Generator Protection Module GPM 500: Operation and Service Manual

Operation and Service Manual
Generator Protection Module

GPM 500
Doc. 271.195 999 BAW EN Revision: – (2005-03 / 00)

For this document we reserve all rights also in the event of patent granting or registration
of a utility model. Duplication of this document and its utilisation in some other way and
the disclosure to third parties are not permitted unless expressly authorised by us. Sub-
ject to modifications serving the technical progress.
SAM Electronics GmbH

D - 22763 Hamburg
Phone: + 49 (0) 40 8825-0

Fax: + 49 (0) 40 8825-4000
E-mail: [email protected]
Titel_Kap_05_GB.fm / 01.04.05
GPM 500
List of Contents
List of Contents
List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-I

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-IV
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-VI
1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.1 General Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.2 Module Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.1 Functional Description of the Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.1 Protection Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.1.1 Short-circuit Protection (ANSI 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.1.2 Stator Protection (ANSI 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.1.3 Independent Overcurrent Protection (Definite Time (DT), ANSI 51) . . . . . . . . . . . . . . . . . . . 1-12
1.4.1.4 Dependent Overcurrent Protection (Inverse Time (IDMT), ANSI 51) . . . . . . . . . . . . . . . . . . 1-12
1.4.1.5 Current Asymmetry (ANSI 46) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.4.1.6 Undervoltage (ANSI 27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.4.1.7 Overvoltage (ANSI 59) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.4.1.8 Phase Failure/Phase Sequence (ANSI 47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.4.1.9 Underfrequency (ANSI 81L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4.1.10 Overfrequency (ANSI 81H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4.1.11 Reverse Power (ANSI 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4.1.12 Underload (ANSI 37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4.1.13 Underexcitation (ANSI 40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4.1.14 Load Shedding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.4.1.15 Optional protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.4.2 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.4.2.1 Blackout Start (Mains monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.4.2.2 Start Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.4.2.3 Start Failure (ANSI 66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.2.4 Start Passing on/ relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.2.5 Automatic Start and Synchronising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.2.6 Synchronising Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.2.7 Circuit-breaker Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.2.8 Stop Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.2.9 Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.3 Power Management Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.3.1 Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.3.2 Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.3.3 Topload Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.3.4 Load Monitor Functions (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.3.4.1 Load-dependent Diesel Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.4.3.4.2 Load-dependent Diesel Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.4.3.4.3 Load dependent Start of big consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.4.3.5 Net Synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.4.3.6 Net Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.4.3.7 Connection to a Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.5 Technical Data; Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
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1.5.1 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

1.5.2 Mechanical Data of the GPM500 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.5.3 BAT500 for Door Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.5.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.5.5 Data Bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.5.5.1 GPM Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.5.5.2 CANopen Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.5.5.3 Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.5.5.4 Optional Redundant Modbus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Operating and displaying elements of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Menu structure on the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Display pages on the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.2 Overview page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Measurement page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.4 Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.5 Setup page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.6 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3.7 Menu Page Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.8 Identity page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.9 Nominal Values page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.3.10 Power Control page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.3.11 Example for protection parameter page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.3.12 Preferential Trip page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.3.13 Synchronism check page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.3.14 Internal failures page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.4 Switching on GPM500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.5 Operation sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.5.1 Starting and Stopping of a Diesel-Generator-Set in manual mode . . . . . . . . . . . . . . . . . . . . 2-21
2.5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.5.1.2 Starting a DG-Set in manual mode via the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.5.1.3 Starting a DG-Set in manual mode from the Switchboard panel . . . . . . . . . . . . . . . . . . . . . 2-22
2.5.1.4 Stopping a DG-Set in manual mode via the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.5.1.5 Stopping a DG-Set in manual mode from the switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.5.2 Starting of a Diesel-Generator-Set in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.2.2 Starting a DG-Set in automatic mode via the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.2.3 Starting a DG-Set in automatic mode from the switchboard . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.5.2.4 Stopping a DG-Set in automatic mode via the BAT 500. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.5.2.5 Stopping a DG-Set in automatic mode from the switchboard. . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.5.3 Parameterisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.5.3.1 How to input the password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.5.3.2 How to input or to change nominal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.5.3.3 How to change parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.5.3.4 How to activate / deactivate the function codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.5.4 Power Management System, load monitor (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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3.2.1 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.1 Check of sufficient ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1.2 Cleaning the Surface of BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Failure identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Component replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.1 Replacing fuse plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.2 Replacing defective modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.2.1 Installation in General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.2.2 Dismounting modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.2.3 Mounting modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.3 Wiring of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.3.1 Description of the Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.4 Replacing of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.4.1 Dismounting of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.4.2 Installation of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4.4.3 Connection of the BAT500 Operator Control and Display Panel . . . . . . . . . . . . . . . . . . . . . 3-17
3.4.4.4 Jumper settings of the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
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List of Figures
List of Figures
Fig. 1-1 Design of the GPM500 assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Fig. 1-2 Design of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Fig. 1-3 Labelling fields of the SLE500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fig. 1-4 Labelling fields of the USS500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fig. 1-5 Design of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fig. 1-6 Figure: Connection of Generator, Busbar and Net Numbers . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Fig. 2-1 Operating and displaying elements BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fig. 2-2 Structure of menues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fig. 2-3 Overview page for operating the assigned unit (e.g. generator) . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fig. 2-4 Overview c.b. status indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fig. 2-5 Page for measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fig. 2-6 Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fig. 2-7 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Fig. 2-8 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Fig. 2-9 Menu Page Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Fig. 2-10 Identity page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Fig. 2-11 Nominal Values page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fig. 2-12 Power Control page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fig. 2-13 Protection parameter page Instantaneous Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Fig. 2-14 Preferential Trip page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Fig. 2-15 Synchronism check page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Fig. 2-16 Internal failures page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fig. 2-17 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Fig. 2-18 Confirmation page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Fig. 2-19 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Fig. 2-20 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Fig. 2-21 Confirmation page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Fig. 2-22 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Fig. 2-23 setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Fig. 2-24 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Fig. 2-25 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Fig. 2-26 Identity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Fig. 2-27 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Fig. 2-28 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Fig. 2-29 Instantaneous Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Fig. 2-30 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Fig. 2-31 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Fig. 2-32 Instantaneous Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Fig. 2-33 Number block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Fig. 2-34 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Fig. 2-35 Power Management 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Fig. 2-36 Power Management 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Fig. 2-37 DG Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Fig. 2-38 Measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Fig. 3-1 Construction of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Fig. 3-2 Connecting the Modules Using Grooved Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fig. 3-3 Position of the Individual Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fig. 3-4 Dismounting module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Fig. 3-5 Mounting module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Fig. 3-7 Detailed View of a Plug-and-Socket Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Fig. 3-6 Connecting the Modules Using Grooved Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Fig. 3-8 Position of the Individual Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
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GPM 500
List of Figures
Fig. 3-9 Stripping the Line Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Fig. 3-10 Rear Side of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Fig. 3-11 Fitting the Narrow Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Fig. 3-12 Fitting the Broad Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Fig. 3-13 Inserting the BAT500 into the Mounting Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Fig. 3-14 Rear Side of the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Fig. 3-15 Inserting the Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Fig. 3-16 Battery with the Red Plastic Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Fig. 3-17 Ports on the BAT500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Fig. 3-18 Power Supply Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Fig. 3-19 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Fig. 3-20 ZKG500 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fig. 3-21 DI0500 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Fig. 3-22 GOV500 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Fig. 3-23 TRV500/501 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Fig. 3-24 TRV502 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Fig. 3-25 SLE500 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Fig. 3-26 SLE510 assembly jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
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GPM 500
List of Abbreviations
List of Abbreviations
AO Analog Output
AC Alternating Current
AI Analog Input
ANSI American National Standards Institute
BAT Operating and indicating panel (Bedienungs- und Anzeige-Tableau)
CAN Controller Area Network
CPU Central Processing Unit
DG Diesel Generator
DO Digital Output
DC Direct Current
DCC DC/DC-Converter
DI Digital Input
DIF Differential-Current Detection (Differenzstrom-Erfassung)
DIO Digital-I/O card
GOV Governor-Motor Control
GPM Generator Protection Module
IP Internet Protocol
LCD Liquid Crystal Display
MBM Modbus master unit (Modbus Masterbaustein)
NEG Power supply unit (Netzgerät)
OV Object directory (Objektverzeichnis)
PCB Printed Circuit Board
PDO Process data object (Prozessdatenobjekt)
RMS Root mean square
RTU Remote Transmission Unit
SDO Service Data Object (Servivedatenobjekt)
SLE Current and Power Acquisition (Strom und Leistungserfassung)
SPS Storage-programmable logic controller (Speicherprogrammierbare Steuerung)
TCP Transmission Control Protocol
TRV Isolated Voltage Acquisition (Trennverstärker)
USS Voltage Backup for Undervoltage Coils (Unterspannungsspulenstützung)
ZKG Central unit (Zentralkarte)
ZM Central Module (Zentralmodul)
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GPM 500 Description
1.1 Purpose
1 Description
1.1 Purpose
The generator protection module GPM500 is a system for protection of low-voltage and
medium-voltage generators and electrical power nets for ships and other applications.
The main task of the protection equipment is to protect the net and its capability to supply other
items of equipment.
In case of a fault in the net the fault location is disconnected from the supply and the equipment
and net items being not concerned remain supplied with power. The protection of equipment is
a secondary task.
Additionally it provides important control and power management functions.
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GPM 500 Description
1.2 Design
1.2 Design
1.2.1 General Design
The GPM500 consists of a basic configuration

of individual modules (1) being assembled to a
protection system. Depending on the applica-
tion requirements this system can be extended
by adding further modules.
The modules are installed by "snapping" them
onto a top-hat rail according to DIN. The
internal connections (data bus and analog bus
respectively) are established via plug-in
connections at the sides of the modules.
The operator control and display panel
BAT500 (2) is a touch screen display showing
an operator environment with operating and
switching conditions as well as measured 1
values via process displays. Operating pages
are opened via navigation buttons and inputs
are made or functions are called via function
buttons.
Fig. 1-1 Design of the GPM500 assemblies
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GPM 500 Description
1.2 Design
1.2.2 Module Descriptions
The basic mechanical design of the modules is described in the following:

The casing (3) of the modules is made from
polyamide plastic and is delivered in two
widths, namely 22.5 mm and 45 mm.
The 22.5 mm casing is equipped with one
electronic assembly (2) whereas the 45 mm
casing is equipped with two electronic assem-
1
blies (with the exception of the USS500).
2
Dimensions and weight are listed in the tech-
nical data (section 1.5).
After the withdrawal of the connectors (1),
unlocking the snap-in casing parts and
removal of the casing cover including elec-
tronic assembly (2) the electronic assembly is
accessible. It is connected to the data bus (4)
via a plug-in connection at the bottom of the
module.
Fig. 1-2 Design of the Modules
Identification of the Modules

The individual modules of the GPM500 are identified by means of labels. The labels are glued
on the side and on the top side of a module each.
The side labels are always glued on the side with the protruding bus connectors. In the following
table there are shown two labelling fields as examples.
The side label contains the The serial number label contains:
– Module designation – Manufacturer
– Terminal assignment – Manufacturer's code
– Module designation
The front label contains the – Identity No.
– Terminal numbers – Serial No.
– LED status displays
– Notes on changeable fuses installed.
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GPM 500 Description
1.2 Design
Module Side Top side

SLE500
Fig. 1-3 Labelling fields of the SLE500
USS500
Fig. 1-4 Labelling fields of the USS500
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GPM 500 Description
1.3 Functional Description
The generator protection module GPM500 is a microprocessor-controlled system being used to

protect low-voltage and medium-voltage generators and electrical power nets for ships and
other applications. The GPM500 can be operated as "stand-alone" unit or in combination with
other GPM500 devices (the communication taking place via a data bus)
Generally each protective application (e.g. generator, coupler circuit-breaker, consumer etc.)
requires an own GPM500.
A complete Power Management System (PMS) is realized by connecting all related GPM500
via the GPM bus, i.e. two redundant CAN bus systems. In this way all main PMS functions are
provided.
Thanks to the modular design of the GPM500 its functions and possible connections can be
easily extended because the modules are directly interconnected via plug-in connections.
The GPM500 can be connected via an interface (Modbus) to external power management
systems and (optionally) to the Internet (Modbus / TCP). The authorisation for the external
access to display and parameterisation can be restricted.
Operation, parameterisation and monitoring of the GPM500 are effected via the operator control
and display panel (BAT500). The graphical representation on the main picture enables the
immediate survey of the status of e.g. a generator and the connected generator circuit-breaker
including the relevant data such as current, voltage and power. For control / modification
purposes the parameters are combined according to the protection function (protected by a
password). Faults are displayed in an alarm list and can be acknowledged on the BAT500.
An integrated programmable logic controller (PLC) allows the free programming of additional
protection functions and switchpanel controls. The PLC can be graphically programmed on a
PC using functional blocks in accordance with IEC1131.
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GPM 500 Description
1.3.1 Functional Description of the Assemblies
GPM500 Power Supply Module NEG500 / Combined Power Supply Module NEG501 + 510
(Identity No.: 271.197 879) and NEG502 Respectively
The NEG500 is the standard power supply module for GPM500 systems with less extension
modules. For higher power demands in case of a larger number of extension modules the
combined power supply module NEG501+510 resp. NEG502 is required. The NEG501
assembly is a NEG500 variant without (5 V) DC/DC converter. The NEG510 assembly operates
in combination with the NEG501 assembly to make available the 5 V.
The power supply modules perform the following tasks:
– Filtering of the 24 V supply voltage
– Supply of a second (19 V 3-phase) supply voltage
– Monitoring of the 24 V DC and 19 V AC supplies
– Making available of a backed-up 24 V output voltage
– Making available of a regulated 5 V output voltage.
Additionally the NEG module provides the connectors for data bus to BAT500.
ZKG500 Identity No.: 271.195 020

GPM500 Central Unit
The ZKG500 assembly is the standard micro processor central unit for GPM500 systems.
It performs the following tasks by processing the implemented standard program:
– Initialisation of all internal assemblies via the internal system bus
– Acquisition of all data via the internal and external busses
– Evaluation of all data acquired
– Transmission of data and commands to all assemblies being connected.
DIO500 Identity No.: 271.195 021

GPM500 Digital I/O Module
The DIO500 is the standard digital I/O assembly for GPM500 systems.
It consists of the following functional units:
– One CAN bus controller
– 8 digital input channels (isolated)
– 4 digital output channels (relays 250V/8A)
– 3 x 4 light-emitting diodes (LEDs) on the front panel (8 x DI, 4 x DO)
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GPM 500 Description
GOV500 Identity No.: 271.195 022

GPM500 Governor Motor Control
The GOV500 is used for the governor motor control and as general I/O module in GPM500
systems. It consists of the following functional units:
– One CAN bus controller
– 2 digital input channels (isolated)
– 2 digital output channels (relays 250V/8A for the motor control)
– 2 analog outputs (+/-10 V or +/-20 mA)
– 4 light-emitting diodes (LEDs) on the front panel (2 x DI, 2 x DO)
TRV500 Identity No.: 271.195 028

GPM500 Buffer Amplifier for Low-voltage Systems
The purpose of the TRV500 is the isolated voltage acquisition in GPM500 systems for low-
voltage systems of up to 450 V.
The TRV500 is equipped with 3 measuring channels which, as standard, are configured as
voltage inputs. By using other components (shunt resistors) the TRV500 can also be used for
current measuring purposes.
or
GPM500 Buffer Amplifier for Medium-voltage Systems
For medium-voltage systems with voltage transformers with an output voltage of 100 V the
TRV501 module is used. Apart from the voltage adaptation this module corresponds to the
TRV500 module.
or/and
GPM500 Buffer Amplifier for Earth-fault Detection
The TRV502 module is available to detect displacement voltages and earth-fault currents in
medium-voltage systems. If it is installed without TRV501, the jumpering is to be adapted, see
section 3.4.4.4. The module is based on the hardware of the TRV500 module, too.
DCC500 Identity No.: 271.195 029

GPM500 DC/DC Converter
The DCC500 assembly is a DC/DC converter (24 V) for the connection of devices which are to
be operated on a floating basis with respect to the 24 V mains.
The DCC500 makes available of an isolated 24 V output voltage (relevant when connecting a
BAT500).
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GPM 500 Description
SLE500 Identity No.: 271.195 030

GPM500 Current and Power Acquisition
The SLE500 assembly is used for the current and power acquisition in GPM500 systems.
This assembly is made up of 2 boards namely SLE500 and SLE510 and is accommodated in a
Phoenix double housing (ME45).
The SLE500 module converts the analog signals of the analog bus (on the right) into serial data
on the internal CAN bus (on the left). The internal CAN bus is used for the purpose of commu-
nication between the individual assemblies via CAN and is managed by the ZKG500. The
analog bus serves to acquire analog values (currents and voltages) of assemblies TRV500 and
DIF500.
The SLE500 can be used for undervoltage tripping and open-circuit tripping. In the latter case
the jumpering is to be adapted, see section 3.4.4.4.
The SLE500 board comprises the following functional units:
– One processor (24 MHz, 512K FLASH, 14K RAM, 1K EEPROM)
– One test and download interface (RS-232 / BGND)
– One isolated CAN bus terminal (internal system bus)
– One isolated CAN bus terminal (external CAN bus)
– One watchdog relay
– 16 internal analog inputs (current and voltage measurement)
– 3 current transformers: 1A nominal current (assigned to 5 of the 16 analog inputs)
– 4 light-emitting diodes (LEDs) on the front panel (Sync, Reserve, Breaker.On,
Breaker.Tripped).
The following functional units are arranged on the SLE510 board:

– One autonomous overcurrent detection
– One overcurrent relay "Circuit-breaker off"
– One "Circuit-breaker on" relay with separate enable input
– 4 digital inputs (isolated).
The assembly performs the following tasks:

– Acquisition of all analog data (internal and via analog bus)
– Evaluation of all acquired data (current and power calculation)
– Monitoring of the currents and, if necessary, overcurrent shutdown
– Switching on and off of a circuit-breaker via relay
– Communication with the ZKG500 (data exchange)
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GPM 500 Description
DIF500 Identity No.: 271.195 032

GPM500 Differential-current Detection
The purpose of the DIF500 is the isolated (differential-) current detection in GPM500 systems.
The DIF500 is equipped with 6 current transformers 1A/20mA. By means of them 6 currents can
be measured and two three-phase systems can be compared to one another respectively.
By means of a GPM500 including differential protection a load monitor with the current meas-
urement of up to three big consumers can be realised (without differential protection: up to 6 big
consumers).
USS500 Identity No.: 271.195 040

GPM500 Undervoltage coil supply
The USS500 module ensures the voltage back-up for undervoltage coils of circuit-breakers in
case of short voltage dips (e.g. in the event of a short-circuit). The USS500 is designed for the
connection of two independent supply voltages (e.g. for the use with coupler circuit-breakers,
shore-connections etc.).
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GPM 500 Description
BAT500 Identity No.: 271.188 465

GPM500 Operating and indicating panel
The BAT500 is a touch screen panel with a serial data bus according to the CANopen standard.
The BAT500 offers the following information
and input possibilities to the operator:
– The overview page with the status indica-
tion of the respective circuit-breaker, DG
set and generator with the essential
measured values as well as the output of
commands such as start, stop, selection
of the automatic mode etc. including the
corresponding check-back signals (see
Fig. 2-3).
– The measurement pages show the meas-
ured values of the respective generator
such as currents, voltages and power. In
addition, special measured values such
as earth-fault currents, displacement volt-
ages and excitation currents are displayed
with the aid of additionally optional Fig. 1-5 Design of the BAT500
assemblies (see Fig. 2-4).
– The setup page enables the adjustment of the screen brightness, the selection of the
desired operator and display language (English, German, other languages on request) as
well as the call of the event list (see Fig. 2-7). Moreover, the password is entered here so
that parameters can be changed.
– On the parameter pages the parameters of the GPM500 are shown and can be changed
(protected by the password). Furthermore, the protection functions can be observed via the
parameter pages (from exceeding of the trip value up to trip).
– On the alarm page faults are displayed in an alarm list. They can be acknowledged there
as well as hardwired via contact (push button).
The operator can change between the individual displays by actuating buttons in the (common)
lower navigation bar where an alarm message is displayed, too.
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GPM 500 Description
1.4 Functions
1.4 Functions
The GPM500 makes available the following functions:
Protection Functions for:

– Diesel generators
– Shaft generators
– Emergency generators
– Bus tie breakers
– Transfer line circuit breakers
– Transformers
– Motors
– Shore connection
– Filters
– High-resistance earthing
Protection Functions in Detail are:

– Short-circuit
– Stator protection
– Overcurrent
– Phase current asymmetry
– Under- and overvoltage
– Phase failure
– Under- and overfrequency
– Reverse power
– Circuit-breaker failure
– Excitation monitoring
– Load shedding
– Differential protection (optional)
– Earth-fault protection (optional)
– Voltage displacement protection (optional)
Control and Power Management Functions:

– Blackout start
– Automatic start and synchronising
– Monitoring of start, stop, synchronising and c.b. status
– Start pass on / relay to next available DG-Set
– Frequency control
– Power control incl.
– Symmetrical load sharing
– Asymmetrical load sharing
– Unloading before shutdown
– "Topload" function
– Load monitoring functions (optional) with
– Load dependent diesel start
– Load dependent diesel stop
– Load dependent Start of big consumers
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GPM 500 Description
1.4 Functions
1.4.1 Protection Functions
The GPM500 offers a variety of protection functions for which the tripping value, the delay time
and the function / effect can be parameterised. The functions alarm, circuit-breaker tripping, de-
excitation, stop of the diesel-generator set (DG set), requirement of a local acknowledgement,
blocking until acknowledgement, start passing-on to the next DG set and a busbar blocking
against switching on can be adjusted via function codes ( see Table 2-15).
For almost all protection functions a pre-alarm can be parameterised in the same way.
The basic configuration of the GPM500 comprises the following basic protection functions:
1.4.1.1 Short-circuit Protection (ANSI 50)
Protection against short-circuits from line to line. The protection works as an independent over-
current-time protection with extremly short time-delay tripping after exceeding of the high trip-
ping value. For the short-circuit protection two levels can be parameterised.
1.4.1.2 Stator Protection (ANSI 50)
Protects the generator in the event of internal faults (by de-excitation).

It is an overcurrent-time protection with reduced operating value, and becomes active, if a
current is detected although the circuit-breaker is open. For this purpose, three current trans-
formers being installed at the star point of the generator are evaluated.
1.4.1.3 Independent Overcurrent Protection (Definite Time (DT), ANSI 51)
Protection against overcurrent with delayed trip. Corresponds to the short-circuit protection, in
principle, but with lower operating values and considerably larger delay times. Serves primarily
to protect an equipment.
With generators the shedding of load, i.e. switching off of unimportant consumers becomes
normally active prior to the operation of the overcurrent-time protection.
1.4.1.4 Dependent Overcurrent Protection (Inverse Time (IDMT), ANSI 51)
The dependent overcurrent-time protection trips after a period of time depending on the current
intensity (inverse characteristic/fuse characteristic).
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GPM 500 Description
1.4 Functions
1.4.1.5 Current Asymmetry (ANSI 46)
To protect electrical machines from a too high asymmetry of the phase currents.
1.4.1.6 Undervoltage (ANSI 27)
As net protection and less as equipment protection, too. In case of generators being operated
as stand-alone units this is important to disconnect an underexcited generator from the net and
to make it possible to connect a spare DG set.
1.4.1.7 Overvoltage (ANSI 59)
Serves to protect all generators and consumers, but is essentially used with equipment only
which can cause an overvoltage as e.g. generators and possibly capacitor groups and net
filters.
1.4.1.8 Phase Failure/Phase Sequence (ANSI 47)
Monitors the three phase voltages for

– Phase failure and voltage unbalance: The r.m.s. values of the three phase voltages may
differ from one another by max. 10%.
– Correct phase sequence: The three phase voltages form a positive clockwise rotating field.
In case of this fault during the connecting process of a generator the synchronisation is blocked
and starting is inhibited.
Further functions / effects can be parameterised via the function codes (see Table 2-15).
The limit value and the delay time are non-adjustable and cannot be changed by parameterisa-
tion.
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GPM 500 Description
1.4 Functions
1.4.1.9 Underfrequency (ANSI 81L)
This protection is almost exclusively used with generators in case of overload or faults of the
DG set.
NOTE
Switching off of the DG set should be the protection becoming
effective last after shedding load by switching off unimportant
consumers in case of underfrequency first.
1.4.1.10 Overfrequency (ANSI 81H)
This protection is to be used almost exclusively with generators in order to protect from overfre-
quency and overspeed (e.g. in case of disturbed speed controllers or dynamically also in case
of the disconnection of large loads).
1.4.1.11 Reverse Power (ANSI 32)
This protection protects power sources from an excessive active power being fed back. This
way e.g. diesel engines can be protected from an excessive reverse power.
1.4.1.12 Underload (ANSI 37)
Protects a DG set from falling below a certain minimum load for a longer period of time. Espe-
cially for DG sets to avoid any unfavourable operating conditions (sutting).
1.4.1.13 Underexcitation (ANSI 40)
To protect from the faulty excitation of a generator or from the lack of excitation, if the generator
does not output a sufficient lagging reactive power.
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GPM 500 Description
1.4 Functions
1.4.1.14 Load Shedding
In case of overload of a DG-Set due to overcurrent or underfrequency load shedding, i.e.

switching off unimportant consumers, is performed. The respective limit values and delay times
are parametrisable. Up to 5 levels, with one current and one frequency tripping value and one
assigned output contact each are available. In the basic configuration 2 levels are realised and
with additional DIO500 modules 5 adjustable levels can be realised at maximum.
1.4.1.15 Optional protection functions
Differential Protection (ANSI 87)

The differential protection function compares the currents at input and output (and internally
respectively, star point) of an equipment and, in case of inequality, it separates the equipment
from the net without delay.
For the purpose of current acquisition at least one additional set of current transformers is
required.
The differential protection is parameterised with the aid of several parameters characterising the
tripping characteristic and the detection of inrushes by acquisition of the second current
harmonic (harmonic restraint).
The reaction can be parametrised by means of the function codes (see Table 2-15).
Earth-fault Protection (ANSI 51N)

Earth faults in insulated and high-resistance grounded medium-voltage nets are acquired with
the aid of current transformers between the generator star points and the ship's ground and/or
core-balance transformers.
The earth-fault current is monitored according to the independent overcurrent-time protection.
Voltage Displacement (59 N)

The displacement voltage as the sum of the three phase-to-earth voltages is used to acquire
earth faults (equal to zero in the undisturbed operation). For this purpose, voltage transformers
in an open delta connection are evaluated.
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GPM 500 Description
1.4 Functions
1.4.2 Control Functions
In addition to the protection functions the GPM500 performs control functions which are impor-
tant especially in the AUTOMATIC mode.
1.4.2.1 Blackout Start (Mains monitor)
In case of a failure of the busbar voltage and closing of the blackout contact the GPM500 initi-
ates an automatic blackout start:
The DG set with the highest resulting priority is started in AUTOMATIC mode after the param-
eterised delay time. The resulting priority is calculated by each generator-GPM from the priority
number (0..7) (highest influence), the operating hours and a parameter to be manually set and
the device number (lowest influence).
When minimum voltage and minimum frequency have been reached, switching on is released
and the circuit-breaker is closed.
The DG sets for which the
– AUTOMATIC mode has been selected
– Readiness for start is available (DG set is ready for operation, GPM500 does not have any
non-acknowledged faults etc.
are available to the mains monitor.

A start passing-on in case of fault can be parameterised.
1.4.2.2 Start Attempts
After a start command is given the start up sequence is activated and the prime mover runs up.
If the DG-set does not reach the pre-set speed limits, detected from the engine safety system,
the start sequence will be interrupted by stopping the diesel engine. After a pre-set delay time
another attempts are carried out one after another up to the specified number of start attempts
resp. successful start. After not successful attempts a
– Start failure is indicated
– Start signal is passed on to the next available DG-Set (ready, automatic and priority)
– Stop signal is activated at the faulty Diesel engine to be sure that the diesel stops
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GPM 500 Description
1.4 Functions
1.4.2.3 Start Failure (ANSI 66)
If, after a start command, there is no switch-on release within the parameterised time due to an
insufficient voltage or frequency, the starting process is aborted and a start fault alarm is output.
Further GPM reactions such as an appropriate start passing-on can be parameterised.
1.4.2.4 Start Passing on/ relay
Due to critical diesel failures which cause no instant switch off a passing of the start-command
to the next DG set can be parametrized by means of the function codes. The affected DG set
will be stopped after the started DG set is connected.
1.4.2.5 Automatic Start and Synchronising
In AUTOMATIC mode an automatic start can be initiated in case of a failure from another DG-
Set, by
– activating the Start button,
– order from the IMCS or
– in case of a load request.
An automatic start includes the running up of the DG-Set, the synchronising, connecting the
generator breaker and carrying out load sharing.
In case of no blackout the automatic synchronising process is initiated for the DG set having
been started according to priority befor switching on. Actuating signals are transferred to the
corresponding speed controller until net voltage and generator voltage are synchronous.
First the main criterion, reaching of minimum voltage and minimum frequency of the generator
voltage is checked (switch-on release).
Afterwards, the following criteria are checked
– Differential voltage (RMS values)
– Frequency difference
– Phase angle
– RMS value of the beat voltage
the latter being a redundant but independently computed criterion. It furthermore takes into
account the deviations of the waveform.
If all above-mentioned criteria are fulfilled, the generator circuit-breaker is automatically
switched on.
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GPM 500 Description
1.4 Functions
1.4.2.6 Synchronising Failure
If switching on does not take place within the adjusted time following a start command and the
synchronisation release, then the synchronising process is aborted and the synchronising failure
is initiated. Further GPM reactions can be parameterised (see Table 2-15).
1.4.2.7 Circuit-breaker Failure
This monitoring unit compares the current actual status of the circuit-breaker with the desired
status preset by the GPM. If they differ from one another over a fixed short period of time, then
the circuit-breaker failure alarm is output.
The following pairs of check-back signals are similarly checked for plausibility (non-equivalence)
by means of this protection function in case of the corresponding parameterisation.
– Circuit-breaker is open / closed
– Circuit-breaker is in the disconnected resp. test position/ operating position
– Trip coil has been controlled / has an open circuit
– Earthing disconnector is open / closed
A circuit-breaker failure is initiated, if for one pair either none or both check-back signals are set
within a specified period of time (e.g. 120sec for disconnected / operating position).
Moreover, the failure is initiated, if the circuit-breaker signals not wound up / ready in the ON
condition.
1.4.2.8 Stop Failure
If switching off does not occur within the adjusted time after a stop command or if, with an open
circuit-breaker, the voltage value exceeds 10%, then a "stop failure" alarm is given. The GPM
reactions are adapted to the application by parameterisation (function codes see Table 2-15).
1.4.2.9 Frequency Control
The frequency is controlled to the nominal frequency under all operating conditions. Like the
other nominal data the value of the nominal frequency is entered as parameter at the BAT500.
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GPM 500 Description
1.4 Functions
1.4.3 Power Management Functions
In its basic configuration the GPM500 offers some important power management functions
which are described in the further course.
But first some fundamental terms, definitions and structures are explained.
1.4.3.1 Fundamental Terms
Net:
The power management functions always exclusively refer to the limited range of a net or
subnet. A net is a section being limited by opened switching devices. Each net has an unequiv-
ocal net number.
Subnet:
A subnet is a net section being limited by opened switching devices.
Busbar:
This term refers to a section between switching devices. In this sense a transformer with primary
and secondary circuit-breaker is a "busbar", too.
Net Number:
The net number is dynamically determined depending on the positions of the generator circuit-
breakers, coupler circuit-breakers and transfer line circuit-breakers. It is permanently shown on
page 2 of the BAT500 for checking purposes. To each net / subnet an unequivocal net number
is assigned in the power management system (PMS).
The net number is determined according to the following rules:
– The net number is the lowest device number each of the generators which can be
connected to the net. Each device has got a net number.
– The net number of the devices of a busbar is influenced by devices being switched on only.
– The number is transmitted to the neighbouring busbar by (closed) coupler circuit-breakers
and transfer line circuit-breakers only.
– Open tie-breakers and transfer line circuit-breakers have got the net number of the side with
the three-phase voltage acquisition.
– Closed ring nets are, as standard, excluded but can be realised upon request, if need be.
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GPM 500 Description
1.4 Functions
The following figure shows the formation of the net numbers in a system with three busbars.
Fig. 1-6 Figure: Connection of Generator, Busbar and Net Numbers
1.4.3.2 Power Control
The load sharing takes place between all generators of one net number. Balancing is realised
by the GPM500 communication via the redundant CAN bus (GPM bus).
The power control offers the following functions:
– Symmetrical load sharing for diesel generators
– Asymmetrical load sharing for shaft generators and turbine-driven generators
(with minimum power for diesel generators)
– Unloading of the generator prior to shutdown
In the event of an asymmetrical load sharing the following protective restrictions are ensured by
the GPM500:
– No underload or reverse power of the other DG sets
– No inadmissible frequency increase in stand-alone operation (e.g. in case of maloperations)
Power can be individually preset for each GPM500. The load sharing is controlled by the
GPM500 accordingly.
The presetting can be changed on the BAT500. The presetting can also be made via Modbus
from an external system (e.g. automation system, IAMCS).
For power distribution purposes the GPM500 transfers actuating signals via the GOV500
module to the speed controller of the DG set.
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GPM 500 Description
1.4 Functions
1.4.3.3 Topload Function
By means of the topload function the DG set can, upon request, be loaded with 80% of its
nominal power, provided that this is possible without the inadmissible unloading of other DG
sets.
This operating mode can be activated by means of button "Topload" on the start page of the
BAT.
1.4.3.4 Load Monitor Functions (optional)
The following load monitoring functions are available:

- Load dependent Start of a DG-Set
- Load dependent Stop of a DG-Set
- Load dependent Start of big consumers (optional)
The load monitoring functions are not performed by one individual device only. They are distrib-
uted among all GPM500 systems being interconnected via the redundant GPM-bus. The basic
functionality is provided in each GPM500.
Operating Modes
The system knows three operating modes which, if necessary, are to be selected simultane-
ously:
- "No DG start": the load monitor does not start additional DG sets
(remark: a blackout start nevertheless takes place, if necessary!)
- "No DG stop": the load monitor does not stop additional DG sets
- "Manoeuvre mode": additional reserve power is made available
(one additional DG set)
Selection of the Operating Modes

These operating modes can, in principle, be selected via each GPM500:
The operating mode is applicable to the respective subnet only.
The operating mode can be selected via
1. Digital inputs and outputs or
2. Modbus connection e.g. to an automation system or to a superior PMS system
The operating mode need not to be selected on every device because the individual inputs are
processed in parallel via the GPM bus (OR logic).
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GPM 500 Description
1.4 Functions
1.4.3.4.1 Load-dependent Diesel Start
A DG-Set will be started if the limit value of one of the two parameterisable minimum reserve
power limits has been exceeded for the pre-set time delay. The rated power output of the
starting DG-Set is taken into account.
Taking the calculated start order and the individual possible DG-Set power into account, the
DG-Set with the smallest nominal power output, which covers the minimum power reserve, will
be started.
The DG-Set to be started next is the one with the highest resulting priority, i. e. the smallest
number. Each Generator-GPM calculated its individual resulting priority from the adjustable
priority number (0...7, highest influence), the operating hours and the device number (lowest
influence). Generally the start order is from the smallest (highest priority) to the biggest (lowest
priority) number. The Stopping order sequence is vice versa.
After diesel start the GPM500 starts synchronising and connecting the breaker. After that load
sharing is carried out.
1.4.3.4.2 Load-dependent Diesel Stop
If several of DG-Sets are feeding to the common bus-bar and the total power consumption is
decreasing, the total power reserve is increasing. If the power reserve is too large one of the
supplying DG-Set will be stopped automatically. After stopping the DG-Set the power reserve
must be larger or equal the specified power reserve minimum power reserve after stop, see
Fig 2-35. Under special conditions it may also happen that a number of DG-Sets are stopping
shortly one after the other to reach specified minimum power reserve.
The stop sequence is as follows:
– unloading the generator to a very small amount of current
– disconnecting the generator breaker
– running in idle speed for a pre-set time (cooling down)
– stopping the diesel engine
– the DG-Set is ready for start again.
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GPM 500 Description
1.4 Functions
1.4.3.4.3 Load dependent Start of big consumers
This function protects the feeding DG-Sets against overload. By means of this function it is
guaranteed that in case a big consumer is selected sufficient power is provided, i.e. a minimum
of one DG-Set starts automatically, if the momentary power reserve is too small. The start of
the selected big consumer takes place when a sufficient power reserve is available.
Consumers are switched on according to the following steps:
1. The GPM500 to which the requested switch-on of a big consumer is available, communi-
cates the required power to the GPM bus. Switching on is delayed so as to be able to take
into account the reactions by the other devices.
2. The total power demand for the subnet is computed by all GPM500 systems from the power
demands.
3. In the same way the actual reserve power is computed.
4. The GPM500 systems of the generators check whether a start condition is fulfilled for them
after evaluation of power demand and reserve power. If this is the case, switching on of
consumers is blocked.
5. It is checked whether the respective start condition remains fulfilled when taking into
account the nominal power / maximum power of generators being already started. If yes,
further DG sets are started according to their priority. The switching on of consumers
remains blocked.
6. From the DG sets with fulfilled start conditions the set with the lowest number and highest
priority is started. (A DG set being shut down is preferred!)
7. If the respective reserve power is sufficient, the blockage is reset and the switching on of
consumers is released.
Current Acquisition of Big Consumers

In principle there are two different types of big consumers: consumers taking the rated load
directly when switching ON and consumers which needs their rated load only sequentially, like
bow thrusters.
For the second type of consumers it is necessary that the respective GPM500 gets the actual
power consumption input via assigned current transformers. Only via this function it is possible
to avoid stopping of a DG-Set in case the power reserve is too high. In general all consumers
with variable power consumption are equipped with current transformers to signal the actual
apparent power to the GPM. So the DG-Set will not stop in case of minimum apparent power
consumption.
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GPM 500 Description
1.4 Functions
1.4.3.5 Net Synchronisation
The GPM500 is able to synchronise nets with one another. For this purpose the tie-breakers
GPM500 are equipped with synchronising and active-power load controllers according to the
devices of the generators. For this purpose, the actuating signals are, however, not output at
the own device but they are given as setpoint frequency to the two nets involved. All devices
involved generate corresponding actuating signals for the speed controllers of the DG sets. The
speed controllers of the DG sets involved should react similarly and the adjusting speed should
be adjusted accordingly.
Within the range of one subnet there is possible only one net synchronisation or net separation
at the same time.
1.4.3.6 Net Separation
In case of an intended net separation first of all the net numbers are recalculated such that the
subnets to the right and to the left of the circuit-breaker are provided with different net numbers.
This way the generators can be supplied with different actuating commands. Within the range
of one subnet there is possible only one net synchronisation or net separation at the same time.
1.4.3.7 Connection to a Control System
A superior control system as e.g. a PMS or an automation system can intervene in the load
monitor in different ways:
1. Alteration of the start priority
2. Selection of operating mode "No DG stop"
3. Selection of operating mode "No DG start"
4. Selection of operating mode "Manoeuvre mode"
5. Selection of "Topload"
6. Requesting an additional power reserve
The operating mode selection from the control system is always combined with the hardware
contacts. If "No DG STOP" has been selected via digital input, this cannot be cancelled via tele-
gram.
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GPM 500 Description
1.5 Technical Data; Interfaces
1.5.1 Environmental Conditions
Ambient temperature 5 °C to +55 °C

Rel. air humidity 5 % to 95 %
Do not expose the BAT500 to permanent sunlight; this might accelerate the ageing of the film.
Avoid any contact of the device with corrosive substances.
1.5.2 Mechanical Data of the GPM500 Modules
Top-hat rail modules with 16 and 32 terminals respectively (in the form of coded 4-pole plug-in
blocks) and a 12-pole plug-in connection to neighbouring modules. The 12-pole plug-in connec-
tion comprises the internal CAN bus, the external CAN bus for the connection of the BAT500
and contacts for the control voltages.
Casing 45
Assemblies for mounting on top-hat rails. Dimensions (W x H x D):
45 x 100 x 115 mm (combined power supply module NEG501+510 and NEG502, SLE500,
DIF500, USS500 respectively)
Casing 225
Assemblies for mounting on top-hat rails. Dimensions (W x H x D):
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GPM 500 Description
22,5 x 100 x 115 mm (ZKG500, DIO500, DCC500, GOV500, TRV500/501/502)
1.5.3 BAT500 for Door Mounting
BAT500
Monochrome LCD monitor
Guaranteed minimum service life 50 000 h
Weight ~ 1,4 kg
Monitor L x H 187 x 147 mm
Graphic display 121 x 91 mm (5.6” diagonal)
Resolution 320 x 240 pixels
Data transfer rate 9600 - 38400 bits
Interface RS-485
Memory 32 KB
Mains voltage 18 - 30 V DC
Max. power consumption ~ 600 mA with 24 V DC
Operating temperature 0 to 55 °C
Protection degree IP65 (front panel)
1.5.4 Electrical Connections
The terminal assignment of the GPM modules is described in annex A.
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GPM 500 Description
1.5.5 Data Bus Connections
1.5.5.1 GPM Bus
For the purpose of communication with other GPM500 systems there are available two CAN
busses (CAN1 and CAN2) being redundant with respect to one another.
CAN1: ZKG500:2, 3, 4 (CAN1- G, L, H)

CAN2: ZKG500:6, 7, 8 (CAN2- G, L, H)
With the last ZKG500 of a bus section the CAN busses are terminated by setting one jumper
each.
NOTE
The CAN busses are looped through from station to station each.
Spur lines are avoided, i.e. the bus connection is made such that
the cores of the incoming bus section and the cores of the
outgoing bus section are connected in parallel at the terminals of
the ZKG500 module and not at a terminal strip to which a spur line
to the GPM500 is connected.
1.5.5.2 CANopen Interface
CAN bus interface CAN4 being operated with a CANopen protocol is used to connect the
BAT500 (or further optional components).
CAN4: Combined power supply module, NEG501:13, 14, 15 (CAN4- H, L, GND)
1.5.5.3 Modbus
For the communication with external systems (e.g. automation system or superior PMS system)
there is available a Modbus interface. The Modbus is based on an RS-485 interface with two
transmission and receiving lines plug GND connection.
Modbus:ZKG500:13, 14, 15 (-S/E, +S/E, RGND)
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GPM 500 Description
1.5.5.4 Optional Redundant Modbus Connection
With the aid of two additional ZKG500 modules a redundant Modbus connection of an individual
GPM500 or of an interconnected system of GPM500 devices to an external system can be real-
ised. The interconnected system can consist of a maximum of 60 GPM500 devices being all
interconnected via the GPM bus.
These two ZKG500 modules which are equipped with the software for the redundant Modbus
connection are working as "gateway computers" each between the redundant GPM bus system
with the connected "target GPM" and the Modbus to a superior external system ("host").
The gateway computer listens on the redundant GPM bus, i.e. CAN1 bus and CAN2 bus
respectively, and stores the data of up to 60 GPM500 devices. The host computer has access
to these data via the RS485 Modbus interface. A command from the host computer is trans-
mitted to the gateway computer. There it is converted into a CAN telegram and passed on to
the target GPM500 to be addressed.
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GPM 500 Operation
2.1 Safety notes
2 Operation
2.1 Safety notes
Safety and Warning Notes Concerning Installation and Commissioning

Please read the complete instructions so as to ensure a safe operation of the unit and to be
able to use all functions!
Installation and commissioning must be performed by the correspondingly qualified personnel
only. In doing so, the relevant national regulations (e.g. VDE, DIN) are to be observed.
In particular, prior to commissioning it is to be ensured that:
– All connections have been professionally established!
– The protection against electric shock is guaranteed!
– The unit can be switched under off-circuit conditions in accordance with the provisions of
EN 60950 (e.g. by the primary line protection)!
– All supply leads are sufficiently fused and dimensioned!
– All output leads are dimensioned according to the max. output current of the unit or sepa-
rately fused!
– A sufficient ventilation is ensured!
The GPM500 is a built-in unit. After the installation the terminal area must be covered so as to
ensure a sufficient protection against the inadmissible touching of live parts!
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GPM 500 Operation
2.2 Operating and displaying elements of
2.2 Operating and displaying elements of the BAT500
Fig. 2-1 Operating and displaying elements BAT500
red OFF No hardware problem detected

BLINK Battery low
ON Hardware fault
green OFF No touch cell active
ON While any touch cell is active (visual feedback)
red OFF No alarms
BLINK Alarm requires acknowledgment
ON Alarm active
Green BLINK Communication error
ON Communication OK
green May be user controlled as LED number 65 using the Macro Editor.
Turns ON when recipe/event backup is being performed.
green OFF Hardware fault
ON Unit in operation
Table 2-1 Operating and displaying elements BAT500
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GPM 500 Operation
2.2.1 Menu structure on the BAT500
The main pages are arranged on one level and can be called up via the buttons in the naviga-
tion bar. Buttons in the page above the navigation bar open submenu pages to:
– start/stop diesel generators (overview page),
– displaying measuring displays (Measured Values pages),
– selecting devices (Identity page),
– numerical input of password (Setup page) and
– numerical input of data (Parameter pages).
The operation device BAT500 displays several types of pages:
Type of page Description
Overview page status indications, operating elements, measuring values etc.
Alarm page presentations of alarms
Setup page brightness, password etc.
Menu page leaps to parameter groups
Parameter pages (accessible with password) device number, bar allocation, definition of device
type, connection release, protection parameters, function codes etc.
Measurement
pages voltages, currents
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GPM 500 Operation
Fig. 2-2 Structure of menues
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GPM 500 Operation
2.3 Display pages on the BAT500
2.3.1 General
In this section, the recurring fields and buttons are described in general. Each display contains
a life sign for the communication with the CPU via CAN bus (rotating slash). The buttons in the
navigation bar at the bottom recur in all pages. Exceptions are described separately.
In general the pages contain three different types of elements:
I Indication
O Operating element
T Text (static)
In the follwing all operating elements which can be touched to modify related data are high-
lighted by different colours.
Subsequently, the monitor pages are described in the same sequence as stated in the menu
structure.
2.3.2 Overview page
Fig. 2-3 Overview page for operating the assigned unit (e.g. generator)
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GPM 500 Operation
No. Description Possible conditions / Remarks Type
1 Indication of operation mode Changes automatically when another operation I

mode is selected.
Is flashing during start sequence. A page with a
Operation element for initiating the start
2 START element opens. It has to be pressed for O
sequence of unit
activating the start.
Operation element for initiating the stop Is flashing during start sequence. A page with a
3 START element opens. It has to be pressed for O
sequence of the unit
activating the start.
4 Actual electrical data of the bus bar T+I
Symbol ”Ready for operation” (wounded This symbol changes if the breaker is not
5 I
up) of the breaker wounded up.
Operation condition of the breaker This symbol signalizes the breaker status (on, off,
6 I
(connected). disconnected, undefined etc., see fig. 2-4).
Symbol of the assigned unit (here
7 I
generator)
8 Active CAN-Bus to the BAT If the CAN-Bus is active the bar rotates. I
Can used for all components (Generators, Trans-
9 Actual operation data of the unit formers, Breaker, Consumers, etc.) I
Bus bar will be shown white the bus bar is not

10 Indication if the bus bar is alive. I
alive
Table 2-2 Overview page for operating the assigned unit
NO CONNECTION X
FIXED CONNECTION X -
POSITION FAILURE DISC./EARTH. X X X X - -
EARTHED X X X X - -
DISCONNECTED X X X X - -
OFF
ON
UNDEFINED
TRIPPED
Fig. 2-4 Overview c.b. status indications
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GPM 500 Operation
2.3.3 Measurement page
Fig. 2-5 Page for measured values
No. Description Possible Conditions / Remarks Type

1 Active CAN-Bus to Display Rotates if the CAN-Bus is alive I
2 Indication element of the generator oper- Data are varying during operation I,T
ation data
Operation element selecting the extended
3 measurement list 1 Display of measured voltages O
4 Operation
element selecting the extended
Display of measured currents O
measurement list 2
Table 2-3 Display for measured values
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GPM 500 Operation
2.3.4 Alarm page
Fig. 2-6 Alarm page

1 Active CAN-Bus to Display Rotates if the CAN-Bus is alive I
Active Alarms are flashing. After pressing the
operation element ”ACK” the flashing indication
2 Acknowledge O
change over to constant indication. Gone Alarm
will distinguish.
Pressing this operation element you leave this
3 BACK display and jumps back to the last opened O
Display.
The number at the end of the Alarm is the ANSI-
4 Indication of active Alarms O
code (see section 3.3)
Table 2-4 Alarm page
The messages of all possible alarms are shown in section 3.3.
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GPM 500 Operation
2.3.5 Setup page
Fig. 2-7 Setup

Check sum and active CAN-Bus to
1 Display Rotates if the CAN-Bus is alive I
2 Operation element Clear To clear the Event list O
3 Operation element Logout To leave the Adjustment level O
Activating this element the number block, see Fig.
4 Operation element Password 4.1 will be opened and the password has to be O
inserted.
5 Operation element Event list The Event List will be opened. O
Operation elements selecting the
6 German or English O
Language
Operation element to adjust the Back-
7 Adjusting the Display brightness O
ground illumination
Table 2-5 Setup
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GPM 500 Operation
2.3.6 Number block
Fig. 2-8 Number block

1 Indication element Gives the information of the momentary task I
2 Indication element, Data field Here the selected numbers are indicated I
3 Numerical operation elements Direct selection of numbers O
4 Operation element ENTER Confirms the numerical inputs O
5 Operation element, right Scrolls the courser position in the data field to the O
right
6 Operation element, downwards Decrements the numerical inputs O
7 Operation element, upwards Increments the numerical inputs O
Scrolls the courser position in the data field to the
8 Operation element, left O
left
Clears the display and jumps back to the former
9 Operation element CLEAR O
display
Table 2-6 Number block
To 1: The contents of this information element divers with respect momemtary active display
menu.
Possible informations:
- Password
- Min., Max.
- Name of Device
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GPM 500 Operation
2.3.7 Menu Page Parameter
Fig. 2-9 Menu Page Parameter
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GPM 500 Operation
No. Description Possible Conditions / Remarks Typ

e
1 Rotates if the CAN-Bus is alive I
Display
Electrical values of the generator or trans-
2 Nominal Values former respectively, see Fig. 2-11 O
Protection functions, 6 submenus, see Fig. 2-

3 Current O
13
4 Frequency Protection functions, 2 submenus O
5 Load Shedding Protection functions, 1 submenu, see Fig. 2-14 O
6 Internal Faults 2 fault lists, see Fig. 2-16 O
Operation element to return to Gener- Display for operation the Diesel-Generator,
7 O
ator Mimic diagram see Fig. 2-3.
8 Earthfault Protection functions, 2 submenus. O
Protection functions, 2 submenus,
9 Synchronising see Fig. 2-15 O
10 Power Protection functions, 3 submenus. O

11 Voltage Protection functions, 2 submenus. O
12 Power Control Nominal values for the speed governor, see O

Fig. 2-12
13 Generator No. Identification Values for the Unit, see Fig. 2-10 O
Table 2-7 Menu Page Parameter
If the Power Management Function Load Monitor is implemented two additional pages are
provided (see Fig 2-35 and Fig. 2-36).
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GPM 500 Operation
2.3.8 Identity page
Fig. 2-10 Identity page

1 Check sum and active CAN-Bus to Rotates if the CAN-Bus is alive I
Display
At this elements the respective numbers/values
2 Identification Values can be set after activating, pressing the individual O
element
Table 2-8 Identity page
In this page, the user can change the displayed device (after password input). This occurs via
tapping on "Dieselgenerator No." and a new selection of the device via a selection page.
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GPM 500 Operation
2.3.9 Nominal Values page
Fig. 2-11 Nominal Values page

Display
2 Nominal Values can be set after activating, pressing the indi- O
vidual element
Table 2-9 Nominal Values page
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GPM 500 Operation
2.3.10 Power Control page
Fig. 2-12 Power Control page

Power Controller parameters and stop At this elements the respective numbers/values
2 can be set after activating, pressing the indi- O
delay (after-run time) vidual element
Table 2-10 Power Control page
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GPM 500 Operation
2.3.11 Example for protection parameter page
This is an example form all parameter pages or protection parameters. Other parameters pages
are build up very similiar.
Fig. 2-13 Protection parameter page Instantaneous Overcurrent

Display
2 Configuration of function code see section 2.5.3.4 O
3 Trip Values can be set after activating, pressing the indi-
vidual element
4 Indication Value of the actual current I
5 Function codes See list below I, O
At this elements the respective numbers / values
6 Trip values O
can be set, see Fig. 4
Table 2-11 Protection parameter page Instantaneous Overcurrent
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GPM 500 Operation
2.3.12 Preferential Trip page
Fig. 2-14 Preferential Trip page

Display
2 Indication Value of the actual current I
The consumers are assigned by wiring of the
3 Unimportant Consumers, tripping values different DIO modules. The values are change- I, O
able after log in
Table 2-12 Preferential Trip page
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GPM 500 Operation
2.3.13 Synchronism check page
Fig. 2-15 Synchronism check page

2 Configuration
of function code with Hex- Opens the number block to activate protection
O
code function
At this elements the function codes for Engine
3 Indication of function codes Failures can be selected after activating function I
code menu
4 Release values can be set after activating, pressing the indi- O
vidual element
Table 2-13 Synchronism check page
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GPM 500 Operation
2.3.14 Internal failures page
Fig. 2-16 Internal failures page

Display
2 Configuration of function code with Hex-
Opens the number block to activate protection
O
code function
Indication of internal hardware and The respective function codes, OP, Protection
3 respective function codes Function is activated I
Table 2-14 Internal failures page
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GPM 500 Operation
2.4 Switching on GPM500
2.4 Switching on GPM500
Prior to initial operation, the technical safety and operational safety regulations are to be
observed, see section 2.1.
Switch on power supply for GPM500 on the switchboard panel.

A switch on test is running when booting up the GPM500, the program software of the ZKG500
module is started. The BAT500 initialises and its Comm-driver is loaded.
The Overview page (Fig. 2-17) appears.
At the ZKG500 Module the LEDs PWR and RUN iluminate.
At the BAT500 the green LEDs "Unit in operation" and "Communication OK" iluminate.
LEDs on the modules:
ZKG500
REL. Release Switch on release
PWR. Power Power supply of CPU (5V) is o.k.
RUN Running Programm ist running
ERR Error Summary failure
DIO500
01 - 04 Digital Output 1 - 4 Iluminated if set
I1 - I4 Digital Input 1 - 4 Iluminated if set
I5 - I8 Digital Input 5- 8 Iluminated if set
GOV500
DI 1 Digital Input Iluminated if set
DI 2 Digital Input Iluminated if set
DO 1 Digital Output Iluminated if set
DO 2 Digital Output Iluminated if set
SLE500
SYNCHRONIZING Synchronizing Synchronisation in progress
WATCHDOG Watchdog Iliminated if alive and O.K.
C.B. ON Circuit breaker on Output command to c.b.
BREAKER-TRIPPED Circuit breaker tripped Failure
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GPM 500 Operation
2.5 Operation sequences
In the following the operation sequences are described for a DG set. For other applications the
sequences are corresponding.
2.5.1 Starting and Stopping of a Diesel-Generator-Set in manual mode
2.5.1.1 General
The ready for start conditions have to be fulfilled:

– The diesel engine has to be ready for START and no fault has to be active. Indication
READY FOR START is shown at the BAT500.
– No fault has to be active.
– The operating mode selector switch at the switchboard has to be set to the Position
MANUAL / AUTOMATIC respectively. See the indication at the BAT (upper left corner at
the display).
– The bar (Fig. 2-17/8) rotates and signals that the CAN-bus between the GPM500 and the
BAT500 is alive.
2.5.1.2 Starting a DG-Set in manual mode via the BAT500
The BAT 500 shows the mimic diagram for operating the DG-Set, see Fig. 2-17. In the upper
left corner the information element (1) shows MANUAL / LOCAL. It is only possible to start the
diesel engine (prime mover) via the BAT:
Precondition:
There is no blackout at the switchboard. The
diagram Operating the DG-Set (Fig. 2-17) is
shown. The DG-Set and generator breaker
are ready to start (5, 6, 2).
- The ready for start conditions have to be
fulfilled, see 2.5.1.1.
- Touch the operating element START (2),
- The confirmation page opens (Fig. 2-18)
- Touch the operating element START (2-
18/3) to confirm the start request.
Fig. 2-17 Overview
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GPM 500 Operation
- The mimic diagram of the DG-Set (Fig. 2-

17) opens again. The operating element
START is flashing during run-up. The DG-
set is starting.
- The display shows the actual operating
data, voltage, frequency.
- The generator-breaker (2-17/6) remains in
open position.
The start sequence is terminated. Synchro-
nising and closing of the generator-breaker
have to be carried out manually from the
assigned switchboard panel.
Fig. 2-18 Confirmation page
2.5.1.3 Starting a DG-Set in manual mode from the Switchboard panel
Precondition:
There is no blackout at the switchboard. The ready for start conditions have to be fulfilled, see
2.5.1.1. To start the diesel engine:
- Press the respective push button START at the switchboard.
- The diesel engine runs up to idle speed.
- The generator does not synchronise, the generator breaker does not close.
- Synchronisation and closing the breaker as well as load sharing has to be carried out
manually from the switchboard.
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GPM 500 Operation
2.5.1.4 Stopping a DG-Set in manual mode via the BAT500
Precondition:
The diagram Operating the DG-Set (Fig. 2-19)
is shown. The DG-Set is running and the
generator breaker is closed (6, 2). The BAT
500 shows in the upper left corner the infor-
mation element (1) MANUAL / LOCAL. It is
only possible to stop the diesel engine (prime
mover) via the BAT as follows:
- The generator should be manually
unloaded and the generator breaker
should be opened before.
CAUTION
In case these conditions are
not fulfilled the generator-
breaker opens immediately.
Fig. 2-19 Overview
- Touch the operating element STOP (3),

- The confirmation page opens.
- Touch the operating element STOP to confirm the stop request.
- The mimic diagram of the DG-Set (Fig. 2-19) opens again. The operating element STOP
(3) is flashing during the stop sequence. The stop command is given to the DG-set imme-
diatly.
- The display shows the actual operating data, voltage, frequency.
2.5.1.5 Stopping a DG-Set in manual mode from the switchboard
Precondition:
No fault is active. The analogue instruments are showing actual operating values. To stop the
diesel engine:
- Unload the generator manually with the respective operating devices at the switchboard.
- Open the generator breaker manually from the switchboard
- Press the respective push button STOP at the switchboard. The stop command is given to
the DG-Set immediatly.
- In case of emergency:
- If available press the EMERGENCY STOP pushbutton, or
- press the respective push button STOP at the switchboard without unloading and
disconnecting the breaker.
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GPM 500 Operation
2.5.2 Starting of a Diesel-Generator-Set in automatic mode
2.5.2.1 General
The ready for start conditions have to be fulfilled:

- The diesel engine has to be ready for START and no fault has to be active. Indication
READY FOR START is shown at the BAT500.
- No fault has to be active.
- The operating mode selector switch at the switchboard has to be set to the Position
MANUAL / AUTOMATIC respectively. See the indication at the BAT (upper left corner at
the display).
- The bar (Fig. 2-20/8) rotates and signals that the CAN-bus between the GPM500 and the
BAT500 is alive.
2.5.2.2 Starting a DG-Set in automatic mode via the BAT500
Precondition:
There is no blackout at the switchboard.
Diagram Operating the DG-Set (Fig. 2-20) is
shown. The DG-Set and generator breaker
are ready to start (5,6,2). The BAT 500 shows
in the upper left corner the information
element (1) AUTOMATIC / LOCAL. The DG-
Set will be started via the BAT as follows:
- Touch the operating element START (2),
- The confirmation page opens (Fig. 2-21)
- Touch the operating element START (Fig.
2-21/3) to confirm the start request.
- The mimic diagram of the DG-Set (Fig. 2-
20) opens again. The operating element
START is flashing during run-up. The DG-
set is starting
Fig. 2-20 Overview
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GPM 500 Operation
- The display shows the actual operating

data, voltage, frequency.
- The indication (Fig. 2-20/5) signals that
the breaker is wounded up.
- The DG-Set is now in the synchronising
sequence.
- The generator-breaker (Fig. 2-20/6)
connects automatically, the symbol
changes into connected position.
The start sequence is terminated. The system
carries out load sharing.
Fig. 2-21 Confirmation page
2.5.2.3 Starting a DG-Set in automatic mode from the switchboard
Precondition:
The be ready for start conditions have to be fulfilled.
To start the DG-Set:
- Press the respective push button START at the switchboard.
- The diesel engine runs up to idle speed.
- Watch the analogue instruments, Voltage and frequency at the switchboard panel.
- The generator synchronises and the generator breaker connects automatically after a
successful synchronisation.
- Load sharing is carried out automatically.
The start sequence is terminated. The system carries out load sharing.
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GPM 500 Operation
2.5.2.4 Stopping a DG-Set in automatic mode via the BAT 500.
Precondition:
Diagram Operating the DG-Set (Fig. 2-20) is shown. The DG-Set is running and the generator
breaker is closed (Fig. 2-20/6,2). The BAT 500 shows in the upper left corner the information
element (Fig. 2-20/1) AUTOMATIC / LOCAL. It is only possible to stop the diesel engine (prime
mover) via the BAT as follows:
- Touch the operating element STOP (Fig. 2-20/3),
- The confirmation page opens.
- Touch the operating element STOP to confirm the stop request.
- The mimic diagram of the DG-Set (Fig. 2-20/1) opens again. The operating element STOP
(Fig. 2-20/3) is flashing during the stop sequence. The DG-Set is automatically unloaded
and the generator breaker opens. The diesel engine runs in a cooling down sequence.
- The diesel engine stops.
A restart is possible every time
The stop sequence is terminated. The DG-Set is ready for the next start.
2.5.2.5 Stopping a DG-Set in automatic mode from the switchboard.
Precondition:
The DG-Set is running and the generator breaker is closed. No fault is active. The analogue
instruments are showing actual operating values. To stop the diesel engine:
- Press the respective push button STOP at the switchboard.
- The DG-Set starts degreasing its load down to a minimum.
- The breaker opens automatically.
- The diesel engine runs in a cooling down sequence.
- The diesel engine stops.
A restart is possible every time
The stop sequence is terminated. The DG-Set is ready for the next start.
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GPM 500 Operation
2.5.3 Parameterisation
2.5.3.1 How to input the password.
All values, nominal values , parameter or func-

tion codes are password protected. To change
one of these values the password has to be
input before.
Precondition:
The display shows the mimic diagram Oper-
ating the DG-Set (Fig. 2-22):
- Multiple touching (3x) the right arrow
element to open the page setup (Fig. 2-
23).
- Touch the operating element Password.
Fig. 2-22 Overview
- The page Number Block (Fig. 2-24) will
be opened.
- Insert the password using the number
block (3), or use operating elements (7,8).
- Using the number block: the pass-
word is input directly. The password
is not directly shown in the left upper
element (2). After entering the pass-
word the operating element ENTER
has to be pressed and the page
setup (Fig. 2-23) opens again.
- Using the operating elements (Fig. 2-
Fig. 2-23 setup
24/7,8). With the operating element
(8) the first digit of the password will
be selected and input. To input the
second digit first the operating
element (8) has to be pressed again,
than the element (7) has to be
touched as often as the value of the
digit is. The third and all the other
digits have to be input in the same
way as explained before, first the
position of the number with element
(8), than the digit with the element
(7).
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GPM 500 Operation
- With the operating elements (Fig. 2-24/5, 6) the setting is made in the opposite direc-
tion. After entering the password the operating element ENTER has to be pressed
- The page (Fig. 2-23) setup appears again and the Password is active.
NOTE:
An access for not authorized persons has to be avoided by imme-
diate log out after parameter modifications.
An automatic logout is performed after some minutes without
touching!
2.5.3.2 How to input or to change nominal data
The nominal technical data of the respective devices have to be input during set to work, or after
a change of devices. Under normal operation conditions it is not possible to change any data in
GPM500, they are Password protected.
CAUTION
The change of data may be dangerous. The operator has to know
the concept of the system.
Precondition:
ating the DG-Set (Fig. 2-22), the password
has to be input before:
- Touch the operating element MENU, the
page Parameter (Fig. 2-25) opens.
- Touch e.g. the operating element "Gener-
ator No." to open the page Identity (Fig. 2-
26).
Fig. 2-25 Parameter
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
- Select one of the identification elements

(Fig. 2-26/2) you want to change. The
page Number Block (Fig. 2-27) opens.
Fig. 2-26 Identity

- Using the number block you put in the
wanted value directly. The new set value
is shown in the upper left area (2). Here
you get also the information about the
range of the possible values to be input.
The momentary set value is also indicated
here.
- After entering the set value the operating
element ENTER (4) has to be pressed.
The page Identity (Fig. 2-26) opens again
and the new inserted value is visible at
the respective position and is active in the
process.
2.5.3.3 How to change parameters
Most of the parameters are parameters of the protection functions. these parameters are limit
values and their corresponding delay times. The correct use of parameters ensures proper and
save operation of the total system.
NOTE:
touching!
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
Precondition:
has been input before:
page Parameter (2-28) opens.
- Touch e.g. the operating element
"CURRENT" to open the page Current
Instantaneous Overcurrent (Fig. 2-29)
Fig. 2-28 Parameter

- Select one of the identification elements
(2,7,9) you want to change by touching.
The page Number Block (Fig. 2-30)
opens.
Fig. 2-29 Instantaneous Overcurrent
- It is only possible to change one value in

the line at once (in this example the
percentage of current or the value of the
delay time). Using the number block you
input the wanted value directly. The new
set value is shown in the upper left area
(2). Here you get also the information
about the range of the possible values to
be input. The momentary set value is also
indicated here.
- After entering the set value the operating
element ENTER (4) has to be pressed.
The page Identity (Fig. 2-29) opens again
and the new inserted value is visible at
the respective position and is active in the
process.
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
2.5.3.4 How to activate / deactivate the function codes.
The function codes (Table 2-15) represents individual safety functions i.e. the consequence if
the limit value has been reached for the adjusted time. The first page which shows function
codes is Current, Instantaneous Overcurrent (Fig. 2-29). There are 2 lines each of them with 8
different function codes.
CAUTION
Generally, the function code OP has to be activated first, other-
wise the other function codes are not active.
Function codes:
Protection functions actions may be parameterised to fit to the situation:
Value
Code Description
(hex)
OP In OPeration: Protection function is activated. 01
TR TRip: Breaker should trip in case of fault. 02
DEX DEeXcitation: Generator should be deexcited in case of fault 04
STP SToP: Stop engine 08
LQ L okal Quit: Alarm must be resetted by hardware input (local) 10
Start Passing on / Relay: Another generator is started, the affected generator to be
SPR stopped
after the time set for start supervision (Par. 83) 20
BL Block: Alarm must be resetted to cease trip command, deexcitation command etc. 40
BBB BusBarBlock: No device should be switched on this busbar 80
Table 2-15 Function codes
Precondition:
has been input before:
page Parameter (Fig. 2-31) opens.
- Touch e.g. the operating element
"CURRENT". (3) to open the page
Current Instantaneous Overcurrent (Fig.
2-32)
Fig. 2-31 Parameter
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
- Select one of the configuration elements

(Fig. 2-32/2) of the line you want to influ-
ence. The page Number Block (Fig. 2-33)
opens.
Fig. 2-32 Instantaneous Overcurrent
- In the upper left corner the momentary

active hex-code and the possible min/max
values are indicated. The area for the
next inputs is flashing.
NOTE
In this menu all values are
hexadecimal values. To acti-
vate individual combination
of function codes the respec-
tive value has to be calcu-
lated by adding the individual
hexcodes.
- In the function code list (Table 2-15) you see the column value, hex. This values are hexa-
decimal numbers. Each of the mentioned function codes have their own hex-code number.
- The basic hexadecimal counting is, 1,2,3,4,5,6,7,8,9,A,B,C,D,E,F. The numbers 1 - 9 have
to be input with the number block or using touch element (Fig. 2-33/7). The letters A - F (10
– 15) have to be input only using touch element (Fig. 2-33/7). After entering the configura-
tion code you leave the menu by pressing the ENTER (Fig. 2-33/4) touch element.
NOTE:
touching!
A list of all parameters incl. function codes is given in Annex B.
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
2.5.4 Power Management System, load monitor (option)
If the optional power management load monitor function has been implemented, two additional
pages are available on the BAT500. In addition five pages already described under 2.3 with
supplements and slight amendments are also available..
PMS function on the menu page (s. Fig. 2-34)
- Touch the operating element PMS, the
page Power Management (Fig. 2-35)
opens.
The PMS user interface comprises two pages.
The first page shows the performance data
and the stipulation of the start and stop limits
for load-controlled starting and stopping of
diesel generators (Fig. 2-35). Consumer-
specific data are entered in the second page
(Fig. 2-36).
Fig. 2-34 Parameter
The maximum available power (Pmax), the

currently-available reserve power (Pres), the
required consumer power (Preq) and the
current actual power (Pact) are shown.
The power reserves and start delay times are
preset in the Start1 and Start2 backgrounded
areas. If the limit of the pre-set reserve power
falls short beyond the pre-set delay period, the
generator allocated will start
Fig. 2-35 Power Management 1

The power reserve in the Stop backgrounded area is accordingly pre-set subsequent to the
corresponding generator being switched off, and when the power reserve is exceeded beyond
the pre-set delay time it will trigger a switch-off of the corresponding generator.
The ACTIVE/inactive selection item is used to stipulate for each generator whether it is active
under power management or not. The mode select /----------- selection item is used to stipulate
whether special digital input and output (selector switch) is available for selecting the operating
modes (= mode select). Otherwise, i.e. on preselecting with the Modbus, --------------- will be indi-
cated.
In the manoeuvre mode indicator field the operation mode of the manoeuvre modus is indicated
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Operation
In the power management 2 page the rated

apparent power (Pres) of up to 6 consumers is
entered.
In the case of a positive value only one
impulse lasting one second will be generated
for the switch-on release of a consumer.
Entering a minus sign before the reserve
power figure will enable the output of a
steady-rate signal for the switch-on release of
a consumer, so that the switch-on release
signal will be put out until connection has been
made or until the reserve power is no longer
sufficient.
Fig. 2-36 Power Management 2
The second parameter is the transmission
ratio of the current transformer.
Since the load monitor function is spread over
several appliances, consumer entries can be
made on several GPM 500s, so that it will be
possible to correctly allocate the consumers to
bus sections.
On the homepage the priority code number for
the start can be influenced with the help of a
"P+" and "P-" button.
Settings can be selected between 0 and 7.
The priority code has the greatest influence
when determining starting priority (besides
operation hours and aggregate no.) Fig. 2-37 DG Set
An operation mode can be selected with the

"topload" touch key in which the generator is
charged with up to 80% of its rated power. At
the same time the other aggregates are
unloaded up to the parameterised minimum
output.
On the measured values page, the available
output of a generator can be varied between
100% and 0% of the rated power (90% in the
example). The load monitor only uses avail-
able power for its calculations and the active
load is distributed accordingly.
Fig. 2-38 Measured values
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Kap_05_Part2_GB.fm / 01.04.05
GPM 500 Service
3.1 Safety notes
3 Service
3.1 Safety notes
1. The GPM500 modules must be installed by the responsible, trained personnel only.
2. The applicable safety, environmental and operating safety regulations must be obeyed.
3. The constructor must observe the accident prevention regulations in accordance with the
statutory provisions.
4. The repair work on and in the units must be carried out by the personnel only having been
specially trained for this purpose.
5. It is to be ensured that the measuring inputs of the GPM500 are voltage-free and dead
respectively. Special care is to be taken in connection with the terminals marked red.
6. If maintenance and repair work can be carried out only if parts of the unit / of the equipment
are under tension, then at least the following additional measures are required:
- Insulating cover of the parts being under tension.
- Presence of a second, trained person who, in case of danger, can switch off the equip-
ment and provide aid.
- Use of insulated tools.
- Working on an insulated standing surface.
7. When replacing the assemblies the following safety regulations are to be observed:
CAUTION
Electronic assemblies can be damaged, if they are replaced
during operation. Assemblies are to be replaced only with power
off!
In doing so, it must be borne in mind that the GPM500 has got two
redundant supplies.
Due to the fact that the installation of an assembly at a wrong mounting position might
cause damage to the equipment, the following procedure is to be applied:
- Replace only one assembly each. Before inserting the new assembly it is to be made
sure that the jumpers of the new assembly are correctly set. For this purpose, the
jumpers must be compared to the corresponding figures.
- Defective assemblies must be marked as such at the front panel, e.g. by means of an
adhesive label.
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GPM 500 Service
3.1 Safety notes
CAUTION
THIS UNIT CONTAINS ELECTROSTATIC SENSITIVE DEVICES.
OBSERVE THE PRECAUTIONS DURING HANDLING IN ACCORD-
ANCE WITH DIN EN 61 340-5-1!
- The GPM500 modules contain components (MOS) being sensitive to electrostatic

discharges (ESD). They might be destroyed or pre-damaged in case of an improper
handling. The pre-damage does not necessarily lead to an immediate failure, but it might
permanently change a component and considerably shorten its life. In order to avoid this,
they must be protected by appropriate technical and organisational measures.
- The corresponding handling rules as per DIN EN 61 340-5-1 are to be observed.
- Further fundamentals with respect to the handling of electrostatic sensitive devices are
contained in DIN EN 61 340.
8. Fuses may be replaced only if the circuit has been switched off.
9. Spare fuses must have the same electrical values.
10. If a fuse has been replaced or a miniature circuit-breaker has been switched on again for
the first time and the equipment fails again, then the cause of the failure is to be eliminated
before re-starting the equipment.
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GPM 500 Service
3.2 Care and Maintenance
3.2 Care and Maintenance
3.2.1 Care
3.2.1.1 Check of sufficient ventilation
Periodically (monthly) it is to check and to ensure that the cooling of the modules and the
BAT500 is sufficient and not disturbed by dirt.
3.2.1.2 Cleaning the Surface of BAT500
CAUTION
The BAT500 must be cleaned using a soft cloth and a neutral
cleaning agent only.
Do not use any solvents.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.3 Failure identification
In the following all possible alarm messages are listed:
Int. Message list ANSI code

Fail.
No.
001 Overcurrent Instantaneous 1 50
002 Overcurrent Instantaneous 2 50
003 Stator protection 50
004 Overcurrent 1 51
005 Overcurrent 1 Pre-Alarm 51
006 Unbalanced Current 46
007 Unbalanced Current Pre 46
008 Undervoltage 27
009 Undervoltage Pre-Alarm 27
010 Overvoltage 59
011 Overvoltage Pre-Alarm 59
012 Underfrequency 81L
013 Underfrequency Pre-Alarm 81L
014 Overfrequency 81H
015 Overfrequency Pre-Alarm 81H
016 Reverse Power 32
017 Reverse Power Pre-Alarm 32
018 --------
019 Preferential Trip 1 -!-
024 Earthfault 51N
025 Earthfault Pre-Alarm 51N
026 Displacement 59N
027 Displacement Pre-Alarm 59N
028 Field failure 40
029 Field failure Pre-Alarm 40
030 Underload 37
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GPM 500 Service
Int. Message list ANSI code

Fail.
No.
031 Underload Pre-Alarm 37
032 Differential Protection 87
036 Linebreak EMERGENCY-STOP
041 Overcurrent 2(IDMT) 51
042 Overcurrent 2(IDMT) PRE 51
043 Startfailure -!-
044 Stopfailure -!-
045 Blackout-Start -!-
046 Phase failure / PSR -!-
047 SYNC time 25
048 Breaker Failure 62BF
049 Voltage-NEG 1 27s
050 Voltage-NEG 2 27s
051 CAN0 failure -!-
055 Checksum FLASH -!-
056 Checksum EEPROM -!-
057 Checksum Protection SW -!-
058 Diesel failure -!-
059 RS485-failure -!-
090 Earthfault, differential 87N
091 Earthfault, diff. PRE 87N
Remark: Code -!- not defined clearly in ANSI.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.4 Component replacement
3.4.1 Replacing fuse plugs
WARNING
If avoidable, do not work with power ON!
Apart from that, observe the regulations for work on live parts.
1. Unfasten connector (1) and pull out.

2. Unfasten and detach casing cover (2) with
the aid of a small screw driver.
3. Pull out casing cover incl. electronic board
(2) from casing.
4. Carefully unfasten and pull out fuse plugs 1
2
on electronic assembly with the aid of
tweezers.
5. Carefully insert new identic fuse plugs
with the aid of tweezers.
6. Attach casing cover.
7. Insert connector, pay attention to coding
in doing so.
Fig. 3-1 Construction of Modules
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GPM 500 Service
3.4.2 Replacing defective modules
3.4.2.1 Installation in General
Prior to the Beginning of the Installation Work

– Disconnect the switchboard from the supply.
– Provide a safeguard to prevent unintentional re-closing.
– Verify the safe isolation from supply.
– Earth and short-circuit.
– Cover or safeguard adjacent parts being under tension.
– Observe the given mounting notes.
– With respect to this unit/system operator action is allowed by the correspondingly qualified
personnel only.
– During the installation work attention is to be paid that the personnel is statically discharged
before it touches the switchboard.
– Connecting leads and signal lines are to be installed such that the functions are not affected
by inductive and capacitive interference.
– Protective relaying equipment and its controls are to be installed such that they are
protected against the accidental operation.
– To avoid that a break of a lead or of a conductor strand on the signal side can lead to unde-
fined conditions in the protection system, there are to be taken corresponding safety
precautions on the hardware side.
– As far as the 24 V supply is concerned, a safe electrical separation of the extra-low voltage
is to be ensured.
– Variations and deviations of the system voltage from the nominal value respectively must
not exceed the tolerance limits given in the technical data. Otherwise, functional failures
and dangerous conditions cannot be excluded.
– EMERGENCY-OFF devices in accordance with IEC/EN 60 204-1 must remain effective in
all operating modes of the protection equipment. Unlocking of the EMERGENCY-OFF
devices must not lead to an uncontrolled or undefined restart.
– Take precautions so that after voltage dips and voltage failures the interrupted program
execution can be correctly resumed. In this connection there must not occur any dangerous
operating conditions, not even for short time. If necessary, EMERGENCY-OFF is to be
enforced.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.4.2.2 Dismounting modules
WARNING
Separate modules
1. Separate modules, until the defective
module is accessible.
2. Pull out grooved pins.
grooved
pin
Fig. 3-2 Connecting the Modules Using Grooved

Pin
3. Pull out the four connectors.
Fig. 3-3 Position of the Individual Connectors
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
Dismounting:
1. Pull down to open the clip-on catch with
the aid of a screwdriver.
2. Detach the module at the bottom edge of
the top-hat rail.
Fig. 3-4 Dismounting module
3.4.2.3 Mounting modules
WARNING
Mounting:
1. Put the module with the top-hat rail guide
onto the top edge of the top-hat rail.
2. Press the module down and let it snap into
place.
Fig. 3-5 Mounting module
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
Connecting the Modules

1. Insert the grooved pins (DIN 1474 3 x 16
mm).
Insert at least 2 grooved pins into the
upper two blind holes. It would, however,
be better to insert 4 grooved pins into the
upper and lower blind holes.
2. Push each module against the neigh- grooved
bouring module until the modules lie next pin
to one another.
When the modules are connected to one
another, then the internal CAN bus
connection is established, too.
Fig. 3-6 Connecting the Modules Using Grooved

Pins
All GPM500 assemblies are equipped with a plug coding.

All GPM500 modules are connected by means of 4-pole connectors. When coding with two
coding pairs each (clip/coding pin) the following 6 possible combinations are obtained:
Terminal
Coding number 1 2 3 4
1 U U R R
2 R U U R
3 R R U U
4 U R U R
5 U R R U
6 R U R U
Fig. 3-7 Detailed View of a Plug-and-Socket

Connection
R = Clip on the board connector

U = Coding pin on the connector
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
In the opposite figure the position of the indi-

vidual connectors is shown.
Fig. 3-8 Position of the Individual Connectors
In the following table the coding of the plug-and-socket connections is given by the above-
mentioned coding numbers (1-6).
Plug-and NEG502 resp.
SLE SLE
socket connec- DCC 510 / 501 ZKG DIO GOV TRV DIF USS
tion left right left right
A 1 5 3 1 5 3 1 5 3 1 5
B 2 6 4 2 6 4 2 6 4 2 6
C 3 1 5 3 1 5 3 1 5 3 1
D 4 2 6 4 2 6 4 2 6 4 2
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.4.3 Wiring of the Modules
WARNING
Do never work with power ON! Danger to life!
The modules are equipped with connectors. This way the units can be quickly connected and
visibly disconnected in case of need.
CAUTION
Connectors must be plugged or withdrawn in the de-energised
condition only!
Use a screwdriver with an appropriate blade

width of approx. 3.5 mm for wiring.
Strip the line ends according to the figure to
obtain a reliable and shockproof connection.
Fig. 3-9 Stripping the Line Ends
Cross-section of the flexible line Tightening torque Stripping length L

[mm²] AWG [Nm] [lb in] [mm]
0,2 – 2,5 24 – 14 0,5 – 0,6 4,4 – 5,3 7
3.4.3.1 Description of the Terminals
Modules ZGK500, GOV500, DIO500, TRV500/501/502, DIF500, DCC500 and USS500 have
got 16 external terminals each.
Module SLE500 and power supply module NEG502 and combined power supply module
NEG501/510 respectively have got 32 external terminals.
The detailed terminal assignment is given in Annex A.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.4.4 Replacing of the BAT500
3.4.4.1 Dismounting of the BAT500
WARNING
1. Disconnect connections on the rear side of the BAT500.

2. Hold the BAT500 on the front side and
unfasten the four clamps with fastening
screws. (Fig. 3-10/1).
3. Detach BAT500.
Fig. 3-10 Rear Side of the BAT500
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
3.4.4.2 Installation of the BAT500
CAUTION
Do not use any etching chemicals during the installation.
Do not use any tools (screwdriver or similar) to work on the

display of the BAT500.
Installing the Seals

Two strips (1 x narrow, 1 x broad) of sealing material are used as seals.
Narrow seal:
This strip is inserted into the mounting cutout

into which the BAT500 will be installed later.
1. Start to fit the narrow seal approx. in the
middle of the lower edge.
2. Fit the seal in the clockwise direction.
Make sure that the seal has a sufficient
clearance.
3. The two ends of the seal must not
overlap.
Fig. 3-11 Fitting the Narrow Seal
– Replace the seal every time the BAT500
is dismounted.
Broad seal:
This strip is fitted at the BAT500 directly

behind the bezel.
1. Start to fit the broad seal approx. at one
third of the lower edge.
2. Fit the seal in the clockwise direction.
Make sure that the seal has a sufficient
clearance.
3. The two ends of the seal must not
overlap. Fig. 3-12 Fitting the Broad Seal
– Replace the seal every time the BAT500
is dismounted.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
Inserting the BAT500 into the Mounting Cutout

1. Insert the BAT500 with inserted memory
card into the mounting cutout.
Fig. 3-13 Inserting the BAT500 into the Mounting

Cutout
2. Attach the four clamps with fastening

screws and tighten them. (Fig. 3-14/1).
Fig. 3-14 Rear Side of the BAT500
Inserting the Memory Card

If the BAT500 has not been delivered with inserted, programmed memory card, attention is to
be paid to the following when inserting the memory card:
- Handle the memory card with care when inserting it into the BAT500.
- Prior to the installation the contacts on the memory card must be clean. All impurities
caused by oil or grease must be carefully removed.
CAUTION
Impurities on the golden contacts of the memory card can lead to
malfunctions of the electrical contacts.
The memory card must not get in touch with any chemicals
because in case of contact this might cause a permanent damage.
The use of synthetic cloth might cause a permanent damage to

the memory card because electrostatic discharges are caused.
Do not touch the contact surface with your fingers.
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
- If the memory card is to be removed and to be transported, the transport is to be carried

out in an anti-static container.
1. Insert the memory card in the slot

provided for this purpose on the rear side
of the BAT500 from below. In doing so,
the contacts must be visible from the rear
side.
2. Following the insertion the interlock of the
slot is to be closed.
Fig. 3-15 Inserting the Memory Card
Activating the Battery

In the scope of delivery there is included a battery. In the condition as delivered the battery is
deactivated by means of a red plastic strip.
1. Remove the red plastic strip.

This way the battery is activated.
2. When the 24V DC voltage has been
applied, the red LED is illuminated twice
and then extinguishes.
In case the LED is flashing the battery is
to be checked.
Fig. 3-16 Battery with the Red Plastic Strip
Removing the Protective Film
NOTE
The BAT500 can be operated also with the protective film on it.
For this reason, do not remove the protective film until after
completion of all work steps.
1. Loosen the protective film at the front at the places marked with "REMOVE" and completely
remove it.
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GPM 500 Service
3.4.4.3 Connection of the BAT500 Operator Control and Display Panel
On the rear side the BAT500 has got one

power supply connector (POWER) as well as
three further ports:
– AUX port (for the CAN bus connection to
the ZKG500)
– PLC port (not used)
– PC/printer port (for programming)
Fig. 3-17 Ports on the BAT500
The power supply connectors are shown in the

opposite figure.
The BAT500 must always be earthed.
Fig. 3-18 Power Supply Connectors

The power supply must have a double or a
reinforced insulation.
All electrical components of the system must
be earthed.
Earthing must be in accordance with the valid,
applicable regulations.
NOTE
In case of non-earthed 24 V systems
the BAT500 is to be supplied on a
floating basis with a DCC500 because
the BAT500 establishes a connection
between M and casing.
Fig. 3-19 Earthing
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Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
Connecting the AUX Port

The AUX port is a 9-pole sub D port. The cable of the CAN bus (to the NEG module, CAN4) is
to be connected to the AUX port. The bus is to be terminated via a 120 Ω resistor at the
BAT500. The use of the prefabricated CANopen cable (identity No. 271.188.464) with integrated
terminating resistor is recommended.
Pin Assignment
2 CAN - L
6 CAN - GND
7 CAN - H
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GPM 500 Service
3.4.4.4 Jumper settings of the modules
ZKG500 assembly jumpers
J14
2 4
1 3
J10 2 4
J13
J3
J2
1 3
J7
J6
J5
2 4
J12 2
1
4
3 1 3 J11
Fig. 3-20 ZKG500 assembly jumpers
These jumpers are not set as a standard.

J2 and J3 are the jumpers required to activate the RS-485 bus termination impedances.
If the RS-485 interface is connected at the end of a bus, both jumpers must be set.
Setting the J5 jumper deactivates the monitoring function of the watchdog IC.
This prevents the CPU, on downloading or in a test run, from constantly receiving re-set signals
from the watchdog IC. In standard operation the CPU will generate cyclical signal changes for
the watchdog IC, so the J5 will not need to be set.
The connection of the RS-232 interface to the CPU is made with J6 and J7.
These two jumpers must be set for the program test via the RS-232 interface.
The connection between the debug/download interface (BGND) and the reset entry of the CPU
is made with J10. These jumpers must be set for the program test/download via the BGND inter-
face.
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-19

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
The J11, J12, J13 and J14 strips are used to impede the CAN buses (0, 4, 1 and 2) (120 ohm
bus termination impedance). To this purpose two jumpers must be set on each of the respective
strips.
While CAN0 and CAN4 are generally not impeded, the bus for CAN1 and CAN2 on the other
hand are to be impeded for the GPM bus if the GPM is at the end of the bus.
DI0500 assembly jumpers
J4
1 3
1
1
J1
J14
J13
J11 4
J12
1 3
3
1
J2
1 3
J3
4
J6
1
3
2
4
J5
3 1
Fig. 3-21 DI0500 assembly jumpers
The J5 strip stipulates how the DA relays react when the watchdog relay is released.
Pins 1-2 bridged: all of the DA relays are disconnected by the watchdog relay (supply of
connected 24 volts). Standard setting.
Pins 2-3 bridged: no effect on the DA relay (supply of supported 24 volts).
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-20

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
The J1, J2, J3 and J4 3-pole strips are used to preselect whether a break contact or a make
contact for the respective DA channel is made to the output terminal.
Bridging pins 1-2 will lead through the break contact and bridging 2-3 will lead through the make
contact.
The 4-pole strips J11, J12, J13 and J14 are used to preselect whether the DE channel terminals
1 to 4 are self-contained or whether they serve the purpose of monitoring line breaks of adjacent
channel terminals (5-8).
Pins 2-3 bridged: the respective DE channels are self-contained without a line-break monitoring
device.
Pins 1-2 and 3-4 bridged: the respective DE channels are programmed for line-break moni-
toring.
The CAN bus is impeded with the J6 strip; this is however not necessary for the GPM.
GOV500 assembly jumpers
J10
J9 J3
3 1
J7
J4 J1
3 1
J8
J2
J11
2 4
1 3
J5
1 3
Fig. 3-22 GOV500 assembly jumpers
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-21

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
In the case of the bridged pins 1-2 of the 3-pole J5 strip (default setting) the higher/lower relays
are released when the watchdog relay is released (relay supply by means of connected 24
volts).
In the case of bridged pins 2-3 on J5 the release of the watchdog relay has no effect on the
"higher/lower" relay (relay supply by means of supported 24 volts).
Jumper for configuration of the analogue outputs:
Jumper name Channel 1: J3 (3-pole) J9 (2-pole) J10 (2-pole)
Jumper name Channel 2: J4 (3-pole) J7 (2-pole) J8 (2-pole)
0 bis +10 Volt terminal: 1-2 set 1-2 set 1-2 set
-10 bis +10 Volt terminal: 2-3 set 1-2 set 1-2 set
0 bis + 20mA terminal: 1-2 set nothing set nothing set
-20 bis + 20mA terminal: 2-3 set nothing set nothing set
The internal CAN bus is impeded with the J11 strip; this is however not necessary for the GPM.
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-22

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
TRV500/501 assembly jumpers
J11
J10
J12
J13
J9
J8
J7
J6
J5
J4
J3
J2
J1
Fig. 3-23 TRV500/501 assembly jumpers
Jumpers are used to connect the three output signals of the TRV500 with various bus connec-
tion pins or with external supply terminals.
It is always necessary to "change over" the output channels if several TRV500s are operated
together on the analogue bus.
Jumper name: Function (if the jumper is set):
J2 Connects channel 1 with X7.3/4 (U3) standard setting
J5 Connects channel 2 with X7.1/2 (U2 ) standard setting
J8 Connects channel 3 with X6.10 (U1 ) standard setting
J10 Connects channel 1 with X3.2 (terminal 3)
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-23

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
TRV502 assembly jumpers
J11
J10
J12
J13
J9
J8
J7
J6
J5
J4
J3
J2
J1
Fig. 3-24 TRV502 assembly jumpers
In the case of the TRV502 module the jumpers are set on delivery, so that channels 1, 2 and 3
are not connected to the analogue bus, but to the respective output terminals (J10, J11 and J12
are plugged instead of J2, J5 and J8).
CAUTION
Incorrect jumpering must be avoided since this could result in
damage to the connected modules. J2, J5 and J8 must not be
jumpered on the TRV502!
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-24

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
SLE500 assembly jumpers
J6 J7
J5
J1
3 1
4 2
J4 3 1
J2 4 2
Fig. 3-25 SLE500 assembly jumpers
Setting jumper J5 will result in impulses from an oscillator being transmitted to the watchdog IC.
This will deactivate the monitoring function of the watchdog IC. This deactivation prevents the
CPU, on downloading or in a test run, from constantly receiving re-set signals from the
watchdog IC.
In standard operation the CPU will generate cyclical signal changes for the watchdog IC so the
J5 will not need to be set. These jumpers are not set as a standard.
The connection of the RS-232 interface to the CPU is made with J6 and J7.
These two jumpers must be set for the program test via the RS-232 interface. These jumpers
are not set as a standard.
The connection between the debug/download interface (BGND) and the reset entry of the CPU
is made with J1. These jumpers must be set for program test/download via the BGND interface.
These jumpers are not set as a standard.
The CAN buses (0 and 4) are impeded with the J4 and J2 strips, which is not always the case
with the GPM.
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-25

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
SLE510 assembly jumpers
J4
J7 J5
J8
J6
J1
J2
J3
Fig. 3-26 SLE510 assembly jumpers
Jumpers J4, J5, J6, J7 and J8 are used to set whether the output contact of the "OFF power
switch" relay is to be a make contact or a break contact.
– All of the jumpers set on 1-2: relay contact is a break contact (for low-voltage winding)
– All of the jumpers set on 2-3: relay contact is a make contact (for shunt release)
The release time of the self-sufficient excess current monitoring device is set with jumpers J1,
J2 and J3:
– J1 set: release time = 200 msec.
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-26

Kap_05_Part3_GB.fm / 01.04.05
GPM 500 Service
Overview of relevant Jumpers

Equipped
Card Jumper Function
Delivered
ZKG500 J2 1-2
activation of RS-485 bus terminating resistors
J3 1-2
J5 - Disable Monitoring of watchdog relay
J6 -
for connection of RS-232 interface to CPU
J7 -
J10 - for connection between debug-/ download interface and CPU
J11 - for termination of internal CAN bus (CAN 0)
J12 - for termination of external CAN bus (CAN 4)
J13 1-2
for termination GPM bus CAN1 and CAN2
J14 1-2
NEG500/501 J1 1-2; 3-4 for termination of internal CAN bus (CAN 0)
J3 - earthing of internal supply voltage 5V
NEG510 J3 - earthing of internal supply voltage 5V
DIO500 J1 2-3
J2 2-3 preselection if in each case of DA channel a normally closed contact or
J3 2-3 normally open contact is passed to the output terminals
J4 2-3
J5 1-2 determination of DA relay reaction during drop-out of watchdog relay
J11 2-3
J12 2-3 preselection if DE channel clamps 1-4 are independent or serve as wire
J13 2-3 control of its neighbouring channels clamps 5-8
J14 2-3
GOV500 J1 -
J2 1-2
J3 2-3
configuration of analog outputs
J4 1-2
J5 1-2 setting if "higher/lower" relays drop out when watchdog relay drops out
J7
J8
configuration of analog outputs
J9 1-2
J10 1-2
TRV500/501 J2 1-2 connects channel 1 with X7.3/4 (U3 )
J5 1-2 connects channel 2 with X7.1/2 (U2 )
J8 1-2 connects channel 3 with X6.10 (U1 )
J10 - connects channel 1 with X3.2 (terminal 3)
TRV 502 J2 -
J5 -
J8 -
see TRV 500/501
J10 1-2
J11 1-2
J12 1-2
SLE500 J2 1-3 ; 2-4 for termination of internal CAN bus (CAN 0)
J4 1-3 ; 2-4 for termination of internal CAN bus (CAN 0)
SLE510 J1 -
J2 1-2 setting for releasing the closed over-current control
J3 -
J4 1-2
J5 1-2
setting if output contact of "power switch-ON"-relay is a normally closed
J6 1-2
contact or a normally open contact
J7 1-2
J8 1-2
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 3-27

Kap_05_Part3_GB.fm / 01.04.05
ANNEX A
Terminal assignment
GPM 500
ANNEX A
NEG500 – Terminal Assignment

No. Assignment
1 +24 Volt DC supply voltage
3 0 Volt (-24V) DC supply voltage
5 19 Volt AC supply voltage (L1)
8 Unassigned / unused
9 +24 Volt output (filtered and backed-up)
10 +24 Volt output for digital input contacts (varistor..)
11 0 Volt (-24V) DC-output voltage
12 +24 Volt output (filtered, backed-up)
13 External CAN bus: CAN4-H
14 External CAN bus: CAN4-L
15 External CAN bus: CAN4-GND
Terminal Assignment – NEG502 and Combined Power Supply Module NEG501/510

Respectively
NEG 502 Left and NEG510 Respectively – Terminal Assignment

Nr. Assignment
1 +24 Volt (varistor-protected)
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-2

Kap_05_Annex_A_GB.fm / 01.04.05
GPM 500
ANNEX A
NEG 502 Right and NEG501 Respectively – Terminal Assignment

No. Assignment
9 +24 Volt output (filtered and backed-up)
10 +24 Volt output for digital input contacts (varistor..)
11 0 Volt (-24V) DC output voltage
12 +24 Volt output (filtered, backed-up)
ZKG500 – Terminal Assignment

No. Assignment
1 Diagnostic contact (normally open contact)
5 Diagnostic relay contact (normally open contact)
9 Analog input channel 1 + (0...+10V)
12 Analog input channels 1,2,3 - (GND)
13 RS-485 bus: -S/E
14 RS-485 bus: +S/E
15 RS-485 bus: RGND
16 Digital output +24 V optocoupler
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-3

GPM 500
ANNEX A
GOV500 – Terminal Assignment

No. Assignment
1 GOV motor connection (DC / AC motor)
2 GOV motor connection (DC / AC motor)
3 GOV motor connection (AC motor)
4 GOV motor connection (DC motor)
5 +24 Volt (internal, backed-up)
6 0 Volt (internal)
7 GOV motor supply (+24V / L1)
8 GOV motor supply (0V / L2)
9 Digital input channel 1 (+24 V) sensor contact connection
10 Digital input channel 1 (DE input) sensor contact connection
11 Digital input channel 2 (+24 V) sensor contact connection
12 Digital input channel 2 (DE input) sensor contact connection
13 Analog output 1 (reference potential)
14 Analog output 1 (output)
15 Analog output 2 (reference potential)
16 Analog output 2 (output)
DIO500 – Terminal Assignment

No. Assignment
1 Digital output channel 3 contact (normally closed contact or normally open contact)
9 Digital input channel 1 (or open circuit channel 1)
13 Digital input channel 5 (or input value channel 1)
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-4

GPM 500
ANNEX A
SLE500 – Terminal Assignment

No. Assignment
1 Watchdog relay contact (normally closed contact)
2 Watchdog relay contact (normally open contact)
3 Watchdog relay contact (common)
4 CAN0-GND
5 – Not assigned –
6 External CHASSIS terminal
7 Circuit-breaker ON contact
8 Circuit-breaker ON contact
11 Internal current transformer terminal K3
12 Internal current transformer terminal L3
13 Digital input channel 1 (+ 24 Volt)
14 Digital input channel 1 (input)
15 Digital input channel 2 (+ 24 Volt)
17 US1 (external voltage input of buffer amplifier)
18 US2 (external voltage input of buffer amplifier)
19 2,5 Volt (analog reference voltage)
20 2,5 Volt (analog reference voltage)
22 Digital input channel 3 (+ 24 V)
24 Digital input channel 4 (+ 24 V)
29 Circuit-breaker ON (normally closed contact)
30 Circuit-breaker ON (common)
31 Circuit-breaker ON (normally open contact)
32 Circuit-breaker ON enabling
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-5

GPM 500
ANNEX A
TRV500 – Terminal assignment

No. Assignment
1 Analog output channel 1
4 Reference voltage (2.5V) for analog outputs
5 - Input channel 3 (V3)
6 – Unassigned –
8 + Input channel 3 (U3)
DIF500 – Terminal assignment

No. Assignment
1 Current transformer input L1 DIF1 (I1 = ID1)
2 Current transformer input K1 DIF1 (I1 = ID1)
7 – Not connected –
9 Current transformer input L6 DIF2 (I3 = IE3)
10 Current transformer input K6 DIF2 (I3 = IE3)
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-6

GPM 500
ANNEX A
USS500 – Terminal Assignment

No. Assignment
1 Undervoltage coil terminal (+)
2 Undervoltage coil terminal (+)
3 Undervoltage coil terminal (–)
4 Undervoltage coil terminal (–)
5 Input contact supply (–)
6 Input contact supply (–)
7 Input contact (coil side)
8 Input contact (coil side)
10 L1 system 2
11 L2 system 2
12 L3 system 2
14 L1 system 1
15 L2 system 1
16 L3 system 1
DCC500 – Terminal Assignment

No. Assignment
1 +24 Volt external supply
3 0 Volt external supply
9 0 Volt isolated output
11 +24 Volt isolated output (with NTC thermistor)
12 +24 Volt isolated output (with NTC thermistor)
15 +24 Volt isolated output
16 +24 Volt isolated output
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) A-7

ANNEX B
List of Parameters
GPM 500
ANNEX B
Param. Limit value Delay time Funct.

No. [%] [s] code
Limit / Set-
ANSI- Min. Max. Min. Max.
delay / Parameter description / function ting Remarks
Code value value value value
F.code (HEX)
1/2/101 Instantaneous Overcurrent (Step 1) 50 0 800 0 10
3/4/102 Instantaneous Overcurrent (Step 2) 50 0 800 0 10
5/6/103 Stator protection 50S 3 100 0 10
7/8/104 Overcurrent definite time 51 100 400 0 240
9/10/105 Overcurrent definite time PREALARM 51 100 400 0 240
11/12/106 Unbalanced Current 46 10 120 0 240
13/14/107 Unbalanced Current PREALARM 46 10 120 0 240
15/16/108 Undervoltage 27 50 100 0 240
17/18/109 Undervoltage PREALARM 27 50 100 0 240
19/20/110 Overvoltage 59 10 200 0 240
21/22/111 Overvoltage PREALARM 59 10 200 0 240
23/24/112 Underfrequency 81L 50 200 0 240
25/26/113 Underfrequency PREALARM 81L 0 200 0 240
27/28/114 Overfrequency 81H 0 200 0 240
29/30/115 Overfrequency PREALARM 81H 0 200 0 240
31/32/116 Reverse Power 32 -200 0 0 240
33/34/117 Reverse Power PREALARM 32 -200 0 0 240
35/36 spare
37/119 Preferential Trip Step 1 - I 30 400 0 120
38/119 Preferential Trip Step 1 - f 0 100 0 120
47/48/124 Earthfault [0.01A] 51N 0 5000 0 2400
49/50/125 Earthfault PREALARM [0.01A] 51N 0 5000 0 2400
51/52/126 Voltage Displacement 59N 0 120 0 2400
53/54/127 Voltage Displacement PREALARM 59N 0 120 0 2400
55/56/128 Field Failure 40 -200 0 0 240
57/58/129 Field Failure PREALARM 40 -200 0 0 240
59/60/130 Underload 37 0 100 0 30000
61/62/131 Underload PREALARM 37 0 100 0 30000
63/64 Start condition 1: Power Limit [kW] * 0 10000 0 3600
65/66 Start condition 2: Power Limit [kW] * 0 0 0 0
67/68 Stop condition: Power Limit [kW] * 0 30000 0 3600
69 Consumer 1: Max Power [kVA] * -30000 30000
70 Consumer 1: Current Transf. ratio [1] * 0 10000
81/82 Overcurrent inverse time [10ms] 51 0 30000 0 300
83 Startfailure 0 3600
84 Stopfailure 0 3600
85/86 spare 1 1 1 0,01
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) B-2

Kap_05_Annex_B_GB.fm / 01.04.05
GPM 500
ANNEX B

No. [%] [s] code
Limit / Set-
F.code (HEX)
87 Synchronization failure [0.01s] 0 240
88..92 spare
93 Load sharing: Ramp [0.1 %/sec] 0 1000
94//132 Differential Protect. (2.Harmonics [0.1%]) 87 0 999
95//132 Differential Protection ("ku" ) 87 0 800
96//132 Differential Protection ("a1" ) 87 -800 800
97//132 Differential Protection ("v1" ) 87 -800 800
98//132 Differential Protection ("a2" ) 87 -800 800
99//132 Differential Protection ("v2" ) 87 -800 800
100 Start block [0.1s] 50/51LR 0 300
133 Analog Output 1 OFFSET -1000 1000 rated=xxxx *0.01V
134 Analog Output 2 OFFSET -2000 2000 rated=xxxx *0.01V
135 Bitmask CAN0 0 $FFFF
136 Linebreak Emergency-STOP 0 $FFFF
137 spare 0 0
138 spare 0 0
139 spare 0 0
140 spare 0 0
141 Start Attempts/ Overcurrent IDMT -Funct. 66/ 51 0 $FFFF
142 Overcurrurent IDMT PREALARM -Funct. 51 0 $FFFF in Min.
143 Starting Attempts / Startfailure 66 0 $FFFF
144 Stopfailure 0 $FFFF
145 spare 0 $FFFF
146 Phasefailure / Neg. sequence Function 47 0 $FFFF
147 Synchronis. mode / Synchronis. failure 0 $FFFF
148 Breaker failure -Function 0 $FFFF
149 Voltage-NEG1 -Function 0 $FFFF
150 Voltage-NEG2 -Function 0 $FFFF
151 CAN0 failure 0 $FFFF
155 FLASH 0 $FFFF
156 EEPROM failure 0 $FFFF
157 Protection software failure 0 $FFFF
158 Emergency-Stop - Function 0 $FFFF
159 spare 0 0
160 Rated Voltage [V] * 0 15000
161 Device No. / Device Type * 0 $FFFF
162 Up No. / Down No. * 0 $FFFF
163 Rated Current [A] * 0 32767
164 Rated Power [kW] * 0 32767
165 Rated Frequency [0.1 Hz] * 150 1000
166 Voltage Transformer - ratio [0.01] * 1 16000
167 Current Transformer -ratio [1] prim. S * 1 30000
168 Current Transformer -ratio [1] sec.1 D * 1 30000
169 Current Transformer -ratio [1] sec.2 E * 1 30000
170 Load distrib. Amplification Power control 0 1000
171 Load distrib. Amplification Freq. control 0 1000
172 Load distribution Deadband [0.1%] 0 1000
173 Load distribution Pulse length [ms] 0 32000
174 Load distribution 0.5 Pulse interval [ms] 0 32000 (4 s displayed)
175 ( static ) 0 0
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) B-3

GPM 500
ANNEX B

No. [%] [s] code
Limit / Set-
F.code (HEX)
176 Afterrun [0.1 s] 32767 0
177 Displacem. angle Secondary coil 1 [0.1°] 0 3599
178 Displacem. angle Secondary coil 2 [0.1°] 0 3599
179 Rated Voltage Secondary coil 1 [V] 0 15000
180 Rated Voltage Secondary coil 2 [V] 0 15000
181 Synchronisation – Phase Angle [°] 25 0 30
182 Synchronisation – Voltage Difference [%] 25 0 99
183 Synchronisation – Freq. Difference [%] 25 0 99
184 Synchronisation – Voltage Levitation [%] 25 0 99
185 Switch-on release [% Unenn] -200 200
186 Analog Output 1 SCALE -9999 9999 rated=xxxx *0.01V
187 Analog Output 2 SCALE -9999 9999 rated=xxxx *0.01V
188 TRV configuration 0 $FFFF
189 Blackout Start (Bit0) 76 0 $FFFF
190 Blackout Start [0.1s] 76 0 999
191 Zero-sequence Current Transf. ratio [1] 0 10000
192 Gain synchronising controller [%] 0 100
193 EEPROM check sum 0 $FFFF set via BAT only
194 Smoothing of indication of analogue val. 0 32767 set via BAT only
195 spare 0 0 set via BAT only
198 Power set value 0 1000 set via BAT only
199 spare 0 0
Doc. 271.195 999 BAW EN/ – (2005-03 / 00) B-4


Generator Protection Module GPM 500: Operation and Service Manual

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Generator Protection Module GPM 500: Operation and Service Manual

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Operation and Service Manual

Generator Protection Module

Doc. 271.195 999 BAW EN Revision: – (2005-03 / 00)

SAM Electronics GmbH

Phone: + 49 (0) 40 8825-0

List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-I

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) I

1.5.1 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) II

3.2.1 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) III

Fig. 1-1 Design of the GPM500 assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) IV

Fig. 3-9 Stripping the Line Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) V

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) VI

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-1

1.2.1 General Design

The GPM500 consists of a basic configuration

Fig. 1-1 Design of the GPM500 assemblies

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-2

1.2.2 Module Descriptions

The basic mechanical design of the modules is described in the following:

Fig. 1-2 Design of the Modules

Identification of the Modules

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-3

Module Side Top side

Fig. 1-3 Labelling fields of the SLE500

Fig. 1-4 Labelling fields of the USS500

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-4

1.3 Functional Description

1.3 Functional Description

The generator protection module GPM500 is a microprocessor-controlled system being used to

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-5

1.3 Functional Description

1.3.1 Functional Description of the Assemblies

ZKG500 Identity No.: 271.195 020

DIO500 Identity No.: 271.195 021

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-6

1.3 Functional Description

GOV500 Identity No.: 271.195 022

TRV500 Identity No.: 271.195 028

DCC500 Identity No.: 271.195 029

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-7

1.3 Functional Description

SLE500 Identity No.: 271.195 030

The following functional units are arranged on the SLE510 board:

The assembly performs the following tasks:

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-8

1.3 Functional Description

DIF500 Identity No.: 271.195 032

USS500 Identity No.: 271.195 040

Doc. 271.195 999 BAW EN/ – (2005-03 / 00) 1-9

1.3 Functional Description

BAT500 Identity No.: 271.188 465