchronizer is active. By adjusting the genset speed and voltage it
tries to match the generator phase (V1) with the bus/mains phase (V4). The synchronizer
energizes the relay K#8 any time it succeeds in holding V1 within a Sync Window and
Sync Window V distance from V4 continuously for Sync Dwell Time.

Frostechnic Rev 9.00 June 2004 39

In mode o the controller runs the genset in parallel with the mains. If the command In#1
RUN is active, the genset power increases at Ramp +kW/Sec and Ramp+kVAr/Sec rates until
reaching the Export Power Quotas where they are maintained as long as the command is
active. When removing the In#1 RUN command, the genset power reduces at
Ramp -kW/Sec and Ramp-kVAr/Sec rates until, when reaching zero, the relay K#7 is de
energized, indicating to the PLC that it needs to take the genset off load.
Note: Detecting PARALLEL LOAD SURGE in mode o de energizes the relay K#8 to warn the
PLC against a possible mains failure.
In mode p the controller runs the genset in parallel with other sets. If one of the other
genset controllers is in mode o or q that controller is "the master" and all the other
controllers in mode p, "the slaves", try to match their active (kW) and reactive (kVAr) load
share with that of the master (ie in proportion to each genset Xre: Rated kW and
Xap: Rated kVA). If all the controllers are in mode p, one of them is nominated as the
master and its genset determines the speed and the voltage of the bus.
Example: Given a group of standby gensets sharing a common load, ie the controllers run
in mode p under In#1 RUN commands. The PLC needs to transfer the load softly from the
generators to the mains:
1.
The PLC selects one of the paralleling controllers and switches its V4 channel to
measure the mains (before V4 is connected to the bus). The PLC places the controller in
mode q. This controller automatically becomes the bus master and drags the other gensets
into synchronism with the mains.
2.
When the selected controller relay K#8 energizes, the PLC connects the bus with the
mains and places the controller in mode o.
3.

The PLC places all the other controllers also in mode o.

4.
The PLC removes all the In#1 RUN commands. The gensets power export gradually
reduces. When each genset power reaches zero the controller's relay K#7 is de energized.
The PLC then opens the genset contactor and places the controller in mode n.

Frostechnic Rev 9.00 June 2004 40

GENCON V3.0f

9 May 2004, GENCON version 3.0f


o Adds statuses #71 and #72 to the status map to monitor the state of In#15 and
In#16.
o Bug fix for idle speed logic: only if both the magnetic pickup frequency and
the oil pressure disappear (active In#5) we go back to {CrankFail Rest} retry
properly...
24 Apr 2004, GENCON version 3.0e
It is now safe to change config #5 (AMF Standby + Soft Transfer) and config #6 (AMF
Standby + Peak Shaving) to config #2 (AMF Standby with open/delayed transition)
also when running in parallel with the mains. This is commonly done through the
{In#xx Disable Parll} feature. See special software request #15.

6 Mar 2004, GENCON version 3.0d


The {Check Contactors} option gets more specific breaker error reporting:
CAN'T OPEN GEN-BRKER (K#7 OFF, In#15 ON) shutdown
CAN'T CLOS GEN-BRKER (K#7 ON, In#15 OFF) shutdown
CAN'T OPEN MAINS-BRK (K#8 ON, In#16 ON) shutdown
CAN'T CLOS MAINS-BRK (K#8 OFF, In#16 OFF) warning, genset takes load

29 Feb 2004, GENCON version 3.0c


Selecting the new {Backlight LCD Run} option in the SET-UP/FACTORY menu will
cause the LCD back-light to switch on when the gen-set is running. When the gen-set
is at standstill, to reduce the battery load, the back-light switches off one minute
after the last keystroke as is the usual behavior . The back-light LEDs increase the
current consumption by almost 250mA (!), dissipating about 1W heat. In cold
weather it is desirable to warm up the LCD to make it respond faster and increase
the characters contrast.

16 Nov 2003, GENCON version 3.0b


To interrupt the idle speed run the generator voltage and frequency now both must
reach normal levels. Version 3.0a only considered the frequency.

10 Nov 2003, GENCON version 3.0a


1. The {Load-Sharing AMF} option is introduced to return the {System Auto
Start} (see V2.9l below) back to its intended function, to enable the
sequencing logic (sequencing is not yet implemented in the new load-sharing
AMF configurations, but it is definitely in the planning!). In other words, the
automatic mains failure standby configurations, #2, #5 and #6, can do loadsharing with their own kind once the {Load-Sharing AMF} option is set.
2. The {Extrn Engine Ctrl}=1 option is introduced to treat In#5 as a general
shutdown input rather than the default (=0) action where In#5 directly reads
the engine oil pressure contact. This assignment, together with a {Pick-up
Teeth} count of 0 (see BASICS), makes it easier to work with external engine
control units... (Caterpillar's EMCP, for instance).

Frostechnic Rev 9.00 June 2004 41

3. The {Eng Preglow|Idle}=1 option is introduced to run the engine at idle speed
for {IdleRunTime} delay after starting up the engine. Relay K#1 is energized
and through a suitable governor contact it holds the engine at the desired idle
speed. Idle speed run can be terminated by bringing the engine to normal
speed (most likely by installing a push-button in series with K#1...).

1 Oct 2003, GENCON version 2.9o


The latest NFPA 110 spec requires having a remote "Low Cranking Voltage" fault
indicator. For this purpose in the status report GENCON's ENGINE SLOW CRANK had
to be separated from the ENGINE OVERCRANK status:
From now status #51 indicates ENGINE OVERCRANK only and the new status #52 is
dedicated to the ENGINE SLOW CRANK. Thus, all the statuses listed in the modbus
page from #52 to #69 move to #53 to #70.
A 17th compile time option is now available on demand. See the parameters set-up
page.

24 Sep 2003, GENCON version 2.9n


To cater for a situation where the utility company has the right to tell a peak-shaver
to get offline instantly activating both In#01 RUN and In#02 TEST while In#03 SLEEP
is active from now forces the generator breaker to open up immediately,
abandoning the power ramp down process (this was implemented across all the
configurations, load-sharing included). An active In#03 SLEEP command only would
otherwise open the breaker after the power ramp down to zero is complete. This
change is not expected to affect existing control panel wirings.

18 June 2003, GENCON version 2.9m


Small bug-fix for the new load-sharing AMF configurations:
In#16's of all the GENCONs should read the mains breaker status as the diagram
below shows. If this wiring is not made (a wiring bug) the slave GENCONs did not
stop when their master GENCON stopped (a software bug)...

Frostechnic Rev 9.00 June 2004 42

19 May 2003, GENCON version 2.9l


Introduces load-sharing to the automatic mains failure (AMF) configurations: #2, #5
and #6. This development is expected to simplify the design of projects such as the
following one where earlier we had to use either the fixed hybrid model (for
example, a 1x config#6 + 2x config#3 combination) or design the system around the
generic configuration using a PLC to achieve a symmetrical solution which does not
depend upon the working of any single generator-set.

Load-sharing is enabled by the {System Auto Start} option. For example, a loadsharing config#6 is introduced by:
{Generic Configure} = 0
{Parallelin System} = 1
{Mains Standby ATS} = 1
{Cogeneration Mode} = 1
{System Auto Start} = 1
All the controllers must be programmed the same.

Frostechnic Rev 9.00 June 2004 43

Under normal conditions the GENCON controller that has its K#6 relay energized is
the bus master and in control of the mains breaker, however:
If all the controllers have pending shutdown faults (or if they all are in "off mode")
they keep their K#6 relays energized.
If the DC supply of all the controllers is switched off no K#6 relay can of-course be
energized.
To detect these two special cases one can set the option {R#2 Alarm|Usable} in all
the controllers to 1 and connect the N/C contact of their R#2's in series...
When running in parallel with the mains only the master directly controls the export
kW/kVAr level, the slaves operate their load-sharing controls only to match their
output with their master's load%.

Frostechnic Rev 9.00 June 2004 44

Miscellaneous
Mechanical mode switches
TEST
AUTO
Traditional rotary mode switches can be
In#2 TEST W/O LOAD
OFF
constructed using the IOB1 In#1/2/3 lines.
In#3 SLEEP
See this figure:
MAN
In#1 RUN WITH LOAD
It is an alternative to the controller's OFF
AUTO, AUTOOFF, OFFMAN and MANOFF software commands. The rotary switch
operates in AUTO mode only. It is also possible to reset the pending faults by activating
In#3 SLEEP, see the SleepClearsFaults? option.

Dynamic export quota control


When paralleling a generator-set with the mains, with the controller in configuration #4, it
is often required to prevent export of genset power to the grid. Indication of export to the
grid can be obtained from a reverse power relay that is installed on the mains. When the
reverse power relay trips, it is required to
kW Output
decrease temporarily the export quota.
IOB1 input terminal In#16, receives this kW
QUOTA LIMIT indication:
An active In#16, after a kW QuotaDec timedelay, decreases the kW export quota by a
kW Quota Dec set-point value. An inactive
In#16, after a kW QuotaInc time-delay,
increases the kW export quota by a kW
Quota Dec set-point value.

CONFIG. #4 -- Paralleling With The Mains


Full Export Quota

IN THIS EXAMPLE In#16 IS ACTIVE WHEN THE


GENSET kW Output EXCEEDS THE DASHED LINE

kW Quota Dec.
set-point

In#16 is active
kW Quota Inc.
set-point

In#16 is inactive

kW QuotaDec
time-delay

The time-delays can be adjusted from 0 to


100 minutes. The set-points can be adjusted in 1 kW steps.

kW QuotaDec
time-delay

kW QuotaInc
time-delay
Time

Basic load control


The controller monitors the system's load per rating ratio, kW/Xre, in single and in
parallel genset applications. kW is the total active load. Xre is the running sets total kW
rating. If the option R#1 Shunt|kW Load: is 1, RELAY#1 provides the following decisions
based on the load ratio:
Non essential load release and re-entry
Case 1: The two set points satisfy: %kW/XreR#1 On < %kW/XreR#1 Off:
If the load ratio is %kW/XreR#1 On for R#1 OffOn time continuously, RELAY#1 is
energized.
If the load ratio is %kW/XreR#1 Off for R#1 OnOff time continuously, RELAY#1 is de
energized.

Frostechnic Rev 9.00 June 2004 45

Dummy load control example:


It is required to introduce an artificial load to a lightly loaded genset and to remove this
load once normal loading returns. The dummy load is 20% of the rated kW.
Solution: Drive the artificial load contactor by RELAY#1 AND K#7 (ie both relays must be
energized).
Set points: %kW/XreR#1 On = 15, %kW/XreR#1 Off = 40,
Delays: R#1 OffOn = 5'00"0, R#1 OnOff = 5'00"0.
When the engine load is for 5 minutes less than 15% of its rating the dummy load contactor
is closed. When the load is for 5 minutes more than 20% of the engine rating the dummy
load contactor opens.
Parallel genset automatic start/stop
Case 2: The two set points satisfy: %kW/XreR#1 Off < %kW/XreR#1 On:
If the load ratio is %kW/XreR#1 On for R#1 OffOn time continuously RELAY#1 is
energized.
If the load ratio is %kW/XreR#1 Off for R#1 OnOff time continuously RELAY#1 is de
energized.
Example:
We are given two 100 kW gensets, G1 and G2, that can parallel on a common bus. Eg, the
genset controllers are in configuration #3 (random access paralleling). It is required that
G1 operates alone if the load is 60 kW or lower and that G2 is started automatically when
the load is 80 kW or higher.
Solution: Activate In#1 RUN of the controller handling G2 by its RELAY#1 and set the setpoints as follows:
%kW/XreR#1 On = 80%, kW LoadR#1Off = 30%. Time delays are set according to need.

Handling motor driven contactors (breakers)


~
In high current installations the use of spring charged motor operated
M
contactors is common. They are suited for auto-sync applications since they
have a fast, 50 ms, closing action.
~
This type of contactor has two notable characteristics:
OPEN
1.
Charging the spring by the motor takes a few seconds, no more than 5
seconds usually.
CLOSE
2.
Unless an undervoltage release mechanism is installed, the contactor
stays closed when AC is removed from the motor.
This requires special handling because:
1.
Before a contactor can be closed, time must be given to charging the spring.
2.
In European standby applications, time must be given to opening the mains
contactor before closing the generator contactor.
The solution is: Set the K#6 Engine|Gen On option to 1: The relay K#6 energizes when the
generator builds normal phase voltages. Delay the generator contactor closing command
(through the relay K#7) by an appropriate Set Stabil Min time delay. K#6 can then switch
AC to the contactors' motors to charge the springs or, where applicable, to open the mains
contactor, long enough before the closing command is given.
If you want to verify the contactors' action set the Check Contactors and Motor Contactors
options to 1.

Frostechnic Rev 9.00 June 2004 46

CAVEATS
GENCON II reliability had already been proven in many installations. Nevertheless, in a
good switchboard design there should exist additional means, even duplicate, to prevent
catastrophic consequences if there is a single component failure -- GENCON II is a single
component in this respect.
Since the probability of simultaneous failure of two, same function, protection devices
whose failure mechanism is statistically independent is the product of the failure
probability of each, the effective overall system reliability is greatly enhanced.
For a generator-set operating in parallel with the mains we recommend to add as a
minimum a short-circuit and a sync-check protection relays.

Frostechnic Rev 9.00 June 2004 47

Fault & status messages


GENCON UP: SET CLOCK
This message indicates that the computer program has restarted. If the DC supply
was not interrupted look for...

An un-suppressed EMI source. Not all can be reported by an EMI (NOISE)


DETECTED message.
Internal GENCON problem. Typically bad PC-board to motherboard
connection. This can be resolved by re-plugging the PC-boards gently!

See also EMI (NOISE) DETECTED


GENCON LOW DC DANGER
This alarm is raised by GENCON's internal DC voltage regulator and by default it is
treated as a shutdown fault that cannot be bypassed. Letting this alarm to have
warning severity through the {GENCON LOW DC S|W} = 1 option is not recommended
as it can lead to complete depletion of the starter motor battery when cranking.
Note that when when the low DC danger is detected the RAM based (volatile)
counters are written into the EEPROM memory for safekeeping.
REVISE SETPOINTS
This is a reminder that an earlier change of parameters in SET-UP>BASICS may have
influenced other parameters in SET-POINTS. This is why the parameters in BASICS
have to be adjusted first.
ENGINE SHUTDOWN FAIL
This message indicates that {Stoppin Max} time after blocking the fuel supply the
engine still shows some "signs of life". If it is just the oil pressure remaining high
(i.e., the In#5 OIL PRESSURE contact remains open) this is just a warning fault. If the
engine seems to be rotating, as indicated through the magnetic pick-up read RPM or
the generator voltage, this is a shutdown fault that also energizes the air-flap relay
K#4 for two seconds.
STOP BUTTON PRESSED
This shutdown fault is the response to pressing the red GENCON push-button. Note
that unlike other shutdown faults here the audible alarm (Relay#3) is not turned on.
ENGINE SLOW CRANK
The engine speed after two seconds of cranking should reach 20 RPM or the relay
K#3 de-energizes and cranking of the engine is cut short (the critical speed was 60
RPM prior to version 2.8l). After the prescribed number of {Cranking Attempts} this
shutdown message is logged. This shutdown fault can be bypassed in fire
extinguishing applications. See also FAQ #3.
ENGINE OVERCRANK
All the engine-cranking attempts have failed. See SET-UP\SET-POINTS.
See also FAQ #3.
VOLTAGE NOT BUILT
Following detection of engine firing speed, after delay, normal gen voltage level
was not reached (see SET-UP\SET-POINTS & DELAYS).
FREQUENCY NOT BUILT
Following detection of engine firing speed, after delay, normal gen frequency was
not reached (see SET-UP\SET-POINTS & DELAYS).
OIL PRESS NOT BUILT
Following detection of engine "firing" speed, after delay, normal oil pressure was not
reached. Check In#5 OIL PRESSURE SHUT status. See also SET-UP\DELAYS.
Frostechnic Rev 9.00 June 2004 48

GENCON IOB: MALFUNCT


When using either the IOB1 or the IOB2 check that:

GENCON-IOB data cable is installed.


GENCON and its IOB should have a common DC supply. Use the duplicate DC
+/- terminals of the IOB to extend supply to GENCON. It is recommended to
connect the DC supply directly to the battery. See the "Battery and DC supply"
notes.
GENCON-IOB data cable is not in the same loom with high voltage conductors.
There is no un-suppressed EMI source inside the control cubicle and near the
IOB. See also EMI (NOISE) DETECTED
The IOB input and output lines that connect to the generator-set do not run in
parallel (in close proximity) to the high voltage power lines.
There are no metal specks (due to cubicle drilling) on the board.

When using the IOB2 check also that:

The analogue channels are not damaged. If using single lead senders it is
important to install protective TransZorbs.

RPM v FREQUENCY ERRO


This warning indicates that the engine speed as read from the magnetic pickup unit
(MPU) and the generaor frequency as read via channel V1 do not agree. For this
alarm to be declared the difference must be at least 1 Hz, it must exist for one
second and the generator voltage must be high. Check your {Number of Poles} and
{Pick-up Teeth} settings in BASICS. Also, note that early C-model units had a
problem of reading double MPU frequency when their signal was large. See the
Magnetic Pickup page for more details.
ILL GEN PHASE ORDER
GEN OVERVOLTAGE
This shutdown fault is declared when the voltage of any generator phase is
{Gen OvVoltage} volts or higher for {Gen OverVolts} seconds. Shutdown can be
bypassed (when the generator-set powers a fire extinguishing system) through the
{In#00Bypass Shutdn} set-point.
GEN UNDERVOLTAGE
This is a shutdown or a warning fault according to the {Gen UnderVolt S|W} option.
Fault is declared when the voltage of any generator phase is {Gen UnVoltage} volts
or lower for {Gen UnderVolts} seconds, but that only if the genset is past the {Set
Stabil Min} time interval. When a shutdown fault is declared the generator breaker
opens up immediately but the generator-set continues to run one second more. If
the voltage recovers the generator-set stops after {Coolin Down} minutes. If the
voltage does not recover the generator-set stops without cooling off. Shutdown can
be bypassed (when the generator-set powers a fire extinguishing system) through
the {In#00Bypass Shutdn} set-point.
GEN OVER FREQUENCY
This shutdown fault is declared when the generator frequency is {Gen OvFrequen} Hz
or higher for {Gen OverFreq} seconds, but that only if the genset is past the {Set
Stabil Min} time interval. When declaring fault the generator breaker opens up
immediately and the genset is stopped after {Coolin Down} minutes. This shutdown
can be bypassed (when the generator-set powers a fire extinguishing system)
through the {In#00Bypass Shutdn} set-point.

Frostechnic Rev 9.00 June 2004 49

GEN UNDER FREQUENCY


This is a shutdown or a warning fault according to the {Gen UnderFreq S|W} option.
Fault is declared when the generator frequency is {Gen UnFrequen} Hz or lower for
{Gen UnderFreq} seconds, but that only if the genset is past the {Set Stabil Min}
time interval. When a shutdown fault is declared the generator breaker opens up
immediately but the generator-set continues to run one second more. If the
generator frequency returns to normal level the generator-set stops after {Coolin
Down} minutes. If the frequency does not recover the generator-set stops without
cooling off. Shutdown can be bypassed (when the generator-set powers a fire
extinguishing system) through the {In#00Bypass Shutdn} set-point.
GEN OVERCURRENT
This protection follows the "very inverse" curve of IEC 60255-3 (1989). Shutdown
fault is declared when any phase current (I Amp) exceeds the {Gen OvCurrent} setpoint (Is Amp). The time delay before the fault is declared (t sec) depends on the
amount of over-current and on the {G 2x OvCurr} delay (T sec): t = T*Is/(I-Is), the
"very inverse" curve. The generator breaker opens up when fault is declared. If, as a
result, the phase currents drop within one second below Is the genset shuts down
after a regular {Coolin Down} time interval. Shutdown can be bypassed (when the
generator-set powers a fire extinguishing system) through the {In#00Bypass
Shutdn} set-point.
The very inverse curve for T=13.5 seconds:

GEN REVERSE POWER


Shutdown fault is declared when the total active power (kW) that enters the genset
is {Gen Revrse kW} or more for {G Revrse kW} time. This may indicate in parallel
applications failure of the genset engine which is then powered by the bus or mains.
When fault is declared the generator breaker immediately opens up. If as a result
the fault condition disappears within one second the genset is allowed to shut down
after a regular {Coolin Down} time interval. Shutdown can be bypassed (when the
generator-set powers a fire extinguishing system) through the {In#00Bypass
Shutdn} set-point.
GEN EXCITATION LOSS
Shutdown fault is declared when the total reactive power (kVAr) that enters the
genset is {Gen Rvrs kVAr} or more for {G Rvrs kVAr} time. This may indicate in
parallel applications failure of the generator voltage regulator which then draws
reactive power from the the bus or mains. When fault is declared the generator
breaker immediately opens up. If as a result the fault condition disappears within
one second the genset is allowed to shut down after a regular {Coolin Down} time
Frostechnic Rev 9.00 June 2004 50

interval. Shutdown can be bypassed (when the generator-set powers a fire


extinguishing system) through the {In#00Bypass Shutdn} set-point.
GEN HIGH HARMONICS
Heavy non-linear loads? Improper generator type or size? Stator short-circuit can
also cause high harmonics. See also SET-UP\SET-POINTS & DELAYS.
HIGH BATTERY VOLTAGE
Battery voltage higher than SET-UP\SET-POINTS existed at least for 1 second.
LOW BATTERY VOLTAGE
Battery voltage lower than SET-UP\SET-POINTS existed for 1 second while the set
was stationary or running (ie not during start-up).
REMOT EMERGENCY STOP
The result of active In#4 EMERGENCY STOP.
LOW OIL PRESS SHUTDN
The result of active In#5 OIL PRESS SHUT when the set is running.
LOW OIL PRESS WARNIN
The result of active In#6 OIL PRESS WARN when the set is running.
HIGH WATER TEMP SHUT
This shutdown type alarm is raised immediately when an active In#07 contact is
detected. Since the coolant temperature rises when the engine stops the status of
In#07 is ignored while the engine is being stopped or when it reaches standstill. This
alarm is bypassed when using the generator-set to power a fire pump.
HIGH WATER TEMP WARN
The result of active In#7 HIGH TEMP SHUT.
LOW WATER TEMP WARN
The result of active In#8 HIGH TEMP WARN.
LOW WATER LEVEL
This alarm is raised when In#10 is activated. By default the severity of this alarm is
shutdown unless the option {LowWaterLevel S|W} is set to 1.
LOW FUEL LEVEL WARN
This warning alarm is raised when In#11 is activated.
BATTERY CHARGR FAULT
The result of active In#12 CHARGER FAULT.
AIR DAMPER CLOSED
This shutdown type alarm is raised immediately when an active In#13 contact is
detected. This alarm is bypassed when using the generator-set to power a fire
pump.
EXTERNAL OVERLOAD
This alarm is raised when In#14 is activated. By default the severity of this alarm is
shutdown, the generator breaker immediately opens up and the set stops after
completing the cooling-off interval. If the option {Ext. Overload S|W} is 1 the
alarm is for warning only.
NOT IN AUTO MODE
If the {NOT IN AUTO Warn} option is set this alarm is raised whenever the controller
is taken out of "Auto" mode by an AUTOOFF command or an active In#3 SLEEP line.
Check the current operating mode by pressing "0" to examine the OVERVIEW display.
CONTACTOR(s) FAILURE
If the option {Check Contactors} is set, GENCON compares the state of the breaker
command relay K#7 with the breaker status that it reads through In#15. If a conflict
exists for more than the {Contactor Delay} time allows and if the conflict cannot be
explained by the {Motor Contactors} option (where the breaker needs AC supply to
open or close) the shutdown alarm CONTACTOR(s) FAILURE is declared. This
shutdown fault can be bypassed in fire extinguishing applications. The same
protection exists for the mains breaker, comparing K#8 state against the mains
breaker In#16 read status, if GENCON is responsible for the mains breaker too
Frostechnic Rev 9.00 June 2004 51

(where the the {Mains Standby ATS} option is set). Note that spring driven (stored
energy) type of breakers need some time to charge before the breaker can obey the
close command. With a sufficient {LoadBreakMake} delay you can prevent this
common reason for CONTACTOR(s) FAILURE...
SHUTDOWNS BYPASS ON!
The result of active In#3 BYPASS. Most shutdown faults become warning only!
EMI (NOISE) DETECTED
Unexpected program restart due to electrical noise. As a precaution the program
"write protects" all the EEPROM based parameters even if the {WRITE PROTECT...!?}
option is not set. See our "tears saving" guide.
In rare cases this EMI (NOISE) DETECTED message can be a result corrupt EEPROM
data or a result of some software bug. The EEPROM can be erased by the eraser.exe
utility -- the next time the program starts it would initialize the EEPROM to its
factory default state. If the EMI report is a result of a software bug then in most
cases you would be able to provide an exact sequence of actions/events that can be
repeated to evoke this bug.
It is important to rid the control panel of EMI sources as they affect the reliability of
the system. Program restarts due to EMI also cause loss of accumulated kWH and
RunTimeHours count as their values in RAM could not be written into the EEPROM for
safe keeping.
RPM OVERSPEED SHUTDN
Engine speed higher than SET-UP\SET-POINT existed for SET-UP\DELAY.
SYNCHRONIZER TIMEOUT
This alarm indicates that within the allotted {SyncTimeout} time-delay the
synchronizer failed to bring the generator phase (V1) "in sync" with the reference
phase (V4). If while watching the synchronizer action on the MEASURE / SYSTEM
display you notice that the ANALOG/PWM "levers" are frozen check to see if the
mains/bus reference phase that is measured by channel V4 is perceived by GENCON
as being abnormal, that is, being outside the permitted {V4 Ov Voltage} through {V4
Un Frequen} setpoint range. Note that in some cases this alarm is just a warning. For
example, if the AMF genset that needs to return the load to the mains through
ramped parallel unloading declares a SYNCHRONIZER TIMEOUT alarm it would return
the load through delayed open transition, just as in configuration #2.
GENCON PROGRAM ERROR
Built-in test message. FLASH data error (software memory). Try loading the
controller software again under safe DC conditions. If the problem continues contact
the nearest service facility.
GENCON MEMORY ERROR
Built-in test message. EEPROM data error (parameters memory). Contact nearest
service facility.

Frostechnic Rev 9.00 June 2004 52

PARALLEL LOAD SURGE


This message indicates detection of a possible loss of mains during paralleling. In
response GENCON immediately isolates the generator-set from the national grid: In
config#4 relay K#7 de-energizes to open the generator breaker, in configs #5 and #6
the relay K#8 energizes to open the mains breaker and the generator-set continues
to work in standby mode (requiring {Standby Off} time of healthy mains conditions
to return to paralleling). In the generic configuration (#0) under the export mode
the relay K#8 de-energizes to indicate the occurrence of PARALLEL LOAD SURGE.
This protection operates by comparing the newly measured kW with the value that
was measured 100ms earlier. An increase or decrease (if the {kW Drop=LoadSurge} is
1) by more than the {Mains kW Surge} set-point allows is the PARALLEL LOAD SURGE
trigger. Since GENCON isolates the generator-set from the national grid within
200ms it can provide adequate protection against a possible out of phase automatic
re-closing by the mains company which can occur after 300ms. Since parallel
connection with the mains is involved with some power surges it is recommended to
introduce a 1-2 second delay before introducing the PARALLEL LOAD SURGE
protection. This is provided through the {kW Surge Enable} delay.
PARALLEL MAINS FAIL
This message indicates that the phase input to channel V4 was removed while the
generator-set was running in parallel with the mains. In response GENCON
immediately isolates the generator-set from the national grid: In config#4 relay K#7
de-energizes to open the generator breaker, in configs #5 and #6 the relay K#8
energizes to open the mains breaker. Typically the input to V4 passes through a
three phase loss of mains relay that includes step phase angle change detection in
compliance with the G59 code or similar. Loss of mains during paralleling may be
dangerous and it is advised to employ such a relay in addition to GENCON's built-in
PARALLEL LOAD SURGE protection
RS-485 XMT: NO ECHO
RS-485 XMT: BAD ECHO
RS-485 REC: BAD CHAR
RS-485 REC: OVERRUN
RS-485 REC: BAD DATA
These five warning messages indicate detection of the specified problem in the
RS485 communication network. "NO ECHO" typically indicates having a short circuit
condition in the RS485 cable. The "BAD CHAR/DATA" cases indicate coupling of EMI
to the RS485 cable -- is the RS485 cable installed as the RS485 wiring guidelines
recommend? In particular, note that the RS485 cable should not be run in parallel to
the power lines! Also note that these alarms are raised only on repeated RS485
interference -- a single corrupt message would not be reported!
NETWORK SET-UP ERROR
This can be just another RS485 communication error or it may simply indicate that
two GENCON controllers on the same RS485 bus have been given the same ID
number.

Frostechnic Rev 9.00 June 2004 53

UNEXPECTED BUS VOLTS


In the load-sharing config#3 the generator-set that is first to energize K#7 (close its
breaker) expects to find a dead bus, more specifically, it expects to find on V4
voltage that no higher than 25% of the full-scale reading (82V in the 277V model,
etc.). This protection also applies to config#1 unless in FACTORY the {IgnoreV4
Config#1} option is set
You may encounter this message if the RS485 communication bus is not properly
installed between the GENCON controllers. The 2nd genset will shutdown with this
fault as soon as it becomes ready to take load since it is not aware of the 1st genset
activity. Use the SYSTEM function to check for proper communication between the
controllers.
GENERIC CONFIG ERROR
This shutdown fault is specific to the generic configuration (config #0). It usually
indicates having a bug in GENCON's controlling PLC program: Though the generatorset is not ready for load as GENCON indicates by having its K#7 relay de-energized,
the PLC command, as read by GENCON inputs #15 and #16, is not SYNC W/O LOAD.
This illogical condition has to exist {Contactor Delay} time continuously before this
fault is declared.
SETUP CONFLICT CLR'D (i.e., cleared)
GENCON may be complaining because...
1. One has tried to enable the paralleling system when using the limited
GENCON PRO model...
2. The asynchronous (induction) generator isn't used with paralleling...
3. The {Check Contactors} option is attempted in the generic mode (they share
the same #15/#16 inputs!)
4. One cannot use some input channel for dynamic export quota control as they
are already in use.
GENCON MEMORY CRASH
Built-in test message. EEPROM data error (parameters memory). Contact nearest
service facility.
MAINS CONTACTOR OPEN
This is a warning message indicating that the mains breaker fails to close (relay K#8
is de-energized yet In#16, which reads the breaker status through an auxiliary
switch, is not active). In this case the genset continues to carry the load. This
protection applies to configurations where the options {Mains Standby ATS} and
{Check Contactors} are both "1".
GENCON AMPS READ ERR
GENCON reports that its current measurement subsystem malfunctions. The
waveform that it reads does not look as a reasonable sinusoid, it is too flat, as if
having a DC component. In the earlier B model this message usually indicates that
the generator CTs which are supposed to be potential free are externally grounded
(see also the current inputs page). This fault can also indicate that the V/I card or
the microprocessor card are not plugged well into the front panel motherboard.
BUS CB FAILS TO OPEN
Protects multiple load-sharing generator-set systems, config#3 and hybrids. If the
{Check Contactors} option is on, GENCON shuts down its genset if it finds that
another genset in the system has failed to disconnect its breaker from the common
bus. The bus breaker status is monitored by In#15. If the bus breaker does not open
within 0.5 second from the moment the relay K#7 de-energizes, this system wide
protection activates.
Frostechnic Rev 9.00 June 2004 54

AVR CONTROL FAILURE


GENCON cannot control the generator voltage regulator. Its PWM output (B3) is
stuck at 0% or at 100% for 0.5 second or more.
GOV CONTROL FAILURE
GENCON cannot control the engine governor. Its ANALOG output (B21) got stuck at
0V or 7.5V for 0.5 second or more. Perhaps there is a problem with the fuel supply
and the genset cannot provide the required power level... Perhaps the genset
breaker simply tripped open during paralleling...
COMM2 TIMEOUT ERROR
If COMM2(modbus) or COMM2(phone) start to send GENCON "stop", "test" or any "run
with load" command, through the coils of COMM2(modbus) or through the
management subsystem of COMM2(phone), they must continue to do so at least once
every 25 seconds (even "stop" has to be repeated!). If GENCON ceases to receive
these commands it raises this timeout warning and assumes that the last effective
command was a "stop". Check if COMM2 is connected to the RS485 bus and if it is
"alive". In the COMM2(modbus) case also check the functioning of the
SCADA/HMI/PLC system.
UNEXPECTED OIL PRESS
In#5, the oil pressure contact input, indicated that normal oil pressure existed
before starting to crank the engine. This is by default just a warning (is the oil filter
blocked? is it failure of the oil pressure contact? is it a wiring open circuit?). Since
low oil pressure is arguably the most important engine protection you may decide
not to run the engine without it by raising the severity of this fault to shutdown
through the {Hi Oil Press Shut} = 1 option.
GENCON IOB: NO COMM
This error message is specific to the IOB2. GENCON reports that it cannot
communicate with IOB2. Perhaps the five lead cable is not well connected; Perhaps
the IOB2 has no DC supply.
SENDER 1: LOW OHMS
SENDER 2: LOW OHMS
SENDER 3: LOW OHMS
SENDER 4: LOW OHMS
SENDER 1: HIGH OHMS
SENDER 2: HIGH OHMS
SENDER 3: HIGH OHMS
SENDER 4: HIGH OHMS
SENDER1 OPEN CIRCUIT
SENDER2 OPEN CIRCUIT
SENDER3 OPEN CIRCUIT
SENDER4 OPEN CIRCUIT

Frostechnic Rev 9.00 June 2004 55

IOB1 -- Auxiliary I/O board


Attention!
There are 2 IOB1 models: One for 12 Vdc batteries and one for 24 Vdc batteries.
Be sure that you are using the correct model!

General
IOB1 is an auxiliary input and output interface board. It adds to GENCON II 16 input and 8
output channels. The input channels implement the set of alarms and pre-alarms that is
specified in NFPA 110 level 1 (USA code), control the diesel engine and control the
generator and mains (when applicable) contactors.
IOB1 is mounted on a DIN rail inside the control cubicle. It is connected to GENCON II by a
special 120 cm symmetrical cable. Proper operation of the IOB1 is continuously monitored
and shutdown fault is declared on any malfunction. If the cable is removed all IOB1 relays
are off.

Input channels
The 16 input channel terminals are connected through "normally open" (N/O) or "normally
closed" (N/C) contacts to the battery (-) potential. The type of contact to use with each
input, N/O or N/C, is defined by SET-UP\IN 1..16. The input channels activity is displayed
by MEASURE\ IN 1..16.
In#1RUN WITH LOAD
Active In#1 starts the genset in AUTO mode unless a shutdown fault exists. When the
genset is ready it takes the load or enters paralleling.
In#2 TEST W/O LOAD
Active In#2 starts the genset in AUTO mode unless a shutdown fault exists. When
In#2 is deactivated, following the Test Delay time, the genset stops.
In#3 SLEEP or BYPASS
In#3 can be used in two ways according to the In#3 Sleep|Bypass option:
SLEEP:
Active In#3 inhibits genset startup in AUTO mode. When it is active OVERVIEW
displays "Mode=Sleep." It can be activated by a clock to disable standby operation
after working-hours.
BYPASS:
Active In#3 converts most shutdown faults to warnings (except In#4 EMERGENCY
STOP). Active In#3 is also a warning fault. It is typically used when powering fireextinguishing pumps.
In#4 EMERGENCY STOP
Active In#4 is a shutdown fault. It also activates the K#4 AIR DAMPER relay.
In#5 OIL PRESS SHUT
Active In#5 indicates low lubricating oil pressure (see In#6). In#5 passes 0.5 sec
delay to filter out transient contact statuses. When the engine is running it causes a
shutdown fault. When the engine stops, after Stoppin Max time delay, it causes an
ENGINE SHUTDOWN FAIL warning.

Frostechnic Rev 9.00 June 2004 56

In#6 OIL PRESS WARN


Active In#6 indicates low lubricating oil pressure. When the genset is running it
causes a warning fault.
In#7 HIGH TEMP SHUT
Active In#7 that is detected when the genset is running is a shutdown fault. It is
ignored if detected when the engine stops since temperature in that case tends to
rise.
In#8 HIGH TEMP WARN
Active In#8 that is detected when the genset is running is a warning fault. It is
ignored if detected when the engine stops since temperature in that case tends to
rise.
In#9 LOW TEMP WARN
Active In#9 is a warning fault.
In#10 LOW WATER LEVEL
Active In#10 is a warning or a shutdown fault. See SET-UP\OPTIONS.
In#11 LOW FUEL WARN
Active In#11 is a warning fault.
In#12 CHARGER FAULT
Active In#12 is a warning fault.
In#13 AIR DAMPER SHUT
Active In#13 is a shutdown fault. K#4 AIR-DAMPER does not operate if In#13 is
already active.
In#14 EXTERNAL OVERLOAD
Active In#14 causes a warning or shutdown fault according to the Ext. Overload S|W
option. The genset is taken off load immediately.
In#15 GEN CONTACTOR
Active In#15 indicates that the generator contactor is closed. In#15 status is
expected to follow that of the K#7 GEN CONTACTOR relay within a Contactor Delay
time. This time limit, if exceeded, is a shutdown fault condition. Under the Generic
Configure? option this input has a special function.
In#16 MAINS CONTACTOR or kW QUOTA LIMIT
When SET-UP\OPTIONS Mains Standby ATS is 1,
an active In#16 indicates that the mains contactor is closed. In#16 status is expected
to follow the K#8 MAINS CONTACTOR relay command within a time limit (see SETUP\DELAYS). This time limit, if exceeded, is a shutdown fault condition.
Under the Generic Configure? option this input has a special function.
When SET-UP\OPTIONS select configuration #4, and the genset is in parallel with the
mains,
an active In#16 indicates that the export kW quota has to be decreased. An inactive
In#16 input indicated that the export kW quota has to be increased. See Dynamic
export quota control in Applications.

Frostechnic Rev 9.00 June 2004 57

Output channels
There are 8 output relays, K#1 to K#8, driving 24 output terminals. The relays have
Single Pole Double Throw (SPDT) contact configuration. 3 terminals belong to each
relay: Pole, N/C Throw, N/O Throw. Follow the PC-board marking. Each contact
rating is 380 Vac / 10 Amps.
K#1 PRE-GLOW
K#1, through a N/O contact, energizes an electric heater before cranking the
engine. Use SET-UP\DELAYS to define the pre-glow time.
K#2 FUEL SOLENOID
K#2, through a N/O contact, operates the fuel solenoid. The fuel solenoid can be
defined as either "energize to run" or "energize to stop", see SET-UP\OPTIONS. The
genset should stop within a predetermined time after blocking its fuel supply (see
SET-UP\DELAYS) or otherwise a fault is declared. If it just the oil pressure not falling
fast enough (In#5 OIL PRESS SHUT), it is a warning fault only. However, if speed and
voltage are measured, shutdown fault is declared and the K#4 AIR DAMPER relay is
also activated.
K#3 CRANK
K#3, through a N/O contact, energizes the starter motor solenoid. Use SETUP\DELAYS to define the maximal cranking time and the delay between the cranking
attempts. Use SET-UP\SET-POINTS to define the number of cranking attempts and
the minimal speed to stop cranking (ie engine "firing" RPM).
K#4 AIR DAMPER
K#4 is active for 2 seconds following an engine overspeed or following failure to stop
the genset by K#2 FUEL SOLENOID. K#4 is inhibited if In#13 AIR DAMPER is already
active.
K#5 LUBRICATION PUMP
K#5, when the genset is stationary, activates an auxiliary lubrication pump
repetitively, with a predetermined on and off duration. See SET-UP\DELAYS.
K#6 SET RUNNING
If the K#6 Engine|Gen On option is:
0 K#6 is active when the engine is running: RPM 60 or Hz 15.
1 K#6 is active when the generator voltage is high: V1, V2 and V3 Gen
Undervoltage setpoint.
K#7 GEN CONTACTOR
K#7, through a N/O contact, operates the generator to load contactor. In
conjunction with K#8, complete automatic transfer switch (ATS) logic is provided. If
the genset parallel operation with the mains is enabled, the ATS contactors should
not use a mechanical or electrical interlock mechanism. It is recommended,
especially when paralleling is used, to bring to In#15 GEN CONTACTOR an auxiliary
contact from the gen contactor, to compare K#7 command with the contactor
status.Under the Generic Configure? option this relay indicates that the genset is
ready for load.

Frostechnic Rev 9.00 June 2004 58

K#8 MAINS CONTACTOR


If Mains Standby ATS = 1, K#8, through a N/C contact, operates the mains to load
contactor. In conjunction with K#7, complete automatic transfer switch (ATS) logic
is provided. If the genset parallel operation with the mains is enabled, the ATS
contactors should not use a mechanical or electrical interlock mechanism. It is
recommended, especially when paralleling is used, to bring to In#16 MAINS
CONTACTOR an auxiliary contact from the mains contactor, to compare K#8
command with the contactor status.
If Mains Standby ATS = 0, K#8 follows K#7 with a programmable delay. See
(ATS=0) K#7K#8.
Under the Generic Configure? option this relay indicates that the genset runs in sync
with the bus or mains.

Frostechnic Rev 9.00 June 2004 59

Current inputs
GENCON channels I1=[A51-A52], I2=[A61-A62] and I3=[A71-A72] measure the generator
phase currents through standard 5A current transformers (CTs). Their full-scale reading is
5.9A.
To improve the accuracy of measurement choose CTs with {CT Ratio} as small as possible.
GENCON units built before January 2001 have non-isolated current inputs. Check how the
rear panel is marked.

NON-ISOLATED
The generator CTs should be potential free. The wires leading to each CT should be
twisted:
If the CT is not kept potential free (#1) current will flow through the 100 ohm resistor and
will cause measurement errors. Large current may even burn out this resistor.
Measurement errors are usually caught by GENCON and reported as GENCON AMPS READ
ERR.

ISOLATED
Since the revised current inputs are isolated and since they have low input impedance the
following wiring method is safe:

Note* It is better though to use three independent twisted-pairs as bad CT insulation,


grounding by an external gauge that shares the CT.
Frostechnic Rev 9.00 June 2004 60

COMMON CT CONNECTION FAULTS / TESTING


Incorrect CT phasing or incorrect matching of the voltage channels with their
corresponding current channels are common installation mistakes. If the generator is
tested with a pure resistive load these mistakes are easy to analyse.
Suppose the gen-set real load is 3 x 10KW: If the CT wires are connected to channel I1 but
in reverse:
Gen phase A will measure -10kW and 0kVAr.
If the CT wires that are connected to I1 belong to phase B (ie, should be connected to I2):
Gen phase A will measure -5kW and +8.66kVAr as the current lags after the voltage by
120.
If the CT wires that are connected to I1 belong to phase C (ie, should be connected to I3):
Gen phase A will measure -5kW and -8.66kVAr as the current leads the voltage by 120.
If the CT wires that are connected to I1 belong to phase B but in reverse:
Gen phase A will measure +5kW and -8.66kVAr as the current leads the voltage by 60.
If the CT wires that are connected to I1 belong to phase C but in reverse:
Gen phase A will measure +5kW and +8.66kVAr as the current lags after the voltage by 60.
Similar analysis will find wiring mistakes in phase B and phase C.

Frostechnic Rev 9.00 June 2004 61

Voltage models
GENCON model is specified in terms of the nominal phase-to-neutral Vrms level of the
generator. The full-scale reading of each voltage measuring channel in GENCON is
approximately 20% above the model nominal Vrms. The following models are currently
standard:
Nominal Vrms Full-scale Vrms
120V

143.5V

127V

150.5V

220V

260.4V

240V

286.8V

277V

330.8V

345V

420.7V

415V

497.0V

For maximal accuracy the model voltage should be as near as possible to the nominal
generator voltage. However, if the input voltage is larger than the full-scale value, the
GENCON "sees" a distorted waveform where the AC sinusoid peaks are clipped. The
following shows what a 220V model sees (in red) when connecting a 280Vrms input:

Frostechnic Rev 9.00 June 2004 62

Measuring 3-wire systems


The following explains how to measure the power of delta-connected generators and the
power of star connected generators where there is no access to the neutral point. 3 wire
systems are common in high voltage generator-set applications.
Let R, S, and T denote the generator three phases. The phase rotation is R->S->T, ie, phase
R leads phase S by 120.

Connect:
V1 = UTS (i.e., A11 = T, A12 = S)
V2 = URS (i.e., A21 = R, A22 = S)
V3 = any phase to phase voltage
I1 = IT
I2 = IR
I3 = Not connected
This technique, known as Aaron's technique for measuring 3-wire systems using two
wattmeters, gives an accurate reading of the total active (kW) and reactive (kVAr) power
output of the generator-set also for non-symmetrical loads. The total kW's and total kVAr's
are what the load-sharing PID loops in GENCON regulate.
Since UTS leads URS by 60, we have to connect them to V1 and V2 respectively to avoid ILL
GEN PHASE ORDER error messages; See the following phasor diagram. We connect a phaseto-phase voltage also to V3 just to avoid GEN UNDERVOLTAGE error messages. V4, the
generator-set synchronization reference, should be connected to the corresponding bus UTS
phase-to-phase voltage.

Frostechnic Rev 9.00 June 2004 63

Magnetic Pickup (MPU)


GENCON measures the engine speed through a pickup coil sensor. This sensor generates a
sine wave voltage signal.
If a dedicated magnetic pickup is available connect it as follows:

If the magnetic pickup is shared with the electric governor connect it as follows:

The lowest detectable MPU signal is 0.5 Vrms.


Model "B"
reads the MPU frequency through dc coupling. Hence, it is important to reduce the
ground voltage between GENCON and the governor MPU.
Model "C"
reads the MPU frequency through ac coupling. Hence, this new model is insensitive
to sensor biasing (a method whereby computerised governing systems detect open or
short circuit of the sensor before beginning to crank).

Frostechnic Rev 9.00 June 2004 64

IMPORTANT! -- 15 Feb 2001 -- The following applies to the new model "C":
If GENCON measures an RPM value that is twice the correct one, attenuate the MPU signal
by inserting a series resistor before B11.

All the reported problem cases had a strong MPU signal, 15Vac and more. With 5Vac and
lower signals there was never a problem.
Attenuation Resistor
Factor
Value
2

200k

430k

4
620k
It is suspected that in the problem cases large ground noise is being added to the pick-up
signal due to the engine governor (sharing the magnetic pickup). Hence, lowering the
ground noise through the use of lower resistance cables may work too.
This is done since in most governors the input terminal MPU- is internally connected to
BAT- and SHIELD (also in GENCON B12 is internally connected to C13 DC-).
The smallest signal that can be detected by B11 is 0.7V peak-to-peak relative to B12/C13
(ie, 0.5V rms).
The MEASURE\ENGINE menu function displays the engine speed in RPM (r) and displays the
alternator frequency in Hz (h). It derives its values from the PICK-UP frequency (f) and it
uses the definitions Number of Poles (p) and Pick-up Teeth (t) from SET-UP\BASICS. The
formulas are:
h=(f/t)*(p/2), r=(f/t)*60, r=h*(120/p).
Usually the Number of Poles is 4. Hence, the formulas become: h=(f/t)*2, r=(f/t)*60,
r=h*30.

Frostechnic Rev 9.00 June 2004 65

Battery and DC supply


The starter motor battery usually powers GENCON but an auxiliary DC supply can also
power it. In this case the starter motor battery and the auxiliary DC supply must have a
common negative potential, C13. C11 measures the starter motor battery; C12 is for the
DC supply input.
The following picture shows how to provide DC to the I/O board and GENCON and how to
turn the metallic control cubicle into an effective Faraday Cage for electrostatic shielding.

Frostechnic Rev 9.00 June 2004 66

Tears saving notes


Place spark suppression devices across ALL the switched inductive loads (coils) in the
system: Install diodes across DC switched coils and varistors (or RC snubbers) across AC

switched coils.
The correct place for the suppressor is across the coil, not across the switch.
Do not forget to suppress the fuel-solenoid, starter-relay, breakers, electric heaters,
buzzer... Even the primary transformer of a battery charger, when switched on/off, can
cause interference if it is not properly suppressed!
Move the electric governor and its DC supply wires away from the GENCON/IOB cubicle.
I.e., use a slave relay that is adjacent to the governor to switch the governor DC supply
on/off. Do not use the IOB relay K#2 FUEL SOLENOID to switch the governor DC supply
directly! Of-course; twist the DC supply wires leading to the governor and its actuator.
Apply the same rule to other power devices that are under GENCON control. For example,
the lubrication pump place is next to the engine, so should be the place of its supply
contactor, don't place it inside the GENCON/IOB cubicle!
Move the generator AVR away from the GENCON/IOB cubicle. The recommended place for
the AVRx and its 24VAC transformer is in the AVR box.
The most sensitive circuits in GENCON are at its centre, next to terminals B11,..., B43 and
B5. Let all the high AC voltage and current carrying conductors pass as far as possible from
this part of the controller. For example, the battery charger, especially the switching
regulator type, should not be installed near this sensitive part of the controller.
Make the control cubicle an effective electrostatic shield (a Faraday cage) by connecting
the DC- terminals of GENCON/IOB to the cubicle as shown in the section on battery
supply.
The current transformers (CTs) should be potential free -- do not ground them! Connect a
twisted pair of wires to each CT -- do not use a common return wire! See also the section
on the current inputs.
Segregate the cables in the system into AC power and return, DC power and return, analog
controls and digital controls. For example, do not run the RS485 communication cable in
parallel to AC power cables; Keep a safe distance.
Being so compact, the natural place to install the GENCON controller is on the genset
itself. In this case make sure that the control cubicle where GENCON is installed is well
protected from the genset vibrations: the cubicle should be mounted through rubber shock
absorbers that also insulate it from the genset body. If you have to install GENCON
elsewhere be aware of the caveats.

Frostechnic Rev 9.00 June 2004 67

Hydraulic-mechanical Software features


GENCON is using a new synchronisation algorithm, using an adaptive length
up/down pulsing method, that is expected to bring the generator-set into synchronisation
with the reference phase within seconds rather than within minutes as is the experience
with the traditional constant duration pulsing method.
Frequency correction of the governor droop.
kW load sharing correction of the governor droop.
Mixing generator-sets with electric and hydraulic governors is allowed.

Software set-up
BASICS
{Ideal Freq Hz} -- The desired bus frequency, usually 50 or 60 Hz.

SETPOINTS
{HYD Gov Hz ERR} -- The "master" controller will up/down the motor if the measured
frequency vis--vis the ideal is so and so Hz in error.
{HYD Gov Hz/Sec} -- The minimal rate of frequency change effected by the up/down
contacts. Note that the larger this value is the longer will be the up/down pulse duration.
In the demo software the simulated motor changes the frequency at 0.15 Hz/sec so we
enter 0.1 Hz/sec here by default.
{HYD Gov kW ERR} -- A load-sharing/exporting controller will up/down the motor if
the generated kW versus the required is so and so kW's in error.

Frostechnic Rev 9.00 June 2004 68

Controlling voltage regulators (AVRs)


This page shows how to connect the AVRx to a selection of common generator voltage
regulators.

"Tears Saving" and other reminders:


Test the output voltage of the transformer which powers the AVRx module and make
sure that it does not exceed 30 Vac. Note that the actual output voltage of the
transformer may be higher than its label indicates because of the low current
consumption of the module.
Make sure that neither AVRx output, A1 or A2, sources or sinks more than 10mA
continuously. This is important when you design your own AVRx to AVR interface.
The purpose of the AVRx is to provide a potential-free (floating) voltage source.
Hence:
Do not ground the transformer output.
Do not connect the AVRx black COM wire to ground. Cut this wire if you don't have
any use for it.
Do not power AVRx modules of different generators from a common transformer.
Each AVRx should have a transformer of its own.
To test the AVRx effect on the generator you need to simulate 0%, 50% and 100%
PWM duty-cycles:
0% means simply to disconnect the B31 or the B32 wires that lead to the AVRx. The
corresponding AVRx A1-A2 voltage is -3V to -9V, according to the trimmer position.
50% is GENCON's normal PWM duty cycle when the paralleling system is disabled. The
corresponding AVRx A1-A2 voltage is approx. 0V. A1-COM and A2-COM voltage is
approx. 1.5V to 4.5V, according to the trimmer position.
GENCONII PRO ONLY: Connecting the AVRx B32 wire to any ground point simulates 100%
PWM-OUT conditions, B33 is convenient. The corresponding AVRx A1-A2 voltage is +3V to
+9V, according to the trimmer position.

Newage Stamford AVRs -- SX440, MX341,


A 16Vac transformer is recommended. Adjust the AVRx trimmer to the minimal 3V
range. Connect the AVRx A1/A2 wires to the terminals with the same name of
Newage AVR. Adjust Newage sensitivity trimmer, found next to its A1/A2 inputs, to
obtain a %10 response to the PWM-OUT 0%-100% range.

Frostechnic Rev 9.00 June 2004 69

Marathon Electric PM100 and PM200


Use a transformer with 24Vac secondary to power the AVRx. Adjust the AVRx
trimmer to the maximal 9V range. Use the following voltage divider:

Since PM100 6/7 terminals (originally provided for an external 10k Remote Voltage
Adjust) are very sensitive to noise, it is recommended to install the AVRx and this
voltage divider as near as possible to the PM100.
The above circuit was tested on a 277Vac L-N generator. In response to a 50% to 0%
PWM-OUT change (simulated by pulling out the B31 wire) the generator voltage fell
by 40Vac.
Customer comment: The above voltage divider was found to cause the generator to
have a 10Vac droop (between zero to full load), an unexpected phenomenon. It was
also noted that when the voltage "trim pot" on PM100 is fully counter clockwise
(minimal setting) the droop is at its minimum.

Marathon Electric DVR2000E


This voltage regulator model has an "Analog (Auxiliary) Input" whereby a 3Vdc
voltage forces a 30% Vac change around the regulator's nominal setting. See page 6
in the DVR2000E manual. As the input impedance is 1 k the following simple
interface should give GENCON the required 10% control range:
A1 -- 2.2k -- A
A2 ---------- B

Set the AVRx trimmer to the minimal 3Vdc range. The AVRx transformer can be as
low as 16Vac

Frostechnic Rev 9.00 June 2004 70

Caterpillar VR3

Remove the VR3 droop CT1 and 8 ohm rheostat if they are installed. Remove also
the remote level 10K ohm potentiometer.
Power the AVRx off a 24Vac transformer and adjust its trimmer to achieve a +/- 10%
response to the 100/50/0 PWM% simulation around the chosen VR3 nominal Vac
level.

1.
2.
3.

4.

Mecc-Alte's UVR6

Power the AVRx from a 16 to 24 Vac transformer.


Set the AVRx trimmer to its minimum 3Vdc position.
Connect the AVRx wires A1 and COM to the "remote voltage control 100Kohm" inputs
of UVR6.

When the genset runs with the paralleling system disabled (when PWM-OUT is 50%),
adjust the Vac level of UVR6 to the nominal level using their "tensione"
potentiometer. Simulating 0% and 100% PWM change should cause the generator Vac
to fall and rise by 10% respectively.

Frostechnic Rev 9.00 June 2004 71

MarelliMotori AVR M40FA610A

1.
2.
3.
4.

Power the AVRx from a 16 to 24 Vac transformer.


Set the AVRx trimmer to its minimum 3Vdc position.
Connect the AVRx wires A1 and A2 to the AVR terminals 6 and 8 through a 36k
series resistor. Cut the black COM wire to prevent wiring mistakes.
GENCON's 100% and 0% PWM-OUT levels should apply 1.5 Vdc across the AVR 6-8
terminals which should in turn respond by a 10% generator Vac change.

Frostechnic Rev 9.00 June 2004 72

Interfacing Marelli's M25FA600A AVR


You may need to adjust the gain trimmer on the VR3 to achieve a satisfactory kVAr load
sharing. Interfacing Marelli's M25FA600A AVR
1.
Connect terminal 5 of the AVR directly with A2 of the AVRx.
2.
Connect terminal 6 of the AVR through two 100k OHM series resistors with A1 of the
AVRx.
3.
Between these two 100k OHM resistors connect a 1F capacitor. The other end of
this capacitor is connected to terminal P of the excitation unit. Place the capacitor as near
as possible to the AVR.

Frostechnic Rev 9.00 June 2004 73

Leroy-Somer's R448&R440 voltage regulator

The excitation level of Leroy-Somer's voltage regulator (AVR) can be controlled by


applying a floating voltage source to its ST4 terminals.
Remove the link from terminals ST4 or remove the external 470 Ohm potentiometer.
Power the AVRx off 24Vac. Adjust its trimmer to max 9Vdc position.
Install the following voltage divider between AVRx terminals A1 and A2 and R448
ST4 terminals:

While running the genset under Parallelin System?0 adjust the generator voltage
level to its nominal Vac (for example, 230Vac).
While running the genset under Parallelin System?0 stop the PWM_OUT pulse train
by disconnecting the wire leading to GENCONII terminal B32. The generator voltage
should fall (to 200Vac in the example).

Leroy-Somer's Digital Voltage Regulator


The DVR is controlled through its "REMOTE VOLTAGE ADJUST RHEOSTAT" input,
terminals 7 and 45. The AVRx should be powered by a potential free 24Vac
transformer and the following interface circuit is required:

With the AVRx trimmer set at maximum, GENCON's 0 to 100% PWM range is expected
to produce a 11% change around the generator nominal Vac (the nominal Vac is set
under PWM of 50%).

Frostechnic Rev 9.00 June 2004 74

Caterpillar's DVR = Leroy Somer's DVR

Basler Electric

All the models that can be used with Basler's own SCP-250G PF/VAR CONTROLLER can be
used with GENCON's AVRx. In particular:
1. AEC63-7: The following interface provides 10% Vac control range. It was tested on a
380V Marathon generator.

Roper Electronic Eng's REG37

(preliminary)
1. Adjust the AVRx trimmer to the minimal 3V range (hence, the AVRx power transformer
can be 16Vac).
2. Link terminals CT1-CT2 as no C/T is required. Remove the RVT or LINK from terminals ST and install the voltage divider.
3. Calibrate REG37 voltage under 50% PWM level.

Frostechnic Rev 9.00 June 2004 75

Governor Ground Voltage Compensation


The following information applies to the latest GENCON "C" model only.
Terminal B22 by default is a fixed 3.75V REF-OUT (voltage source). Through dip-switches it
is possible to convert this terminal into REF-IN, an input whereby GENCON reads the ground
voltage of the remote engine governor:

The voltage read by B22 REF-IN is added to the internal digital to analog converter output:

In this way what the speed setting input of the remote governor "sees" is exactly the
voltage that GENCON's internal digital to analog converter has set. Fluctuations in the
engine speed due to the voltage between the control cubicle ground (where GENCON is
installed) and the governor ground are eliminated. In the following example if the ground
voltage of the EFC (COM) with respect to GENCON ground (C13) drops by 250mV, the D/A
output (B21) would immediately drop by 250mV too. Hence, the voltage applied between
RMT-SPD (8) and COM (2) remains constant.

It is recommended to connect B22 REF-IN to all engine governors whose speed setting input
is not potential free. This is particularly important to do so with governors whose Hz/Volt
response is very high, CUMMINS EFC, BARBER-COLMAN DYNA, ...

Frostechnic Rev 9.00 June 2004 76

Controlling electric governors


Overview
The ANALOG-OUT signals control the engine governor speed.
B21 D/A
A 0 to 7.5V voltage source driven by a 12 bit digital to analogue converter (i.e., 4096
discrete steps, 1.83mV between each step). This signal controls the engine governor
speed.
NOTE: In the latest GENCON model ("C") the output voltage range can be extended
to 0 to 10V by configuring B22 as REF-IN and leaving it open.
B22 REF OUT (DEFAULT)
A fixed 3.75V voltage source. Note that this is B21's range exact midpoint. It is used
with governors that need bipolar () control voltage.
B22 REF IN (IMPORTANT)
This is an alternative use for B22 that is available in the latest GENCON model C.
This input reads the ground voltage of the remote engine governor in order to cancel
its effect.
B23 COM
Cable screen connection.

General
B21 is connected to the electric governor of the engine. The electric governor, usually,
operates in isochronous (zero droop) mode. When synchronizing and when running in
parallel, GENCON changes the voltage of B21 to adjust the engine speed and the engine
load share. Ideally, the 0 to 7.5V range of B21, when applied to a free running gen-set,
would be able to adjust the gen-set frequency to 2.5% around the nominal 50 or 60 Hz
frequency.
Some electric governors can be driven by B21 directly. Some, due to excessive Hz/Volt
response, require an interface. The voltage level of B21 under which the governor
frequency is calibrated is defined by the parameter {Gov Volt Bias}.
Here is how to connect several common governors:

In Woodward 8290 speed control (part of the 1724 EPG governor) connect B21 D/A
to terminal [11] Aux Input+. Set {Gov Volt Bias} to 1.5V. If GENCON model C is used
it is recommended to connect [12] Aux Input- to B22 REF-IN.
Woodward's (digital) ProAct:

The auxiliary input of ProAct is potential free, its effective input range is 2.5V.
GENCON can apply on terminals 12(+) versus 13(-) a 3.75V range. Set the {Gov Volt
Bias} to 3.75.
Frostechnic Rev 9.00 June 2004 77

Woodward's 2301A family of speed controllers, like ProACT, also has potentialfree biploar speed setting inputs. Hence, use terminals B21 D/A versus B22 REF-OUT
and a {Gov Volt Bias} of 3.75V to create a speed control signal. The sensitivity of
the SPM INPUT is approx. 0.5 Hz/Volt. The sensitivity of the AUX INPUT is approx.
2.5 Hz/Volt.
Woodward's (digital) GenDec:

GenDec's auxiliary speed reference input requires a 500Hz PWM (Pulse Width
Modulated) signal with 24V amplitude. Wexler's Analog to PWM module converts the
0 to 7.5V range of B21 into the required PWM signal. Order "ANALOG/PWM 500Hz".

CUMMINS QST30
Connect B21 ANALOG-OUT to their "Woodward Compatible Speed Input", terminal
16. Use a {Gov Volt Bias} of 5.0 Volts. Since this speed control input is not potential
free it is recommended to configure terminal B22 as a REF-IN to read the governor
signal ground. More information about this governor is wanted, for example, what is
its Hz/Volt response. Thanks!

19 Aug 2003, QSX15 revisited:


The solution in the following paragraph requires Cummins to configure their ECM for
"Woodward mode". As this was not provided in our case a "quick and dirty"
alternative solution had to be found. The following circuit controls the ECM speed
through its frequency adjust potentiometer input (replacing their 5k pot of-course):
B21 D/A

-- R1 --+-- #23
|
GENCON
R2 ECM Connector 03
|
B22 REF-IN --------+-- #14
Select resistors R1 = 1000 and R2 = 560.

Based on page 56 in the manual (3884960(5-9-01).pdf) we were expecting to


command through GENCON's 0-7.5V B21 D/A output a frequency range of -2.57Hz to
+2.52Hz around the ECM nominal frequency. Feedback: Solution works, for nominal
1500RPM/50Hz speed a {Gov Volt Bias} value of 3.2V was needed.

Frostechnic Rev 9.00 June 2004 78

CUMMINS QSX15, QSK45 and QSK60 Generator Drive Control System


The following advice (circa June 2001) is based on Cummins manual 3884960(5-901).pdf .
The ECM should be configured for "Woodward Frequency Bias" mode where speed
control for sync and load-sharing is achieved by applying +/- 2.5V around the ECM 5V
reference. We assume here that pin 12 is the ECM signal ground. Adjust the ECM
speed droop to zero, i.e., to operate in isochronous mode (this is done by shorting
the ECM connector-03 pin #24 (Droop Adjust) to pin #14 (Analog Ground)). Enter 5.00
into GENCON's {Gov Volt Bias} or, preferably, the exact value that causes B21 to
match precisely the voltage of the ECM connector-03 pin #06 (+5V).

Additional wiring advice (please check each point carefully!):


1. Enter a {Pick-up Teeth} value of zero to GENCON as Cummins may object to
sharing of their MPU...
2. Connect the N/O contact of GENCON relay K#2 (FUEL SOLENOID) between the
ECM connector-06 pins #05 (Run/Stop) and #08 (ECM GND).
3. Set the ECM "Crank Switch Enable" parameter to "Enabled", select "Continuous
Cranking" mode and match the ECM "Continuous Crank Engage Time" with
GENCON's {Engine Crank} parameter. Connect the N/O contact of GENCON
relay K#3 (STARTER MOTOR) between the ECM connector-03 pins #03 (Crank
Switch) and #16 (Crank Return).
4. Connect the N/C contact of GENCON relay K#4 (AIR DAMPER) between the
ECM connector-06 pins #01 (Emergency Stop) and #25.
5. To acknowledge faults through a "common reset" push-button set
{SleepClearsFaults} in OPTIONS to 1 and use a push-button with two N/O
contacts to (1) apply DC- to In#3 and (2) connect pin #24 to pin #08 in the
ECM connector-06.
6. Disable the relay driver diagnostics in the ECM through InPower. Connect the
ECM "Alarm Lamp/Relay Drivers" of Connector 03 directly to the IOB inputs as
follows:
"COMMON SHUTDOWN" pin #08 to GENCON In#13 (AIR-DAMPER
SHUTDOWN). Change of GENCON text is needed.
"HIGH ENGINE TEMP" pin #07 to GENCON In#7 (HIGH COOLANT
TEMPERATURE SHUTDOWN).
"LOW OIL PRESSURE" pin #19 to GENCON In#5 (OIL PRESSURE
SHUTDOWN). Connect also DC- through the N/C contact of GENCON K#6
(GENERATOR RUNNING INDICATOR) to In#5 to simulate low oil pressure
when the genset is at standstill.
Frostechnic Rev 9.00 June 2004 79

"OVER SPEED" pin #04 to GENCON In#9 (LOW COOLANT TEMPERATURE


WARNING). Set the option {In#09 Aux Shutdn} to 1. Change of GENCON
text is needed.
"PRE-HIGH ENGINE TEMP" pin #25 to GENCON In#8 (HIGH COOLANT
TEMPERATURE WARNING).
"PRE-LOW OIL PRESSURE" pin #15 to GENCON In#6 (OIL PRESSURE
WARNING).
Cummins new digital EFC model:

The EFC is used in "Run Mode", its RMT SPD input range is 0 to 8V. Adjust RUN1 to 5% below the nominal frequency, eg, 50-2.5=47.5Hz. Adjust RUN2 to +5.7% above
the nominal frequency, eg, 50+2.8=52.8Hz. Set the {Gov Volt Bias} to 3.75V.
GENCON can change the genset frequency by 2.5Hz. Set the {Gov Volt Bias} to
3.75.

The old Cummins EFC and Barber-Colman models respond to Vdc around 3.5 and
4.0 volts respectively. Since the RMT SPD input is too sensitive the following 25:1
voltage divider is required:

Set the {Gov Volt Bias} to 3.5 or 4.0 as appropriate. It is recommended to enable the
ground voltage compensation circuit.
DPG-2201 - Digital Programmable Governor
Since LS-SIGNAL, DPG-2201's analog input, has 10 Hz/Volt sensitivity the following
voltage divider is required:

Frostechnic Rev 9.00 June 2004 80

Set GENCON's {Gov Volt Bias} to 3.75V. B21 0-7.5V is expected to command 2Hz
speed change around the nominal engine speed. Note that B22 should be configured
as a reference input.

GAC model 5131 can be directly controlled:


Run the engine without load. Adjust the governor SPEED potentiometer to reach
standard generator frequency, adjust the GAIN and STABILITY potentiometers of the
governor to the maximum and minimum settings that are respectively acceptable,
i.e., before instability begins. The governor should not use droop. Measure the
voltage between the GAC terminals AUX [N] and BAT NEG [E], appprox. 3.5Vdc is
expected. Set the {Gov Volt Bias} to the value that you just measured. Connect
GENCON B21 D/A terminal to the GAC AUX [N] terminal via a screened cable, the
cable screen should be connected to the GAC BAT NEG [E] terminal only. The
expected sensitivity of AUX [N] to B21 D/A voltage changes is approx. 2 Hz/Volt.
Note that in the GAC case the sign of the {SYstbl V/Hz} set-point is negative, i.e.,
raising B21 D/A voltage lowers the engine speed.

GAC model ESD5500:


The following circuit with a 153 tooth engine flywheel exhibited 1 Hz/Volt generator
sensitivity. The nominal 60Hz frequency was established at a {Gov Volt Bias} of
3.55V. It is recommended to configure B22 as a REF-IN to cancel the voltage
difference to the remote governor ground potential. Note that the sign of the
{SYstbl V/Hz} set-point has to be negative.

GAC = Governors of America

Frostechnic Rev 9.00 June 2004 81

Caterpillar's digital speed control


Preliminary: In one reported case Caterpillar's remote speed adjust module (an
ANALOG to PWM converter) was used with the following interface:

GENCON was using a {Gov Volt Bias} of 3.50V and had a 2 Hz/Volt effect.

Deutz EMR: Connect B21 D/A to the EMR pin 25 of plug F. Adjust the EMR response
to 2V around a 2.50V {Gov Volt Bias} to 5% change around the nominal engine
speed.

VOLVO

EDC III notes, work in progress:


Connect B21 to the EDC III terminal [3] GN/OR (POT). You may do so via
terminal C of the "Stand Alone Connector".
o Recommended: Configure B22 as a REF IN, by default it is a 3.75V reference
output. Connect it to the EDC III terminal GN/Y (POT-). You may do so via
terminal B of the "Stand Alone Connector".
o Set the {Gov Volt Bias} parameter to 2.87V for nominal engine speed.
o

Frostechnic Rev 9.00 June 2004 82

JOHN DEERE's JDEC


GENCON was successfully tested with the following John Deere engines that are
equipped with the JDEC level 11 governor: 4045HF475, 6068HF475, 6081HF070 and
6125HF070. The {Gov Volt Bias} is 2.50V.

MTU's MDEC

Set the {Gov Control Bias} to 5.0 Volts. Important! By default MDEC has this speed
setting input disabled. Contact MTU.
MDEC has five positive switched alarm outputs and four 0-10V analog outputs. An
interface circuit is available, marked A65, to convert these signals into IOB2
compatible digital and analog inputs. Contact WEXLER.
Since GENCON is not in direct control of the engine the following changes are
necessary:
o
o

Use the special software with option #8 to enable multiple cranking attempts.
Set the {Pick-up Teeth} count in BASICS to zero and the {Extrn Engine Ctrl} in
OPTIONS to 1.

Frostechnic Rev 9.00 June 2004 83

DDC's DDEC III


DDEC III has a non isolated speed control input. Hence, it is recommended to apply
the ground voltage cancellation circuit of GENCON model C as follows:

Set the {Gov Control Bias} to 2.6 Volts for 1800 RPM / 60 Hz.

Frostechnic Rev 9.00 June 2004 84

Interfacing Heinzmann KG 604 governor


Courtesy of Lindsay Wood, IES, Australia (23 June 2000).
Re: Heinzmann KG 604 Governor Control Card.
There is a set of documents usually located on the inside of the front cover of the box that
this card is housed in.
The instructions will tell you how to set up the feedback loop from the actuator, the gain
and stability and will also tell you that you should expect about a 3Hz change for every
change of 0.1VDC gov volt bias. These instructions should (for obvious reasons) still be
adhered to, but wait till after you have installed the voltage divider!
The problem here is the magnitude of change of frequency per gov volt, for the purpose of
load sharing, but even if this set were to stand alone I would still recommend that this
modification be done anyway.
On trialling this situation (3Hz : 0.1VDC) this governor behaves in a most unsatisfactory
manner. It is possible to synchronise the machine without too much difficulty but
controlling it when sharing load is near on impossible and really not worth the grief.
IMPORTANT - The old speed trim potentiometer that was part of the module before must
still exist and be in good working order!
Usually this pot will be mounted on the door near the speed card, so find it and set it at
about half way.
The remedy:
Use a voltage divider to drop the voltage out of the G2P to a more suitable level. This will
enable much more acceptable control and you should find that the machines accept load
and stabilise straight away. Obviously they won't be perfect but this will get you to a stage
where all you need is to fine tune the LS values to get the load to sit flat.
Governor volt bias should be set to 4.5V DC, and create the Voltage Divider as shown on
the attached PDF file. You should now proceed to spin the machine up to 1500 rpm. Use
the max speed trim pot to adjust rpm to 1500 and then shut it down and go ahead with the
set up of the feedback loop as per the instructions. Then set gain and stability. This
machine is now essentially ready.
As an exercise, have the machine sitting @ about 50Hz and change gov. volt bias up or
down by 1Vdc. You should see a change of approx. 2.5Hz (but no more than 3!). Gov volts
of 6.5V should shoot the machine just past 55hz and into over frequency. Gov volts of 2.5V
should drop the machine to just over 45Hz. upon removal of B21 (out of the back of the
G2P) the machine should drop to around 48.5 to 49.5Hz.
All that is left is to make sure it behaves ok with load on it's own, and make any necessary
fine adjustments and you should be right to synchronise and then share load as per any
other set that you would do (don't forget to set up the AVR too!!!).
We found the values for the voltage divider by substituting the 2 resistors for 100K pots and
just playing until we got about 2.5Hz per 1 gov volt and about 1500 rpm with the speed
card's pots at about half way each with a gov volt bias of 4.5VDC.
We learned this lesson in Australia with 3 x V12 Rolls Royce units, equipped with
Heinzmann E6 actuators + KG 604 speed cards driving 600 kVa Marathon alternators. The
AVR's were from Genaust.

Frostechnic Rev 9.00 June 2004 85

Generator-set commissioning
1. PATIENTLY make sure that the wiring fully complies with our Tears Saving Notes. If
GENCON is installed at some distance from its generator-set, be aware of the problems
that can result from having a different ground potential at the generator-set and at the
control cubicle.
If the generator-set is used for paralleling make sure that fast closing breakers were
provided, for example, contactors or spring operated breakers.
2. Make sure that the frequency and the voltage of the generator-set is stable under
various load conditions. The frequency should be stable to 0.01-0.02 Hz. Also adjust the
governor potentiometer to high gain, just below the point where the engine starts to
"hunt" -- We can't work with lazy governors! Similarly adjust the AVR.
3. Put the generator-set under resistive load and check the readings at the MEASURE menu
of each phase. Consult section on common cts faults advice how to find common CT
wiring mistakes if you see kVArs or negative kWs on any phase.
4. Confirm that we have good governor and AVR response by changing the {Gov Volt Bias}
and by simulating 0% and 100% PWM conditions.
The governor response should not exceed 3 Hz/Volt.
The AVR should not change the generator voltage by more than 10% in response to 0%
and 100% PWM conditions.
Calibrate the engine speed to the appropriate 50 or 60 Hz frequency under the {Gov Volt
Bias} value, which is appropriate for your governor model
Calibrate the generator voltage to the appropriate 120V,..., 346V L-N level under PWM of
50%.
In load-sharing systems it is important to calibrate the frequency and the voltage of all
the generator-sets to exactly the same level in order to prevent kW and kVAr transients
when generator-set master/slave roles have to change.
5. Make sure that the generator breaker cannot close. Set the {Parallel in System} option
to 1 and run the genset in test mode (via In#2) with a live mains or bus. Two closed
control loops simultaneously work:
The frequency and phase synchronizer that is controlled by the {SYgainV/180} and
{SYstbl V/Hz} parameters and the voltage matching loop that is controlled by the
{SYgain %P/V} parameter. Our aim is to find a max-gain/min-stability adjustment for
each control loop. Use the SYNC scope and the SYSTEM display to see how these
independent control loops work (and also listen to the engine noise). Note that each
time that the genset is within the acceptable phase and voltage window for {Sync Dwell
Time} an asterisk appears in the OVERVIEW display. In a stable loop ANALOG-OUT and
PWM-OUT gently fluctuates around the bias points.
If the synchronizer does not work check the four {V4 Ov Voltage}... {V4 Un Frequen}
setpoints. Probably one of them tells GENCON to regard V4 state as abnormal.

Frostechnic Rev 9.00 June 2004 86

At this stage GENCON holds the genset in sync with the bus/mains (the asterisk on the
OVERVIEW display should appear often). If you have a 3-pole breaker use a voltmeter to
make sure that the voltage across EACH POLE is near zero when the "*" appears on
OVERVIEW. If you are using a 4-pole breaker use another GENCON and with its SYNC
scope (V1 vs. V4) check that there is no phase shift and voltage difference across EACH
breaker pole. DO NOT TRUST phase sequence meters.
6. Change to the appropriate parallel configuration. Use basic configs and not the more
complex variants of it (for example, plain config#3, even if the final project requires
the {Parall Auto Start} option). The {LSgain V/Xre} and the {LSstbl V/Xre} parameters
control the ANALOG-OUT "lever" (and kWs). The {LSgain%P/Xap} and {LSstbl%P/Xap}
parameters control the PWM-OUT "lever" (and kVArs). Pay close attention to the POWER
and SYSTEM display to check how each loop performs. Again we are interested in maxgain/min-stability set of parameters.

Frostechnic Rev 9.00 June 2004 87

EMC questions for the control panel builder


Electromagnetic interference (EMI) poses serious threats to the correct functioning of
modern microprocessor based systems. GENCON II was tested under extreme EMI
conditions to reduce the risk of erratic control behaviour. Nevertheless, the panel designer
should make his system electro magnetically compatible (EMC) to reduce the risk that
GENCON II, even for a brief moment, gets out of control. No effort should be spared if the
error message EMI (NOISE) DETECTED is registered even once. Here are the questions that
should be asked:
1.
Were all the switched inductive loads transients properly suppressed by placing
diodes across the DC coils and capacitor-resistors (or varistors) across the AC coils?
2.
Is GENCON II ground "riding" above the governor ground (the recommended method)?
If not, choosing the easy method, one should not close noisy ground current paths through
B12 and B22.
3.
Are the GENCON II and IOB1 ground terminals (bat-) connected by a short wire to
the cubicle for electrostatic shielding?
4.
Is the GENCON II IOB1 cable separately routed, ie not loomed with high AC
voltage & current wires? and in general
Were all the cables in the system segregated? Cables carrying high frequency interfering
currents should be kept away from other cables, even within shielded enclosures. AC
power and return, DC power and return, analogue controls, digital controls

CE mark
The CE mark indicates GENCON's compliance with the Low Voltage Directive (73/23/EEC) of
the European Union (EU).
The Electromagnetic Compatibility (EMC) Directive does not apply to GENCON, as it is a
"component" (sub-assembly) and not an "apparatus".
Year 2000 (Y2K) Compliance
The GENCONII pro software, as its notion of time is limited to 7 days only, is inherently
safe vis--vis the calendar change from the 19. Years to the next millennium. See the SETCLOCK command.

Note!
The contrast of the LCD characters may change slightly with temperature (visibility is guaranteed from -20C
to +70C). For adjustment use the trimmer on the rear panel. Common menu options

Frostechnic Rev 9.00 June 2004 88

Remote control and monitoring


The RS-485 network connects up-to eight GENCON controllers with an IBM compatible PC.
The program PANEL.EXE simultaneously builds eight control panels on the PC screen, "LCDs
+ Keypad."
Prerequisites: PC DOS operating system.RS-485 serial communication port.
The RS-485 port transmitter (TX) enable signal should be DTR, RTS or OUT1. The RS-485
port should have preferably in built voltage isolation. It is useful to have a mouse and a
printer (with PC 8-bit symbol-set).
Run the program by PANEL SET. The program will ask the following:
RS485 port COM number: 1..4 ( = 1) ?
Number of gensets: 1..8 ( = 0) ?
Disable fault-reset & estop by mouse: no/yes ( = no) ?
Disable fault-reset & estop by Alt R & Alt - S : no/yes ( = no) ?
Data logging yes/no ( = no) ?
If you omit the argument SET, your last set of answers is used.
Each one of the display windows mimics one controller LCD. The Controller ID No
determines the screen position of the LCD mimic. If there is no communication with a
controller, the display window is blank.
The mouse keypad on the screen and the PC keyboard are linked to the controller shown
with a double borderline window. Pressing a function key, F1 F8, links the keys with the
corresponding controller. Alternatively, by clicking the mouse anywhere within a display
window, automatically links the keys with the controller. Operating a controller through
the PC console is identical to operating the controller through its own front panel.
Operating the program through a mouse has the following additional advantages:
Clicking a menu function by the mouse automatically activates the function. Clicking
the lowest display line selects a higher menu level.
When a function is active, clicking the mouse left button is equivalent to ESC and
clicking the right button is equivalent to ENTER .
Press the PC arrow key to print a parameter value. The key prints a carriagereturn/line-feed.

Frostechnic Rev 9.00 June 2004 89

ESPAOL, DEUTSCH, FRANAIS, ...

Software maintenance
Text editing
You may wish to change the name of an input alarm channel,. You can do this by yourself using the
PC program NED.EXE. After editing the texts by NED.EXE, load the revised software into GENCON
PRO using the procedure described in the following load section.
Run the program by NED SET to define the program input and output file, note you must use a file
name that exists in the current directory this file must be a gencon will be over written when you end
the program. If you omit the argument SET, NED.EXE will use the file names that it used in its
previous execution. You can edit an existing software file by specifying the same input and output file
names.

The text editing process is straightforward: Type over the existing text (the PC left, right, insert and
delete keys are at your disposal). Skip text line editing by striking the down arrow key.
Backtrack by striking the up arrow key. To introduce your text changes strike the ENTER key. End
NED.EXE by striking the Esc key. Be careful not to place text where measured values are displayed!
Procedure:
1. Connect GENCON PRO to the PC RS-485 serial port. Only one controller can now be connected
to the PC!.
2. Run NED.EXE by NED SET. Change RS-485 communication port as necessary and follow on
screen instructions. If you type NED only, the program uses the set of arguments it used last.
3. Using a long and thin screw-driver prepare the dip switches for Flash
programming by: SW2 =DOWN. You don't have to open the instrument cover!
See also Dip-switches
4. Turn on GENCON PRO power supply.
5. Press ENTER to begin the software transfer. '>'s appear on the PC screen to
indicate transfer progress. PROG message appears on the GENCON PRO LCD.
Wait for successful programming completion message.
6. Turn off GENCON PRO power supply.
UP
7. Prepare GENCON PRO dip-switches back for normal operation by:
SW2=SW3=UP.
SW1
SW2
8. Turn on GENCON PRO power supply.
SW3

B6

AUX...
DOWN

Frostechnic Rev 9.00 June 2004 90

Software down loading


It may be required to load GENCON PRO with a new software version to enhance its capabilities, or
it may be required to load GENCON PRO with software having modified texts (see Text Editing).
The software is stored in a non-volatile Flash memory. The Flash memory is programmed (written to)
by GENCON PRO itself. Flash memories can undergo 10,000 re-programming cycles. You can
identify the version of the software resident in GENCON PRO using the COMMAND\HELP.
Prerequisites:
1. The PC should have an RS-485 serial communication port, preferably isolated from the PC ground.
The RS-485 transmitter (TX) enable signal should either be DTR, RTS or OUT1. No IRQ line is
required.
2. Minimum 15 volt DC power supply for GENCON PRO. The DC supply should be well regulated
or loading the software may fail. It is advised to avoid electrical transients while loading software!
3. New software disk.
Procedure:
UP
1. Using a long and thin screw-driver prepare the dip switches for Flash
programming by: SW2=SW3=DOWN. You don't have to open the instrument SW1
SW2
cover!
SW3
See also Dip-switches.
B6
AUX...
2. Connect GENCON II to the PC RS-485 serial port. Only one controller can
DOWN
now be connected to the PC!
3. Run LOAD.EXE by LOAD SET. Change RS-485 communication port as necessary. If you type
LOAD only, the program uses the set of arguments it used last.
4. Turn on GENCON II power supply.
5. Press ENTER to begin the software transfer. '>'s appear on the PC screen to indicate transfer
progress. PROG message appears on the GENCON II LCD. Wait for successful programming
completion message.
6. Turn off GENCON II power supply.
UP
7. Prepare GENCON II dip-switches back for normal operation by:
SW2=SW3=UP.
SW1
SW2
8. Turn on GENCON II power supply. Press 0 if you are asked to do so.
SW3

Automatic text translation

B6

AUX...
DOWN

TRAN.EXE is a utility program which picks up translations made for an earlier GENCON II software
version and automatically introduces them to a newly released English software version. Run the
program for further details.

Frostechnic Rev 9.00 June 2004 91

Reading the EEPROM


All GENCON PRO parameters (time-delays, set-points, calibration values, etc.) are kept on a non
volatile EEPROM memory. READ.EXE is a utility program for copying the EEPROM data to a disk
file.
Procedure:
1. Set the dip-switch SW2 DOWN. The position of SW1 and SW3 is irrelevant.
2. Connect GENCON PRO to the PC RS-485 serial port. Only one controller can be connected.
3. Run READ1.EXE by READ1 SET to define the program arguments as follows:
RS485 port COM number: 1..4 ( = 1) ?
EEPROM file name ( = EEPROM.dat) ?
4.
5.
6.
7.

Turn on GENCON PRO power supply. The minimal power supply voltage is 15 volts.
Press ENTER.
Turn off GENCON PRO power supply.
Prepare GENCON PRO dip-switches for normal operation by: SW2=SW3=UP.

Writing the EEPROM -- The Fast Way!


There are two programs that can be use write1 and write2 or the IOB 1 and IOB 2 respectively.
WRITE.EXE is a utility program for copying a file created by READ.EXE to the EEPROM memory.
If the EEPROM file was read from an earlier software release, as early as 's14a', its data is
automatically converted to the latest format.
Procedure:
1. Set the dip-switch SW2 DOWN. The position of SW1 and SW3 is irrelevant.
2. Connect GENCON PRO to the PC RS-485 serial port. Only one controller can be connected.
3. Run WRITE.EXE by WRITE SET to define the program arguments as follows:
RS485 port COM number: 1..4 ( = 3) ?
EEPROM file name ( = EEPROM) ?
4. Turn on GENCON PRO power supply. The minimal power supply voltage is 15 volts.
5. Press ENTER.
6. Turn off GENCON PRO power supply.
7. Prepare GENCON PRO dip-switches for normal operation by: SW2=SW3=UP.

Frostechnic Rev 9.00 June 2004 92

EMC questions for the control panel builder


Electromagnetic interference (EMI) poses serious threats to the correct functioning of modern
microprocessor based systems. GENCON II was tested under extreme EMI conditions to reduce the
risk of erratic control behavior. Nevertheless, the panel designer should make his system
electromagnetically compatible (EMC) to reduce the risk that GENCON II, even for a brief moment,
gets out of control. No effort should be spared if the error message EMI (NOISE) DETECTED is
registered even once. Here are the questions that should be asked:
1. Were all the switched inductive loads transients properly suppressed by placing diodes across the
DC coils and capacitor-resistors (or varistors) across the AC coils ?
2. Is GENCON II ground "riding" above the governor ground (the recommended method)? If not,
choosing the easy method, one should not close noisy ground current paths through B12 and B22.
3. Are the GENCON II and IOB1 ground terminals (bat-) connected by a short wire to the cubicle for
electrostatic shielding?
4. Is the GENCON II IOB1 cable separately routed, ie not loomed with high AC voltage &
current wires? and in general
5. Were all the cables in the system segregated? Cables carrying high frequency interfering currents
should be kept away from other cables, even within shielded enclosures. AC power and return, DC
power and return, analog controls, digital controls

Frostechnic Rev 9.00 June 2004 93

Index
#
#0 Generic configuration............................................................................................................................................................................. 39
#1 American standby................................................................................................................................................................................... 32
#2 Euro standby........................................................................................................................................................................................... 32
#3 Load dependent start/stop sequencing .................................................................................................................................................... 35
#3 Random access paralleling ..................................................................................................................................................................... 34
#4 Paralleling with the mains ...................................................................................................................................................................... 32
#5 Euro standby with soft load transfer....................................................................................................................................................... 33
#6 Euro standby with soft mains return & paralleling with the mains......................................................................................................... 34

A
Applications ................................................................................................................................................................................ 8, 27, 31, 57
Augmented American standby .................................................................................................................................................................... 38
Augmented Euro standby ...................................................................................................................................................................... 38, 39
Automatic mode............................................................................................................................................................................................. 8
AUTOOFF .............................................................................................................................................................................................. 8, 45
AVRs........................................................................................................................................................................................................... 69
AVRx .............................................................................................................................................................................. 1, 67, 69, 71, 73, 74

B
Basic load control.................................................................................................................................................................................. 27, 45
BASICS............................................................................................................................................................8, 9, 10, 11, 19, 33, 36, 65, 68
Bat OvVoltage ............................................................................................................................................................................................. 19
Bat UnVoltage............................................................................................................................................................................................. 19
Battery and DC supply ................................................................................................................................................................................ 66

C
Calibrate ...................................................................................................................................................................................................... 86
Caterpillar VR3 ........................................................................................................................................................................................... 71
CAVEATS .................................................................................................................................................................................................. 47
CE mark ...................................................................................................................................................................................................... 88
Cogeneration Mode..................................................................................................................................................................................... 31
COMMAND ........................................................................................................................................................................... 3, 4, 5, 7, 9, 27
Contactor Delay .................................................................................................................................................................................... 39, 57
Controller ID No ........................................................................................................................................................................................... 8
Controlling voltage regulators..................................................................................................................................................................... 69
CrankStop RPM .......................................................................................................................................................................................... 19
CT CONNECTION FAULTS / TESTING ................................................................................................................................................. 61
CT Ratio ...................................................................................................................................................................................................... 60
Current inputs.............................................................................................................................................................................................. 60

D
Definitions................................................................................................................................................................................................... 36
Delays ......................................................................................................................................................................................................... 46

E
EMC questions for the control panel builder............................................................................................................................................... 88
EMI (NOISE) DETECTED......................................................................................................................................................................... 88
ENGINE............................................................................................................................................................................................ 9, 56, 65
EXPORT........................................................................................................................................................................................................ 8
EXTERNAL OVERLOAD ............................................................................................................................................................................ 57

G
G 2x OvCurr................................................................................................................................................................................................ 24
G Over %THD............................................................................................................................................................................................. 24
G Revrse kW................................................................................................................................................................................................ 24
G Rvrs kVAr ................................................................................................................................................................................................ 24
GEN A, GEN B and GEN C ......................................................................................................................................................................... 9

Frostechnic Rev 9.00 June 2004 94

Gen OverFreq ............................................................................................................................................................................................. 24


Gen OverVolts ............................................................................................................................................................................................ 24
Gen OvFrequen........................................................................................................................................................................................... 19
Gen OvVoltage ............................................................................................................................................................................................ 19
GEN PH-PH .................................................................................................................................................................................................. 9
Gen UnderFreq ........................................................................................................................................................................................... 24
GEN UNDERVOLTAGE ........................................................................................................................................................................... 63
Gen UnderVolts........................................................................................................................................................................................... 24
Gen UnFrequen........................................................................................................................................................................................... 19
Gen UnVoltage............................................................................................................................................................................................ 19
GENCON AMPS READ ERR ...................................................................................................................................................................... 60
Generator Syn|Asy ...................................................................................................................................................................................... 32
Generator-set commissioning...................................................................................................................................................................... 86
GENERIC CONFIG ERROR ..................................................................................................................................................................... 39
Gov Volt Bias .............................................................................................................................................................................................. 86
Governor Ground Voltage Compensation................................................................................................................................................... 76

H
Heinzmann KG 604 governor ..................................................................................................................................................................... 85
HELP........................................................................................................................................................................................................... 10
HIGH WATER TEMP SHUT....................................................................................................................................................................... 7
Hybrids........................................................................................................................................................................................................ 38

I
Ideal Freq Hz .............................................................................................................................................................................................. 68
ILL GEN PHASE ORDER ......................................................................................................................................................................... 63
IN 1..16 ....................................................................................................................................................................................................... 10
In#11 LOW FUEL WARN ........................................................................................................................................................................... 57
In#12 CHARGER FAULT.................................................................................................................................................................... 51, 57
In#13 AIR DAMPER SHUT ........................................................................................................................................................................ 57
In#15 GEN CONTACTOR..................................................................................................................................................................... 57, 58
In#16 MAINS CONTACTOR................................................................................................................................................................. 57, 59
In#1RUN WITH LOAD ............................................................................................................................................................................... 56
In#2 TEST W/O LOAD .................................................................................................................................................................... 8, 25, 56
In#3 SLEEP or BYPASS .............................................................................................................................................................................. 56
In#4 EMERGENCY STOP ................................................................................................................................................................... 51, 56
In#5 OIL PRESS SHUT.............................................................................................................................................................. 3, 51, 56, 58
In#6 OIL PRESS WARN ...................................................................................................................................................................... 51, 57
In#7 HIGH TEMP SHUT...................................................................................................................................................................... 51, 57
In#8 HIGH TEMP WARN.................................................................................................................................................................... 51, 57
In#9 LOW TEMP WARN............................................................................................................................................................................. 57
Input channels ............................................................................................................................................................................................. 56
IOB1...................................................................................................................................................................1, 4, 6, 10, 11, 26, 45, 56, 88
IOB2.......................................................................................................................................................................................................... 1, 4
ISOLATED ................................................................................................................................................................................................. 60

K
K#1 PRE-GLOW ......................................................................................................................................................................................... 58
K#2 FUEL SOLENOID .................................................................................................................................................................. 26, 58, 67
K#3 CRANK ................................................................................................................................................................................................ 58
K#4 AIR DAMPER .......................................................................................................................................................................... 7, 56, 58
K#5 LUBRICATION PUMP........................................................................................................................................................................ 58
K#6 Engine|Gen On .............................................................................................................................................................................. 46, 58
K#6 SET RUNNING .................................................................................................................................................................................... 58
K#7 GEN CONTACTOR ..................................................................................................................................................................... 57, 58
K#8 MAINS CONTACTOR............................................................................................................................................................. 7, 57, 59
kW Drop=LoadSurge ............................................................................................................................................................................ 33, 34

L
LED's ............................................................................................................................................................................................................ 3
Leroy-Somer's R448.................................................................................................................................................................................... 74
LOAD-GEN .................................................................................................................................................................................................. 7
LOW WATER LEVEL......................................................................................................................................................................... 15, 57
LowWaterLevel S|W .................................................................................................................................................................................... 15
LS Settling ....................................................................................................................................................................................... 27, 36, 37
LSgain V/Xre ............................................................................................................................................................................................... 87

Frostechnic Rev 9.00 June 2004 95

LSgain%P/Xap ............................................................................................................................................................................................ 87
LSstbl V/Xre ................................................................................................................................................................................................ 87
LSstbl%P/Xap ............................................................................................................................................................................................. 87

M
Magnetic Pickup.......................................................................................................................................................................................... 64
Mains Standby ATS ............................................................................................................................................................. 7, 8, 9, 31, 57, 59
MANOFF ................................................................................................................................................................................................ 7, 45
Manual mode................................................................................................................................................................................................. 7
Marathon Electric PM100 ........................................................................................................................................................................... 70
Marelli's M25FA600A ................................................................................................................................................................................ 73
MEASURE.......................................................................................................................................................................... 3, 4, 9, 56, 65, 86
Measuring 3-wire systems........................................................................................................................................................................... 63
Mechanical mode switches.......................................................................................................................................................................... 45
Motor Contactors ........................................................................................................................................................................................ 46
MPU.................................................................................................................................................................................................. 9, 64, 65
Multiple generator-set applications ............................................................................................................................................................. 34

N
Newage Stamford........................................................................................................................................................................................ 69
NON-ISOLATED ....................................................................................................................................................................................... 60
Number of Poles.......................................................................................................................................................................................... 65

O
OFF mode ..................................................................................................................................................................................................... 7
OFFAUTO .............................................................................................................................................................................................. 7, 45
OFF-LOAD................................................................................................................................................................................................... 7
OFFMAN ................................................................................................................................................................................................ 7, 45
Outlook ......................................................................................................................................................................................................... 2
Output channels........................................................................................................................................................................................... 58
OVERVIEW ............................................................................................................................................................................................. 5, 9

P
Parall Auto Start ..................................................................................................................................................................................... 8, 87
Parallel genset automatic start/stop............................................................................................................................................................ 46
PARALLEL LOAD SURGE .......................................................................................................................................................... 33, 34, 40
PARALLEL MAINS FAIL................................................................................................................................................................... 33, 34
Parallelin System .................................................................................................................................................................................. 31, 74
Parameters............................................................................................................................................................................................. 11, 12
Parll Start.............................................................................................................................................................................................. 27, 36
Parll Stop ........................................................................................................................................................................................ 27, 36, 37
Pick-up Teeth .......................................................................................................................................................................................... 9, 65
POWER+PF .................................................................................................................................................................................................. 9

R
R#1 On->Off ............................................................................................................................................................................................... 27
R#1 Shunt|kW Load..................................................................................................................................................................................... 45
Ramp +kW/Sec ............................................................................................................................................................................................ 40
Ramp -kW/Sec ............................................................................................................................................................................................. 40
Ramp+kVAr/Sec.......................................................................................................................................................................................... 40
Ramp-kVAr/Sec ........................................................................................................................................................................................... 40
REPORT ............................................................................................................................................................................................... 3, 4, 7

S
SEQUENCE .................................................................................................................................................................................................. 8
Set Stabil Min ........................................................................................................................................................................................ 39, 46
SET-CLOCK....................................................................................................................................................................................... 5, 8, 88
SETPOINTS.......................................................................................................................................................................................... 52, 68
SET-UP ....................................................................................................................................................................................................... 10
Short-cuts ...................................................................................................................................................................................................... 4
Single generator-set applications................................................................................................................................................................. 32
Software features......................................................................................................................................................................................... 68

Frostechnic Rev 9.00 June 2004 96

Stoppin Max ................................................................................................................................................................................................ 56


SYgain %P/V ............................................................................................................................................................................................... 86
SYgainV/180 .............................................................................................................................................................................................. 86
Sync Dwell Time.............................................................................................................................................................................. 25, 39, 86
SYNCscope ................................................................................................................................................................................................. 10
SyncTimeout ................................................................................................................................................................................................ 24
SYstbl V/Hz.................................................................................................................................................................................................. 86
SYSTEM......................................................................................................................................................................................... 10, 86, 87

T
Tears saving notes ....................................................................................................................................................................................... 67
Test Delay ............................................................................................................................................................................................. 39, 56
The SET-UP menu ...................................................................................................................................................................................... 11

V
V4 Ov Frequen ............................................................................................................................................................................................ 20
V4 Ov Voltage ....................................................................................................................................................................................... 20, 86
V4 Un Frequen............................................................................................................................................................................................ 86
V4 Un Voltage ............................................................................................................................................................................................. 20
Voltage models............................................................................................................................................................................................ 62

Frostechnic Rev 9.00 June 2004 97