GCM01 Mu GB 12.2
GCM01 Mu GB 12.2
GCM01 Mu GB 12.2
MANUAL:
INSTALLATION USE MAINTENANCE
INDEX
DESCRIPTION
1. USER MANUAL
1.1. Purpose 1.2. Operational principle 1.3. View of the GCM01 unit 1.4. Controls 1.5. Maintenance
PAGE
3 3 3 4 4 6 7 7 8 10 10 12 14 16 17 18 18 18 19 19 20 20 21 22 23 25 25 26 26 27 28 28 29 29 29 30 30 31 31 31 31 31 31 32 32 33
2. TECHNICAL MANUAL
2.1. Constructional description of the control panel 2.2. How it works 2.3. Manual control functions 2.4. Various functions and standard utilities 2.5. Configuration output 11 starter 2.6. External commands 2.7. Special functions 2.8. Optional expansions
3. PROGRAMMING
3.1. Settings 3.2. Time settings 3.3. Alarm thresholds 3.4. Operating functions 3.5. Measures regulation 3.6. Clock and hour recording meter 3.7. Self-programming 3.8. Connections and relative description 3.9. Technical features
4. INSTALLATION
4.1. Positioning 4.2. Power connections 4.3. Starting 4.4. Stopping 4.5. Motor controlling probes 4.6. Electrical strength test
5. SERVICE PROCEDURES
5.1. Servicing procedures 5.2. Servicing procedures with mains supplying (disabled generator) 5.3. Battery replacement procedure 5.4 GCM01 Board replacement procedure
6. MAINTENANCE
6.1. Electrical maintenance 6.2. Efficiency test 6.3. Motor safety devices 6.4. Generator safety devices 6.5. Overload protection 51 6.6. Battery efficiency 6.7. Switching scaling test 6.8. Trouble shooting
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1. USER MANUAL
GENERAL FEATURES
We congratulate you for having purchased the GCM01 control panel for handling your generator unit. As you read through this manual you will realise the outstanding performance and variety of applications offered by this supremely technological unit. This electronic microprocessor module not only completely controls the generator and its switching but, is also prearranged for the direct serial communication with a PC. Moreover using a GSM unit, your generator can be completely remote controlled from miles away. The GC-M02 unit is equipped with a complete set of digital testers that are required to monitor all mains, generator and motor parameters. To make the control of the unit absolutely comprehensible the manual is split up into two parts, namely: 1. The first USER MANUAL part has been prepared to provide a clear and simple guide to help you use the generator rapidly, completely and safely. 2. The second TECHNICAL MANUAL part has been prepared to provide complete and detailed instructions for skilled personnel to start up the generator correctly.
1.1 PURPOSE
The manual has been prepared specifically for the user of the generator unit. Information required for the following is provided: 1. To learn the operational principle of the unit; 2. To interpret the indications given on the electronic control panel; 3. To control it for the various operational requirements; 4. To perform the basic checks required ensuring the efficiency of the generator itself. Technical or adjustment matters are not dealt with as these involve the installation engineer when setting up the system.
QGE GCM01
R
CR C
Fig. 1 USERS
Supposing that the mains R is within the normal limits, the CR mains contact maker is closed therefore the utility is powered from the mains. The GCM01 module controls the R mains and if there should be a drop in voltage, a phase should be missing or the phases should be dissymmetrical, the control panel: 1. Opens the CR mains contact maker; 2. Starts the G-M generator unit, which when the established operating conditions are reached, the GCM01 module closes the CG contact maker that then powers the utility from the generator unit G; 3. When running, the engine M and the generator G are safeguarded against possible anomalies, which if encountered cause to stop the generator immediately; 4. When the R mains is restored within the normal limits, the GCM01 module after an adjustable delay, opens the contact maker of the CG generator and one second later closes the CR contact maker, thus powering the utility from the mains again; 5. The generator continues to run for at least another minute to cool down after which it stops automatically; 6. Only reserve and overload. To ensure the perfect efficiency of the generator a battery charger automatically holds the battery perfectly efficient. An automatic fuel filling system constantly keeps the correct level in the daily tank. A pre-heating system maintains the motor
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10 11
12 14 13
1.4 CONTROLS
The operational modes that can be selected with the programming switch are six, namely: 1. 2. 3. Automatic test: This starts to test the generator without disconnecting the mains power supply from the utility. When the switch is turned back to automatic mode the generator stops following a delay of roughly one minute (it is used for periodic tests or to check the running efficiency following maintenance). Automatic mode: if there should be a failure in the mains the circuit board responds by opening the mains contact maker. Once the mains is re-connected, after a certain time, the utility is switched back to the mains and the generator is stopped (this is the normal operational situation). Lock: this sets the generator in a locked status. It completely disables every possibility of starting while the mains powers the utility. This mode is used to work on the system in complete safety, being certain that the
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4.
5.
6.
generator will not start even if the mains should be disconnected (it is used during maintenance).The mains voltage control its not active. Manual mains: this enables power supply output from the mains even if the command and control electronics are faulty (it is used when the generator is left inoperative). Manual starting: this enables the generator to be started manually using the start push button. The control is direct without the involvement of electronic components. It ensures the operation of the generator even when the electronics are faulty (it is used for the manual emergency controls or for maintenance purposes). Manual generator: this enables the forced power supply from the generator (it is available for manual procedures or in the case of problems with the automatic functions).
WARNING
When the programming switch is in this position all the utility circuits of the generator are powered such as the solenoid valves, electronic rpm regulators etc. If the switch were in this position with the generator stopped the starting battery would run flat very quickly. STOP This is enabled whatever the situation (enabling even only in manual mode) It is to be held down until the motor stops completely EMERGENCY STOP If pressed, the red mushroom push button in the middle of the door stops the generator immediately, instantaneously opening the contact maker of the generator (CG) thus locking it. To release the emergency status set the programming switch in Lock position and then turn the emergency push button and pull up. A newly conceived and remarkably useful LED has been fitted on the GCM01 module to assist the operator, namely the WAIT/PROG LED. This LED flashes each time the timer is triggered informing the operator what is happening even over a lengthy timer period. All leds are provided with a general description that makes the control panel easily comprehensible. LED TEST To verify the functioning of all the leds, bring the programming hand grip to lock.Hold the + /- push buttons down together for 2 seconds. ALARM SILENCING Hold the RESET key down for 2 seconds to silence the buzzer alarm. FUNCTIONS RESET Hold the RESET key down for 2 seconds to reset the alarm status and to restore the functions. SUMMERY In normal running the generator unit is programmed in AUTOMATIC mode. During maintenance on the generator unit put it on LOCKED ENGINE. With no intervention need even in case of mains failure, set the programming switch in MANUAL MAINS. Thus the supply by mains would be assured. CLC SIGNAL With the setting of the automatic TEST or AUTOMATIC LOCK, in case of disconnection of the battery the timer has to be reprogrammed. To indicate the loss of the programming, on the display appears CLC for 0,5 every 1,5. It does not have any influence on emergency functioning; it is only a call-up for the re-programming of the timer. FLASHING HOUR LED Indicates maintenance requirement when programmed hours are up. HOW TO PROCEED IF THE GENERATOR SHOULD FAIL TO WORK A possible alarm status will be shown on the display. Whatever the anomaly, the cause is to be found first and foremost then press the RESET push button twice. The causes and the solutions differ depending on the type of anomaly involved: 1. Flashing led 7: electrical anomalies due to min./max. voltage and frequency. If the anomaly should persist after the RESET push button has been pressed then request technical assistance; 2. Led .8: anomaly due to low oil pressure,(b) high motor temperature,(c) low water or oil level,(d) fuel reserve.(e) Check the relative levels (water, oil, fuel) and top-up if necessary then reset; 3. Led .8: anomaly of the battery dynamo. (a) In this case request technical assistance; 4. Led .8: alarm(f) due to local or remote emergency stop status. Set the programming switch on LOCKED mode, turn and pull the emergency push button enabled then reset; 5. Led .8: alarm due to failed starting,(h) try starting with manual control and inform the supplier;
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6.
Led 13: The generator overload protection switch has tripped. It is to be reset manually by a qualified engineer (see maintenance section).
1.5 MAINTENANCE
SECURITY PROCEDURES FOR THE USER
WARNING
It is strictly prohibited for anyone to touch powered parts.
1.5.1 ELECTRICAL MAINTENANCE Skilled personnel must perform all jobs. The control unit is equipped externally with all the possible command, control and reset functions. Proceed as follows to access the equipment within the control panel: 1. Set the programming switch on LOCKED mode. 2. Check if the unit has stopped completely. 3. Disconnect the mains line that powers the control panel and switch the main switch ON/OFF of the mains off. 4. Check if the mains has been effectively disconnected, which can be seen by the mains OK LED switched off and by the display switched to the mains that must indicate zero. 1. Open the control panel and check for any anomalies in the: Fuses; Automatic switches; Thermal relays. Once maintenance has been completed repeat the procedure in reverse order to reset the unit. MECHANICAL MAINTENANCE 1.5.2 If the generator should fail to start due to an anomaly in the fuel circuit and also in an emergency status, the following tips may prove useful. How restore the fuel circuit: 1. Set the programming switch on Manual Start mode without starting the generator. In this way the 15/54 that powers the fuel interception solenoid valve is activated. 2. Once you have filled up with fuel, operate the hand pump situated on the motor until the circuit is restored, which can be seen by the pump becoming harder to move. 3. Start in manual mode (It is advisable to restrict the starting attempts to 10 seconds each with a pause of 15 seconds in-between to allow the battery to recover efficiently). Once the unit has started and is running regularly reset the automatic functions. 1.5.3 PERIODIC CHECKS To keep the unit efficient some periodic checks must be made together with those scheduled by the manufacturer of the motor and by the installation engineer:
1.
2. 3. 4.
Check the electrolytic level of the battery every 15 days following installation and request the assistance of an engineer if an excessive consumption is noticed. Following the initial period check every 90 days; In generators complete with motor pre-heating system check if the motor is warm each time a check is made otherwise request technical assistance. (WARNING: a cold motor at low temperatures could have difficulty in starting or outputting once started); If the generator is rarely triggered due to the lack of mains power supply execute an automatic test for at least 2 minutes. If new electrical machines are installed in the system powered by the generator, request technical assistance to check the suitability of the CG/CG mains/generator switching to the new load.
SUMMERY On a periodic basis check the electrolytic level of the clear batteries. Touch the motor to feel if it is warm (if equipped with pre-heating system) and execute an automatic test.
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2. TECHNICAL MANUAL
2.1 CONSTRUCTIONAL DESCRIPTION OF THE CONTROL PANEL
The control panel is entirely manufactured in compliance with the following European standards: ANS low voltage electrical control panels EN 60439-1 EMC electromagnetic compatibility directive 89/336/EEC Each control panel or device is completely tested and supplied with test certificate, declaration of conformity and EC marking in compliance with 626 safety standards. The control panel is manufactured in a steel sheet cabinet, 15-20/10 that is skilfully treated and painted with standard grey silicon epoxy powder, Ral 7032, and has a standard protection rating of IP 42. EXTERNAL COMPOSITION The control panel consists of the following: 1. GCM01 electronic circuit board that houses the control logic, control and reading of the operational parameters of the generator; 2. Emergency stop mushroom push button (optional); 3. Nameplate with operational standards; 4. Nameplate with safety instructions. INTERNAL COMPOSITION 1. Numbered cables placed within PVC sheathing; 2. 10 x 38 fuses with not fixed fuse boxes; 3. Battery charger transformer of adequate capacity; 4. Automatic generator protection switch (if provided); 5. Switch with tetrapolar contact makers of adequate capacity for the power of the unit, interlocked mechanically and electrically and scaled in AC1 in compliance with standard ISO DIS 8528-4; 6. Three amperometric transformers for measuring the generator and mains current; 7. Terminal for the mains and generator inputs, the utility output and any auxiliary connections; 8. Safety fuse gauges and connection terminals nameplate. Switching is controlled directly by CG and CR relays built in the MP-GCM01 module, which directly command switching via not powered contacts. IMPORTANT The CG and CR command contacts are normally closed to allow the command circuits, in the case of certain anomalies, to force the mains contact maker to close. For example by disconnecting the battery and also the power supply to the battery charger transformer the mains contact maker is forced to close. FUNCTIONING MEASURES All parameters are visualized on three displays of seven sections. All the reading pages are controlled using the < and > push buttons, which run in both directions. The reading pages available are the following: Mains voltage Generator voltage Generator frequency Generator current Hour counter Battery tension Battery charter current If an alarm is triggered it will be shown on the display. For example a low oil pressure, fuel reserve, high battery voltage alarm, etc. CONTROLS The GCM01 control panel equipped with a programming switch to select the following functions controls all operational modes: TEST It performs all the automatic functions with the exception of the switching function. It tests the efficiency of the whole system without disconnecting the mains power supply to the utility. All safety devices are enabled while the test is running. If the mains should be disconnected while the test is running the generator starts immediately. The test ends automatically when the mains power supply is restored or following a programmed external command.
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AUTOMATIC MODE Its the normal working condition. In case of mains anomaly the generator unit starts automatically after few seconds with the delivery for utility (closing CG). During running the generator is protected against all anomalies, which if encountered would cause the stop of the generator and the visualisation of the cause on the relative. When the main is restored within the normal limits after cc. 1 min. the commutation GEN(CG)/MAINS(CR) takes place and after few minutes the generator stops automatically. LOCKED STATUS It is the safety condition for simple maintenance operation on the generator. Guarantees utility supply through mains, blocks any start possibilities of the generator. If the engine is running it stops automatically. POWER SUPPLY FROM MAINS Forces the utility supply through mains, exclusion of all automatic circuits. Exclusion of automatic intervention of the generator unit
MANUAL START
Enables the push button START that starts the generator. Enables the supply of the auxiliary circuits through 15/54. START Engine start push button, for the start up cycle POWER SUPPLY FROM GENERATOR After a few seconds break, to allow the oil lubrification to all parts moving, bring the commutator of programmation to enables the power supply of the utility from the generator.
STOP
The stop push button is enabled at all times. Press it until the motor stops completely. RESET / SILENT Press ones the push button RESET to deactivate the acoustic alarm, press twice to deactivate the alarm status and bring back to use the normal functions of the electronic module. LED TEST To verify the functioning of all signal leds, select with the programming switch LOCKED ENGINE. And press +/- for 2
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COLOR LED
STATUS LED
ACOUSTIC ALARM
IMMED. STOP
STOP DELAY
Failed start Oil pressure low Level low Water temperature high Generator battery charger Alarm available Fuel reserve Hour counter (maintenance requirement) BATTERY 9 Battery present 10 Battery overvoltage (fixed thresholds) 11 Battery undervoltage (fixed thresholds) 12 Battery overload (fix threshold) GENERATOR 13 Overvoltage (59) 14 Undervoltage (27) 15 Overload (51) 16 Max frequency (81) 17 Min frequency (81) 18 Generator contactor closed (ON) 19 Generator presence MAINS 19 Mains presence 20 Overvoltage (59) 21 Undervoltage (27) dissymmetry (60) 22 Mains contactor closed VARIOUS 23 Wait/Prog 24 Acoustic alarm 25 Emergency button active Legend R = Red V = Green L = Flashing A = Acoustic alarm ON 27 = Min. voltage 5 9= Max. voltage H.What happens in case of alarm with immediate stop? Immediate opening of the generator contactor. Activation of immediate stop. Activation of acoustic alarm. Memorization of alarm cause. Recording of all parameters and signalisations. Block status up to re-establishment
1 2 3 4 5 6 7 8
R R R R R R R
F F F F F F
A A A A A A A
YES SR SR SR SR
V V V V V V V V V G G V V V G G R L
A A A A A A A A YES SR SR YES SR
A A
An alarm with a delayed stop brings about: Immediate opening of the generator contactor Activation of immediate stop. Memorization of alarm cause. Only after engines cooling phase, stop and block status up to re-establishment. In case of alarm the display will automatically show the relative page and light the relative led. Press ones the push button RESET to deactivate the acoustic alarm, pushing twice to deactivate the alarm status and re-establish the normal functions of the electronic module. I. L. M. N. When the voltage is restored within normal limits the mains re-enter delay timer (t2) is active and enables mains stabilization before sending load on it. After commutation, which has a pause of 1, the cooling phase of the engine starts cc. 20'(t4) and to which ends the stop is activated and kept for about 10 . Ready for a new cycle With mains presence the fuel reserve, water level and overload protections are operating.
LOCK STATUS A. If the generator is working the block status actives immediately its stop. B. Supply of all starting circuits is deactivated. C. Guarantees safe maintenance.
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POSITION ON BATTERY VOLTAGE 12V= MAINS SENSOR SINGLE-PHASE MOTOR PROTECTION BPO ATM POSITIVE PROGRAMMING OPERATING
POSITION OFF BATTERY VOLTAGE 24V= MAINS SENSOR THREE PHASE R-S-T 500V MAX STANDARD PROTECTION NEGATIVE STANDARD PROGRAMMING
SUPPLY CIRCUITS CC. The GCM01 is fitted with the first level safety device against excessive power supply voltages: the module is able to operate constantly up to 40V and it can also withstand transitory voltages above 250V. A second level safety device is also fitted against inverted polarity of the power supply, which prevents the circuits in which it is encountered from being powered. Any anomalies cause the F1 fuse to trip (16A) that cuts-out all the electronic circuits.
WARNING
If, after having powered the control panel the battery LED should fail to light up, check the POLARITY OF THE BATTERY before operating any commands. Possible connection errors could cause electronic anomalies in the MP01 module if commands are operated with the poles inverted.
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COMMAND RELAYS Three relays 16A command the starting, stopping and utilities 15/54. These are safeguarded by one single fuse; F1 (16A) considering that only one relay is enabled at a time. Two relays are free contact 10Aand command the contact maker of the commutation and generator (CG-CR). THREE-PHASE MAINS SENSOR To activate the three-phase sensor set up the SW1 DIP2 in OFF position.As it is not possible to work with the two types of mains sensors at the same time, please be sure, before connecting the three-phase mains sensor that the SW1 DIP2 is in OFF position. The connection of the three-phase sensor without setting the relative DIP-SWITCH in the right way could cause a wrong reading of the mains voltage, therefore the module would not work rightly. The three phase mains sensor is made with three 500 K OHM resistance dividers with high insulation voltage capable of withstanding any excessive voltages of up to 8KV for 1 second. It is sensitive to the minimum and maximum voltage on the single phase and to the phase displacement angle of the three phases. SINGLE-PHASE MAINS SENSOR To activate the single-phase mains sensor set up the SW1 DIP2 in ON position. For the single-phase mains sensor you use the output voltage on the secondary of the battery charger transformer. In this configuration the insulation is the same as in the battery charger transformer. It is sensitive to Min and Max voltage.
The precision of main's volage reading, is conditioned from the voltage droop that is had on the secondary one some transformer when the battery is in strong charging, this happens only during installation. To reduce this phenomenon the use of transformers overpowered (100-150va) is recommended
SINGLE-PHASE GENERATOR SENSOR A single-phase transformer of separation supplies the sensor. It is sensitive to Min and Max voltage. On the right side of the module are available two trimmers, (not indicated to avoid wrong use) which enable the adjustment of mains voltage and generator measures.
Volt Generatore Volt Rete
MOTOR PRE-HEATING A single-phase power supply is foreseen that is safeguarded by fuses for the motor pre-heating system. The heater on it must be fitted with built-in thermostat. If required, specific plants to pre-heating system on the motor or generator are possible. AUTOMATIC BATTERY CHARGER The automatic battery charger is the double semi-wave type with phase choker, totally controlled by the micro-controller. It keeps the starting battery charged with a max. Load of 5A and the charge is self-adjusted to compensate for consumption and for when the battery automatically runs flat. The voltage of the battery and the charging current can be displayed on the GCM01 unit. The electronics are built in the GCM01 unit whereas the battery charger transformer is fitted externally. It is equipped with: Automatic cut-out of the charge during the starting phase; Electronic restriction of the current to prevent excessive loads; Electronic restriction of the voltage to limit the maximum load levels (2,3 V/E) 13,5/27V. Protection against short-circuits. Protection against inverted polarity. Protection against excessive input voltage. Protection with low battery voltage for an excessive discharge POSITIVE MOTOR PROTECTION INPUTS Some modern motors are equipped with positive outputs to indicate the Low Oil Pressure and High Motor Temperature anomalies. The GCM01 is pre-arranged to communicate with these motors by modifying the SW1-3 from OFF to ON. MOTOR STARTED READING This requires no external signal. The control is achieved on two parameters, the first and most important one is the voltage, delivered by the three-phase generator produced only with the presence of the remaining magnetism of the generator. The first signal of STARTED MOTOR is given, when during the start cycle are reached 400/500 rpm, with a voltage between 7 and 8 Volt. If due to an anomaly the generator is not powered the starting phase is stopped once and for all by the second safety control established when the oil is pressured, which triggers a delay of 3 seconds that stops the starting phase. EMERGENCY Pre-arrangement for the external emergency command enabled in all operational modes with immediate stoppage of the motor, opening of the generator contact maker and triggering of the alarm. The emergency device not only controls the control software of the circuit board but is also equipped with an electromechanical circuit that totally ensures the stoppage of the unit and the opening of the generator contact maker. WARNING The command is double; the NO contact of the emergency push button is required to ensure the immediate opening of the generator contact maker even in the case of an anomaly in the electronics. In fact to ensure the
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emergency power supply even in extreme cases the contact that commands the mains and generator contact makers (CG-CR) is normally closed (NC), therefore if the contact maker is to be opened, the command relay must be powered.
AC
AC
HOUR COUNTER AND MAINTENANCE REQUIREMENT(t14) From 0 to 9999, after the first 999 hours the visualisation changes in 100 :which means 1000 hours and the recording happens every 10 hours. Anyway minutes and seconds are memorized (for example: 1250 = 1.25). Its forseen the hours reprogrammation in t39 When the relative led is flashing and the acoustic alarm is on, the intervention hours for maintenance (programmed in t14) are up. Do not program when the function RES of two horizontally pivoted Gen-sets is active.
GC-M01
-B
+B
Functioning in manual mode: selecting MANUAL START you have only one glow plug signal. In the case more cycles are required it is necessary go back to MAN MAINS. MOTOR STARTER STR (for petrol motor) In this case at the same time of any start, the output will be enabled for the programmed time in t06. For the programming put T07 in STR and the starter time in T06. This function is independent from T01 START but blocked by MOTOR RUNNING. When the START fails, STARTER cuts off; when the START is successful the STARTER goes on, up to the end of cycle (even in manual mode).
T06
CRANK.
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GAS ELECTROVALVE At the start command, the gas electrovalve opens after the setted time in t06 and the start proceeds for the time in t01. Enables to eliminate the unburnt mixture before every starting. In stoppage phase is enabled first the gas electrovalve and then the start advices. Programming t07 = GAS t06 = 0-20 motor prewashing time.
COMMAND STOP EV GAS CRANK 15/54 T06 MOTOR CRANK MOTOR RUN STOP T06+1 T04
T06+t01
The timing is just an electronic command in automatic mode. RESET Rst In remote controlled plants its necessary to have a command that re-establishes the circuits or closes the switches. The output 11 is active for the time programmed in t06 Programming t07 = RST t06 = 0-20 output time active. ANTITHEFT DEVICE Only for GCM01 with serial output RS232C. Only in remote controlled plants installed. In case of disconnection of the generator the alarm status is given by remote control with GSM or MODEM. The conditions are memorized in the alarm report. FUNCTIONING With the circuit cut above the generator in relation to the relay R1 of 30A that insulates the battery wiring, and the cable 14 which enables the antitheft device, the module GCM01 is anyway supplied by battery2 which supplies the remote control system Functioning Programming T40 = fur With T40 = at the input 14 FREE remains available for normal alarms.
GEN SET
GC-M01 21 20 14
R1
BATT 2 2Ah
+ BATT 1 -
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CONN 7- 8 8 8 7 7
FUNCTION EJP FRANCE SCR forced starting with output. RES two GE alternated (One in reserve to the other) BLC forced lock TST test running
PROG 2 T12
CONF 2 0 28
1
T34 0 255 Hours
EJP1 SCR RES
RES FUNCTION FOR TWO GENERATORS THAT RUN ALTERNATELY By configuring input 8 for the RES function, used in plants composed by two generators one in reserve to the other. Two applications are foreseen: 1. Two gen-sets one in reserve to the other and in stand-by to mains; 2. Two gen-sets one in reserve to the other, as production central without mains. The EJP and SCR are disabled 1 STAND-BY TO MAINS In case of mains anomaly, the pilot generator replaces the mains. If there would be an anomaly during the functioning or if the start attempt fails, the reserve generator is activated and reached the speed it will supply the users. Programming t11=Res t34=255 ore
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2 CENTRAL STATION WITH TWO GEN-SETS ONE IN RESERVE TO THE OTHER The pilot generator GE starts after the disconnection of the lock command (BLC input 7). The running time is adjusted in t34. When the time in t34 is expired, the reserve generator starts and when it reaches the speed it sends a signal to the pilot GE that stops the power output and switches to the reserve GE with a power interruption to the users of 1. At the end of time t34 of the reserve GE the pilot generator is called with the same procedure. If there would be an anomaly during the functioning of the generator the other one will start automatically. Programming t11 = RES, t34 = 1-255 working hours, t13 = BLC To establish the PILOT generator put the programming switch in a position different from AUT (test or lock) for 3 and then switch it back (AUT). The FAILED START led begins flash to indicate that the PILOT generator and with fix light it indicates failed start. It is possible to use the internal timer to program the automatic intervention of the power station composed by to gensets. Programming the lock function with the internal timer it is possible to lock each generator for the programmed time. Given that in case of disconnection of the module GCM01 the timer loses the programming, it is advisable to supply the plant (of two gen-sets) with two diods D1 and D2 of 40 A. If you do not use the internal timer the diods are not necessary. This circuit with diods on the battery is suitable only for plants without battery supplied by mains. WIRING DIAGRAM
GCM01 1 21 8 7 21
GCM01 2 8 7
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T33 = Establishes the starting time of the generator, programmable from 0 to 23,50 hours AUTOMATIC LOCK: Enables to program time and days of the lock device, active even with mains failure. Select t29 to program the day, then chose tot for the total lock and par for the partial lock. With par you enable the lock start time in t30 and the lock stop time in t31. After d7 (Sunday) you will find the function BLC, press ENTER for the option between ON to enable the lock function or OFF to disable the lock function. Programming
= = = = = par = = = = = =
7 days the week divided in total lock tot or partial lock par, enabled by BLC ON - OFF Monday Tuesday tot = total day lock = partial lock, t30 and t31 enabled. t30 enables lock start t31 disables lock end ON enables the lock function OFF disables the lock function 0 23,5 hours and tens to set the lock start in the selected days (t29) 0 23,5 hours and tens to set the lock stop in the selected days (t29)
When the internal timer locks the generator, on the display appears BLC. To using the generator in lock mode, use the manual commands. The lock (Input 7) can be managed manually through a switch or an external timer.
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ALARM REPORT
Memorizes all parameters (measures and alarms) at the moment of a failure, and enables to visualize the last 5 alarms. It is active only with the programming switch in lock position.
To visualize the alarm report press at the same time +/- and enter with ENTER and for 8, St1 appears, select the report from St1 to St5 with
The following measures are memorized at the moment of the alarm: 1. Mains voltage; 2. Generator voltage; 3. Generator frequency; 4. Current; 5. Working hours; 6. Battery voltage; 7. Start attempts; 8. Oil pressure low; 9. Engine temperature high; 10. Fuel reserve; 11. Water level; 12. Alarm 1 or theft; 13. Emergency; 14. Overload; 15. Failed start Selecting the measures, after the I bat led, you pass to led for failed start. The number of start attempts is displayed. ST1-2-3-4-5 the active reports are active Selected the report press and select with +/- to change report. To go back to menu switch back to AUT the programming switch.
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3. PROGRAMMING
3.1. SETTINGS
The programming defines the kind of functioning that can be normal or articulated on need. To simplify the use GCM is given with a standard configuration for a Disel generator group in emergency to the mains. To reach the function programming, bring the switch N 4 in ON position. All displayed measures can be modified. (Ex: 380V into 395 or 378 or in other values) The first displayed setting field is (t00). To enter press located on the frontal of the module; by entering in the field the display shows the actual setting. To increase or decrease the adjusted value use + and -.
To confirm the chosen value and pass to the following field press move on through the fields use
The following features are the minimum for the management of a stand-by generating set. The fields in written round brackets are related fields to the same function.
DESCRIPTION Number of starting attempts This establishes how many starting attempts the failed start function is to be enabled. Starting time and pause This establishes the duration time of the starting and pausing between one starting and another. Mains enabling delay When the mains return within the established limits following the set time, the output is switched from generator to mains. Generator enabling delay The load output is enabled following a set time that is triggered by the motor started signal (minimum 5 sec.) Stopping delay. This establishes the timing required between GE/MAINS switching and stopping to enable the motor to cool down. Starting delay This gives a pre-alarm for the starting procedure and makes the generator insensitive. Glow plug pre-heating time This is the time setting of the sparkplug pre-heating prior to starting.
T00
T01
T02
T03
T04
T05
T06
EJP Delay This is the starting delay (the relative input has to be programmed with the EJP function) Overload delay T28 When the threshold t27 is overload, the led wait starts flashing and at the end of the (T27) time in t28 intervenes the overload alarm.
T12
120
30-255
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T14
T15 T16
T15
+ 10% Vn
440 V
VALUE
FIELD CND o STR GAS 50 60 Hz 110 220 230 260 380 400 440 460 Volts 25405060 100 150 200 250 400 500 600 1000/5
T07
STR
T08
50 Hz
T09
400 Volts
T10
100/5
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T11
Function selection EJP, SCR or RES. This are the functions of the input EJP SCR or RES (input 7). Function selection BLC or TST. Establishes the function of BLC or AVV. (Input 8). Alarm or antitheft device This establishes the function of the available (connection 14 free) alarm
SCR
T13
BLC
BLC TST
T40
All
Fur
DESCRIPTION
Gen-set frequency reading regulation Enables a fine regulation of the visualization of the gen-set frequency on the display. This allows correcting the differences between the real frequency and the displayed frequency. Mains voltage reading regulation Enables a fine regulation of the visualization of mains voltage on the display. This allows correcting the differences between the real mains voltage and the displayed voltage. Gen-set current reading regulation Enables a fine regulation of the visualization of gen-set current on the display. This allows correcting the differences between the real current and the displayed current. Gen-set voltage reading regulation Enables a fine regulation of the visualization of gen-set voltage on the display. This allows correcting the differences between the real voltage and the displayed value. Battery voltage reading regulation Enables a fine regulation of the visualization of battery voltage on the display. This allows correcting the differences between the real voltage and the displayed value. Battery current reading regulation Enables a fine regulation of the visualization of battery current on the display. This allows correcting the differences between the real current and the displayed value.
VALUE
DESCRIPTION
VALUE
OFF 20 7 OFF 8,0 4 0,0-23,5 hours 1-255 hours 0-59 sec. 0-59 mnt 0-23 hours 1-7 day 0-9999 HOURS PAGE 0,0-23,5 hours 0,0-23,5 hours
LOCK days selection It selects the day of the week and establishes if the lock is overall or partial for the single day. It establishes if the functions lock is ON or OFF. LOCK beginning time T30(T29 It establishes the lock beginning time in hours and a dozen minutes, for all the partial programming -T31) days in t29. LOCK stopping time T31(t29It establishes the lock stopping time in hours and a dozen minutes, for all the partial programming t30) days in t29. Automatic test test days selection T32(t33) It selects the test day on 4 weeks and starts or stops OFF all the functions of automatic test.
T33(t32) It establishes the beginning time test in hours and a dozen minutes, for all the partial programming T34 T35 T36 T37 T38 T39
days in t29. Working hours of alternated gen-sets It establishes the working hours of alternated gen-sets with a stand-by group. At the end of the time is asked the attendance of the stand-by group. When this is on speed the load is transferred to clock seconds clock minutes clock hours clock days of the week Its a weekly clock, for the correct functioning it must be programmed the day of the week at the moment of the programmation REPROGRAMMING TOTAL HOURS It permits the reprogramming of the total hours
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GC-M01
SW1 SELECTIONS
1: ON 12Vdc 2. ON SINGLE-PHASE 3: ON 15- 16 POSITIVE INPUT 4: ON PROGRAM MODE
OIL
STARTER - PREHEATING
16A
16A
EMERGENCY
16A
Vac CR
18/27Vac
Vac
TEST - EJP LOCK
OVERLOAD
D-
FUEL RESERVE
CT
STOP NO
ALARM
..../5A
CG
START
STOP NC
LEVEL
FREE
1 2 3 4
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
28 29
ON OFF
CONNECTION ON THE LOWER PART There are 29 terminal boards on extractable connector with two-way receptacle with a capacity of 16A and cross section 2,5 mm2. The wiring diagram of the strip board, the same as on the carter, follows the succeeding numeration:
N terminal
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
DESCRIPTION
Command CG (contact NC 10A) Command CG (contact NC 10A) Gen-set voltage sensor input 0-260V 60HZ (Gen-set neutral) Gen-set voltage sensor input 0-260V 60HZ (Gen-set phase) Battery charger input 0-16-29V 5A Battery charger input 0-16-20V 5 A Functions input LOCK/TEST/EJP2 (programmable) Functions input EJP / SCR / RES (programmable) Input TA / 5 A (phase X) Input TA / 5 A (common) Output PREHEATER OR STARTER Alarm output 100 mA max. Input fuel reserve Alarm Input available Alarm Input oil pressure low Alarm Input water temperature high Alarm Input overcharge Alarm Input water level Alarm Input Emergency Module power supply 0-32V 16 A (-Batt) Module power supply 0-32V 30 A (+Batt) Output start command +B 30 A max Output stop command +B 30 A max Output auxiliary devices command (15/54) +B 30 A max Input battery charger generator 0-32V Input gen-set contact maker signal ON Input mains contact maker signal ON Command CR (contact NC 10A) Command CR (contact NC 10A)
INPUT OUTPUT
O O I I I I I I I I O O I I I I I I I I I O O O I I I O O
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30
-B +B
CR
CG CR
D+
31
CG
32
Vac
PROGRAM CONNECTOR
3.7.2 CONNECTION ON THE SIDE There are 3 terminal boards on extractable connector with two-way receptacle with a capacity of 16A; cross-section 2,5 mm2. These three terminals are the inputs of the three-phase mains sensor.
N TERMINAL
30 31 32
DESCRIPTION
Phase input R 0-500V, strength 500 K between phase and neutral Phase input S 0-500V, strength 500 K between phase and neutral Phase input T 0-500V, strength 500 K between phase and neutral
INPUT / OUTPUT
I I I
On the higher part, is foreseen the output of the connector 9 poles of serial interfacing RS232.
SINGLE-PHASE MAINS SENSOR ( prearranged survey from the battery charge trans.) 100/350V c.a. (second d TCB)
The technical characteristics are subject to modifications without notice following technical improvements.
FUNCTIONS 27 59 60 81 50 51 Min voltage Max voltage Dissymmetry Protection for min/max frequency Instant current or short-circuit Max current with programmable delay
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Vac
Vac
CT
P1 P2 S1 S2
R S T
MAINS
BCT
18/27 Vac
CG CR
CR
.../5A
OVERLOAD
-BATTERY IG CG CR
CG
28
29
10
30
31
32
17
26
27
SERIAL CONNECTOR
BATTERY
CHARGER
RR
RG
GENERATOR CONTACTOR MAINS CONTACTOR MAINS RELAY GENERATOR RELAY GENERATOR CIRCUIT BREAKER ELECTROVALVE EMERGENCY PUSH BUTTON BATTERY CHARGER TRANSFORMER
RTS
GEN. VOLTAGE
CURRENT MEASURES
THREE-PHASE SENSOR
+BATTERY
16A DYN
16A
16A 15/54
EMG STOP
21
20
25
22
START
23
STOP
24
11
PREHEATING - STARTER
12
ALARM
13
FUEL RESERVE
14
FREE
15
LOW OIL PRESSURE
16
HIGH ENGINE TEMP.
18
WATER LEVEL
19
EMERGENCY
7
EJP2 - BLOCK - TEST
8
PRODUCTION - EJP1 - STAND BY GEN SET UNIT
F G D+ BATTERY
-B
R RA RS EV
S
P T
FR
STOP
MOTOR GROUND
OIL
117
105
2 0 0
26
26 4 HOLES 4 mm
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RS232C
GCM-01
4. INSTALLATION
4.1. POSITIONING
The control panel must have a protection rating (IP) suitable for the area in which it will be installed: IP 42 (normal supply) for closed areas; IP 55 in the case of possible splashing of water or for control panels exposed to rain.
WARNING!!! It is advisable not to install the control panel further away than 20 meters form the generator.
QGE
CONTROL PANEL
GENERATING SET
MAX 20mt
This requirement is due to the excessive currents caused by lightening that hits the public mains causing the voltage inside the control panel to rise excessively if the connection line exceeds 20 meters.
If there is no other choice than installing the control panel further away than 20 meters, our engineering department can provide you with various technical solutions.
WARNING!!
To ensure the reliability of the system all of its components must be connected to earth Daily gas oil tank
QGE
FUEL TANK
GENERATING SET
EARTH
OTHER COMPONENTS
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For further information contact a reliable installation engineer or our engineering department.
4.3. STARTING
It is advisable for the start command to install a servo-relay above the motor, so as to avoid that frequent voltage drops can prevent the starting. Even with few wiring meters between panel board and generator.
START
3
16A max
R
50 STARTING MOTOR - BATTERY
RELAY 30A
Fig.: 3
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4.4. STOPPING
The GCM01 module is arranged to command any stopping system. Stoppage with ELECTROVALVE normally energised while the generator is running and while the utilities of the unit are powered. Connection 7 is defined 15/54; it emits the +B with a maximum current of 16A as the GE starting is commanded to stop when the stoppage command is received.
15-54
16A max
10
OTHER MOTOR UTILITIES
EV
4
16A max
R EM
- BATT.
RELAY 30A
INJECTION PUMP
Operation: with the stopping command the electromagnet is energised and stops the motor. To establish the stoppage of the motor the closure of the oil pressure switch is controlled, which after 20 seconds from when it closed automatically disables the electromagnet thus avoiding settings and adjustments.
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VDO VDO
WATER AIR
Fig. 5
THERMOSTAT
PRESSURE SWITCH
FUEL LEVEL
P T NA NC NC - BATTERY
THE PARAMETERS INDICATED ARE NOT BINDING BUT SUBJECT TO TECHNICAL IMPROVEMENTS WITHOUT PRIOR NOTICE.
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5. SERVICE PROCEDURES
5.1. SERVICING PROCEDURES
Before proceeding with the functional test:
1. 2. Isolate all fuses Check the connection of the oil pressure switch. If the connection to earth is not present (-B) by means of the oil pressure switch the motor will not start. Once installation is complete, check its correctness by performing the procedures advised below: 1. 2. 3. 4. Connect the fuses 1 and 2 Set the programming switch on ENABLE STARTING The leds oil pressure low and battery charger generator are operative, thats because the motor is not running yet, but the utility supply 15/54 is active. Once the alarms have been checked (in the case of anomalies see the input/output section) briefly press the START push buttons and then the STOP push button and check if the motor stops (there is no need to start the generator). Check if the fuel reserve, low oil pressure and high motor temperature probes match the indications respectively by disconnecting the wire on these and by temporarily connecting it to earth and checking the exactness of the indication on the control panel display. Visually check the power connections between generator and control panel as the board detects the motor started status via the voltage of the generator and if it is impossible to detect the voltage (as the power connection is missing or a knife switch along the line is open) the starting motor will continue to run with the motor started for three seconds. With the programming switch on ENABLE STARTING press the start push button until the motor starts. Wait 20/30 seconds and switch to POWER SUPPLY FROM GENERATOR. Check the rotation direction of the motors in use (invert two phases if incorrect). Set the programming switch back to Enable Starting, the CG contact maker will open and the load will be disconnected. Command manual stoppage. Close the remaining fuses. Set the programming switch on POWER SUPPLY FROM MAINS. After at least 15/20 seconds power the control panel with the mains and check the rotation direction of the motors in use again (invert two phases if incorrect). Set the programming switch in AUTOMATIC mode; check, if by disconnecting the mains, all the starting functions are enabled, power output and generator protection. When the mains restored there will be a delay before the lines are switched then a further delay to allow the motor to cool down.
5.
6.
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WARNING considering that the battery charger generators output a voltage of between 50 and 150
Volts when disconnected from the battery while the generator is running, which is very destructive for the electronics, the connections must strictly not be touched while the generator is running or the loose cables.
The settings of the type of test TA, the overload and short-circuit current are crucial. Re-connect all fuses and check the efficiency.
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6. MAINTENANCE
The control panel has been designed to operate without the need for maintenance. The following is to be kept under control nevertheless: Every 30-60 days check the electrolytic level of the battery. Every 30 days check the water, oil and fuel levels Every 30 days check the motor pre-heating temperature (if installed) Every 30 days run the unit automatic test Every 6 months check the battery efficiency
WARNING!
The control panel is powered by the mains and by the generator. Before accessing it for maintenance purposes disconnect the mains and stop the generator by setting the programming switch on LOCKED
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Nothing is working
Failed stoppage
Attempt to start
Failed starting
PROBABLE CAUSE
Flat battery Flat battery Battery with inverted polarity
SOLUTION
Fuse 8 4A of battery charger Battery charger Check and invert cables
The pinion fails to engage in the crown wheel No connection with oil pressure switch
Replace pinion or whole starting motor Connect and check the connection to earth of the pressure switch. Calibrate the electronic revs. regulator. Fill up with fuel or disconnect level device Replace the voltage regulator. Replace pressure switch. Replace thermostat Replace 10x38 fuse with identical fuse Replace coil Request assistance Replace fuse with identical fuse Replace coil Replace 10x38 fuses with identical fuse Check earthing of generator control panel and accessories Clean from dirt, lubricate or replace Turn and pull up to release push button Repair or replace pre-heating system
Excessive speed upon starting Immediate alarm due to fuel reserve Immediate alarm due to excessive voltage Low oil pressure High motor temperature Fuse2 blown Remote switch coil burnt No voltage output by generator Fuse4 blown Remote switch coil burnt Fuses 3 and 5 blown Not earth reference on mains sensor
Defect in stopping system Emergency stop push button pressed Motor too cold
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