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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.
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 2
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 push-
button again.
Pending faults cannot be cleared. If you press RESET, the faults will be re declared.
#1 Model variations affect one low cost PCB (A50-3). Re-calibration must follow its
replacement.
#2 Contact factory for special requirements.
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
gencon’s 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 (cosφ). Ie starting from the root call MEASURE, call
GENERATOR and finally call POWER+PF.
Snapshot 1 Snapshot 2
Mode=Auto Tue 22:35 Mode=Auto Tue 22:37
GenSet Stationary GenSet Stationary
Mains OK Stand-by! Mains Fail Run: 0'05
Power Source: Mains Power Source: None!
Snapshot 3 Snapshot 4
Mode=Auto Tue 22:40 Mode=Auto Tue 22:41
Set Runs with Load Set Runs with Load *
Mains Failure Run! Mains OK Stop: 0'24
Power Source: GenSet Power Source: GenSet
Snapshot 5 Snapshot 6
Mode=Auto Tue 22:42 Mode=Auto Tue 22:43
kW Down Ramp: 0'04 * Cooling-off: 2'45 *
Mains OK Stand-by! Mains OK Stand-by!
Parallel Connection! 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.
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.
OFFÖAUTO
This function changes the operating mode to AUTO. User password may be required.
OFFÖMAN
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.
MANÖOFF
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.
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. Non-
linear 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 ΦΦ
Gen Volts Hz: 50.07 Generator phase-A frequency
ΦA: 221 ΦAB: 384 L-N voltage, L-L voltage
ΦB: 222 ΦBC: 383
ΦC: 220 ΦCA: 382
MAINS or BUS
This function displays V4 phase measurements.
Mains ΦA The caption is MAINS or BUS according to SET-
Frequency Hz: 50.14 UP\OPTIONS Mains Standby ATS
Voltage Vrms: 223
Distortion %THD: 0.1
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 Function: Master
information. Network IDs 12------
ANALOG OUT (V): 1.50
A "Master" function indicates that the genset, when PWM OUT (%): 50.0
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.
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.
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.
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 generator-
sets start and stop automatically according to the total bus load following a user
supplied priority sequence, see the COMMAND > SEQUENCE. The set-points
{+%kW/Xre→Start} 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.
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 AUTO→OFF
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 AUTO→OFF 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.
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/Xre→R#1 On} to 80% and
{%kW/Xre→R#1 Off} to 35%. Set the delays {R#1 Off→On } {R#1 On→Off} are set as
needed.
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.
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
(*) 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} time-
delay 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.
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
LoadBreak→Make
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 de-
energizes 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 load-
sharing gen-sets run without load a few seconds before closing their common bus
breaker.
kW Quota++
kW Quota--
kVArQuota++
kVArQuota—
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.
YES GENERIC? NO
#0 NO PARALLEL? YES
#1 #2 NO COGEN?
YES NO
COGEN?
YES
#3 #4 #5 #6
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).
On a mains failure the controller energizes relay K#8 which, K#7
LOAD
V4
through a normally closed#1 contact, opens the mains
contactor. After a predetermined time delay the genset is In#1 G
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) LOAD
generators. See in SET-UP\OPTIONS the parameter Generator K#7
Syn|Asy.
The genset starts immediately on an active In#1 input. The In#1 G
#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
Time Time
Sync with Mains Parallel Connection Cooling-off Sync with Mains Parallel Connection Cooling-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)² + (Export-kVAr)² ≤ (Rating-kVA)². 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 Export Quota
Time Time
Isochronous Sync Parallel Cooling-off Sync with Mains Parallel Isochronous Parallel Cooling-off
Governor with Connection Connection Governor Connection
Operation Mains Operation
Mains Failure Mains Return In#1 ON In#1 OFF
operation with one power cut only as in configuration #5. Mains Contactor
Active In#1 input starts the genset for continuous paralleling
with the mains as in configuration #4. K#7
LOAD
V4
When detecting loss of mains during paralleling, the relay K#8
is energized, the mains contactor opens and the genset In#1 G
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.
B.In#1 G2 LOAD
#3 Load dependent start/stop sequencing
B.V4
1 General
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.
2.1 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.
(a) N = 0, i.e., the plant must have at least one generator-set powering the load.
(b) _ 1, i.e., the load on the current number of parallel running generator-sets is
too high.
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.
As the load decreases the following table shows the load levels when the N-th generator-
set 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 generator-
sets” 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 generator-set whose governor and AVR determine the bus frequency and voltage.
3 If the master stops, the remaining set with the lowest ID number becomes the new bus master.
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.
#0 Generic configuration
This configuration provides GEN ΦΑ BUS OR MAINS ΦΑ
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.
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
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.
To interrupt the idle speed run the generator voltage and frequency now both must
reach normal levels. Version 3.0a only considered the frequency.
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.
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.
Load-sharing is enabled by the {System Auto Start} option. For example, a load-
sharing config#6 is introduced by:
{Generic Configure} = 0
{Parallelin System} = 1
{Mains Standby ATS} = 1
{Cogeneration Mode} = 1
{System Auto Start} = 1
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%.
seconds usually.
2. Unless an undervoltage release mechanism is installed, the contactor CLOSE
• The analogue channels are not damaged. If using single lead senders it is
important to install protective TransZorbs.
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.
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.
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.
K#3 CRANK
K#3, through a N/O contact, energizes the starter motor solenoid. Use SET-
UP\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).
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:
Suppose the gen-set real load is 3 x 10KW: If the CT wires are connected to channel I1 but
in reverse:
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:
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
wattmeter’s, 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 phase-
to-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.
If the magnetic pickup is shared with the electric governor connect it as follows:
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).
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
3 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.
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.
Software set-up
BASICS
SETPOINTS
{HYD Gov Hz ERR} -- The "master" controller will up/down the motor if the measured
frequency vis-à-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.
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.
A1 -- 2.2k -- A
A2 ---------- B
Set the AVRx trimmer to the minimal ±3Vdc range. The AVRx transformer can be as
low as 16Vac
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.
• Mecc-Alte's UVR6
1. Power the AVRx from a 16 to 24 Vac transformer.
2. Set the AVRx trimmer to its minimum 3Vdc position.
3. Connect the AVRx wires A1 and COM to the "remote voltage control 100Kohm" inputs
of UVR6.
4. 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.
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 GENCON®II terminal B32. The generator voltage
should fall (to 200Vac in the example).
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%).
• 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.
(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 S-
T and install the voltage divider.
3. Calibrate REG37 voltage under 50% PWM level.
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, ...
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}.
• 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.
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
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):
The following advice (circa June 2001) is based on Cummins manual 3884960(5-9-
01).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).
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:
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.
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.
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
o 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.
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 Use the special software with option #8 to enable multiple cranking attempts.
o Set the {Pick-up Teeth} count in BASICS to zero and the {Extrn Engine Ctrl} in
OPTIONS to 1.
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.
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 kVAr’s 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.
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 max-
gain/min-stability set of parameters.
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 GENCON®II pro software, as its notion of time is limited to 7 days only, is inherently
safe vis-à-vis the calendar change from the 19. Years to the next millennium. See the SET-
CLOCK command.
Note!
The contrast of the LCD characters may change slightly with temperature (visibility is guaranteed from -20°C
to +70°C). For adjustment use the trimmer on the rear panel. Common menu options
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
8. Turn on GENCON PRO power supply. SW2
SW3
B6 AUX...
DOWN
B6 AUX...
Automatic text translation 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.
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.
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
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
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