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Doc #SED-MAN-GC2599-002
GC2599
CONTROLLER
S
Product Manual Revision # 1.00
Copyright
All rights reserved. No part of this publication may be reproduced, distributed or transmitted
by any means (including photocopying or storing in any medium by electronic means or other)
without the prior written permission of the copyright holder. Any reference to trademarked
product names used within this publication is owned by their respective companies.
SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document
without prior notice. For permission requests and applications to reproduce any part of this
publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
Web Support:
Email: support@sedemac.com
Website: www.sedemac.com
Telephonic Support:
+91-20-67313500
+91-8551039888
+91-8551041888
+91-8551043888
SEDEMACTM
Safety Instructions
General Instructions
This document includes important instructions that should be followed during installation and mainte-
nance of the Generator Set controller.
For safety reasons, the manufacturer recommends that this equipment be installed and serviced by
an Authorized Service personnel. Follow all applicable state and local electrical codes.
Efficient and safe operation of the controller can be acquired only if the equipment is correctly oper-
ated and maintained. Many accidents arise due to ignorance or illiteracy towards the elemental rules
of safety and precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions to
the operator, service personnel or the equipment.
Electrical safety
Electric shock can cause severe personal injury or death.
Ensure the generator set must be grounded before performing any installation or service.
Generators produce high electrical voltages direct contact with it can cause fatal electrical shock. Pre-
vent contact with terminals, bare wires, connections, etc., while the generator and related equipment
are running. Do not tamper with interlocks.
To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wir-
ings must be appropriate to which they will be subjected to.
In operation safety
Before installing Genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generators battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or () first. Re-
connect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical
shock.
Remove electric power supply before removing controller or touching other electrical parts.
Use extreme caution when working on electrical components. High voltage can cause injury or death.
Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near Generator set or other electrical equipment.
Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
This document is controlled when it is printed.
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Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. IT MAY RESULT IN SEVERE ELECTRICAL SHOCK.
Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the
live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
This list contains the list of acronyms used in this document and it can be used to refer their
respective description. This List Does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
BTS Base Transceiver Station
CHG Charging
CKT Circuit
CT Ratio Current Transformer Ratio
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
NC Normally Closed
NO Normally Open
OV Over Voltage
PFC Potential Free Contacts
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
SMPS Switched Mode Power Supply
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
Introduction ....................................................................................................................... 11
Key Highlights of the Product ........................................................................................ 11
Product Features .......................................................................................................... 11
Specifications ................................................................................................................... 13
Terminals ...................................................................................................................... 13
Power Supply ................................................................................................................ 13
Inputs ................................................................................................................................. 14
Generator Voltages and Frequency Measurements...................................................... 14
Generator Current Measurement .................................................................................. 14
Earth leak Measurement ............................................................................................... 14
Mains Voltage and Frequency Measurements .............................................................. 15
Digital Inputs ................................................................................................................. 15
Analog Resistive Sensor Inputs .................................................................................... 16
Magnetic Pick Up Input ................................................................................................. 16
Analog Current/Voltage Input ........................................................................................ 17
Charge Fail ................................................................................................................... 17
BTS Battery Input ...................................................................................................... 17
Sensor Common Point............................................................................................... 17
Outputs .............................................................................................................................. 18
Digital Outputs .............................................................................................................. 18
Actuator Outputs ........................................................................................................... 18
PFC Outputs ................................................................................................................. 19
Communication Ports.................................................................................................... 19
Installation ......................................................................................................................... 20
Dimensions ................................................................................................................... 20
Mounting on Panel ........................................................................................................ 21
Terminal Pin Details ...................................................................................................... 21
Typical Wiring Diagram ................................................................................................. 24
Monitoring Mode ............................................................................................................... 25
Description of Control Keys ............................................................................................ 29
Functions of Control Keys ............................................................................................. 30
Configuration Mode....................................................................................................... 30
Configurable Parameters .............................................................................................. 31
Modes selection in GC2599 ............................................................................................. 49
Start and Stop Sequence .............................................................................................. 50
Operation Modes............................................................................................................... 52
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
This document is controlled when it is printed.
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Auto Mode .................................................................................................................... 52
Manual Mode ................................................................................................................ 58
Load Sensing .................................................................................................................... 62
Features ............................................................................................................................. 63
Deep Sleep Mode ...................................................................................................... 63
Auto Config Exit Mode ............................................................................................... 63
Load Histogram ......................................................................................................... 63
Alarms................................................................................................................................ 64
Troubleshooting ................................................................................................................ 67
Communication Protocol ................................................................................................. 69
Connection Details..................................................................................................... 69
Precautions................................................................................................................ 70
Supported Functions.................................................................................................. 70
Communication Settings .................................................................................................. 71
Product Features
GC2599 is a very enhanced and feature rich genset controller. It has 9 digital inputs and 7 analog
inputs. Full features list is provided in below Table 1.
Table 1: Feature list
Features Spec / Remark
Digital Switch Input 9
Analog Resistive Inputs 5
Analog Current/Voltage Inputs 2
E-gov actuator output Y
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
This document is controlled when it is printed.
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Features Spec / Remark
Differential input (60V DC) for BTS battery voltage Y
Mains V-Input (AMF) Y
DG Alt V-Input, D+ CHG ALT I/O Y
Digital HSD 7
Event logs Y
USB port for PC based configuration Y
RS-485 for MODBUS communication Y
Operating Battery Supply Voltage (with -32V reverse protection) 8 to 32V DC
Operating Temperature Range (deg C) -20 to 65
Ingress Protection with Optional Gasket IP65
Sensor common Input with 2V Sensing Range Y
Warning auto clear enable/disable Y
Fuel reference selection input Y
For 1 phase application, it is mandatory to connect the mains phase and neutral
Cables to the genset controller's phase R and Neutral terminals respectively.
Digital Inputs
Following table gives a brief overview of digital inputs
Table 8: Digital inputs
GCU connector terminal # 33, 34, 35, 36, 37, 38, 39, 40, 41
Number of inputs 9
Type Negative sensing (connect to ground for activation)
0.8 V-DC maximum (measured at the genset
Low level threshold
controllers terminals and battery ground terminal)
8 V-DC minimum (measured at the genset
High level threshold
controllers terminals and battery ground terminal)
Emergency stop, Remote start/ stop, etc. Please
Software configurable options
refer Table 22 for more details.
The MPU (Magnetic Pick-Up) is an inductive sensor fitted on the engine flywheel for the engine speed
sensing. The output of MPU is a sine wave signal.
For genset paralleling application, configure input Aux4 (Pin 23) to accept a 0-5 V-DC speed bias
signal generated by a LSM (Load Sharing Module)
Charge Fail
Table 12: Charge fail
GCU connector terminal # 10
Voltage range 0 to VBATT ; VBATT = 8 to 30 V-DC
Excitation PWM (Current limited to 250mA)
Accuracy 2% of full scale
*The charge fail is a combined input and output terminal. When the genset starts, the terminal provides
the excitation current to the charge alternator field winding. After the excitation is successfully done, the
controller reads the charging alternator's output voltage for monitoring its health. The action for charge
fail is configurable.
BTS Battery Input
Following table gives a brief overview of BTS Battery input
Table 13: BTS battery input
GCU connector terminal # 24, 25
Number of inputs 2
Type Differential
Range 60V
Resolution 0.1V
Accuracy 1% of full scale (0 to +Ve max/ 0 to -Ve max)
Actuator Outputs
Table 15: Actuator outputs
GCU connector terminal # 17, 18, 19, 20
Type Stepper motor drive
Maximum current 1A each coil
Figure 4: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side)
The Actuator outputs are used only for the SEDEMAC's Actuator, if installed. The SEDEMAC's
Actuator is a 4-wire Actuator that is used for creating an electronic governing application in case of
a mechanical fuel system engine. In diesel engines, the Rotary Actuator's shaft output gets
mechanically connected to the stop lever or the throttle lever of an in-line or rotary fuel injection
pump. In case of petrol or natural gas engines, the Rotary Actuator's shaft output gets connected
to the throttle/charge control valve.
Communication Ports
Table 17: Communication ports
USB 2.0 Type B used for connection to PC running
USB
SEDEMAC Smart config.
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
RS485 Serial Port Termination resistor of 120 is provided between
output pin A & B
Common-mode operating range
Maximum distance of line is 1200m
GCU connector terminal # 30, 31, 32 (GND, A, B respectively)
Baud rate used is 250 kbps
CAN Packet size used is 8 bytes
Termination resistor of 120 is provided
Controller's terminal number for CAN 58, 59
The RS485 port on GC2599 genset controller supports a protocol based on MODBUS.
Insert the fixing clip into the slot provided on the side of the controller.
Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is
properly fitted inside the slot provided on the controller.
Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the
panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum
tightening torque is 0.19 N-m.
Figure 8: Power circuit when used in the Auto Mains Failure Mode
(The Y and B phase will be visible only if con- (The Y and B phase will be visible only if config-
figured for 3 phase genset) ured for 3 phase genset)
(The Y and B phase will be visible only if (The Y and B phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
Engine screens
Engine lube oil pressure Engine fuel level
Auxiliary sensor
Alarm Histogram
1 5
2 6
7
3
4 8
Configuration Mode
To configure the controller, follow the below mentioned instructions.
To enter the configuration mode press and hold STOP key for minimum three seconds. Following
screen will be visible for entering the configuration mode.
Press start for configuration edit (write) mode & stop for configuration view (read) mode
Enter the 4-digit password with help of up & down navigation keys
Configuration Mode Authentication page
* Level 2 names in sentence case are written how they display on Smart Config GUI and names in
bracket with capital case are written how they display on controller.
Start Sequence
Once the start command is received by the controller, controller enters Start Wait State. After Start
Delay (Manual or Auto Start Delay) is over, if Preheat Output is configured then controller will enter
Preheating State. If Preheat output is not configured then controller will directly enter Crank Hold State
and will activate Start Relay output. In case of Preheat output configured, controller will enter Crank
Hold State after Preheat time is over or Preheat temperature threshold is reached. If Crank is not
disconnected and Crank Hold time is over, then controller enters Crank Rest State. In Crank Rest, also
if Crank is not disconnected and Crank Rest time is over, then controller enters Crank Hold State for
next cranking attempt. If Crank is disconnected by any means in the Crank Hold OR Crank Rest States
then controller will enter ENGINE ON state. If Maximum cranking attempts are done, then controller will
raise the Fail to Start alarm.
Once the Stop command is received, controller enters Stopping State where it starts the Stop Action
Time and activates Stop Solenoid output. If controller detects engine OFF by all the means even before
Stop action time is over, then controller will enter by skipping stop action time. Once Additional Stopping
Time is over, controller will enter ENGINE OFF State and will deactivate Stop Solenoid output. If Engine
is not detected OFF before Stop Action Time, then Fail to Stop alarm will be raised.
Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit
represents mains contactor status and second digit represents genset contactor status, whereas
0 Contactor unlatched
1 Contactor latched
In this mode if the BTS battery condition is healthy, Shelter temperature is below High Shelter Temp
threshold and mains is unhealthy, the controller keeps both the contactors (Genset and Mains) open
and waits till the BTS battery gets discharged. Once the BTS battery becomes unhealthy or Shelter
temp is detected high, the controller then gives a start command to the genset. Then Genset will Start
according to Start Sequence. When genset loading voltage and frequency are above the Minimum
Healthy thresholds, Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. Then genset will run for DG run
Duration. According to the factor which triggered DG start (BTS battery voltage Low OR Shelter Temp
High), Run duration (BTS low Run duration OR High Shelter Temp run duration) will be taken. After the
duration is over or mains becomes healthy during the DG Run duration, controller will open genset
contactor. If shelter temp run duration is over and the temp is not below Low Temp Threshold, then
genset will continue to run for the set duration. After opening genset contactor, Engine Cooling Time
starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving
Stop command.
This mode is used for running the genset for a pre-specified time for a cycle of max 12 hours each. The
time of genset to be kept ON & OFF is configurable.
Mains is being monitored in this mode. Load is on mains when mains is healthy. If mains is detected
unhealthy, controller gives a start command to the genset. Then Genset will Start according to Start
sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds,
then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking
Load Transfer Delay. Engine run hours will start incrementing if the genset is in running condition till
the stop command is received. After completion of the ON time or if mains become healthy during ON
time, controller will open the genset contactor. After opening genset contactor, Engine Cooling Time
starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving
Stop command. When genset is off, controller will start DG off time.
After completion of DG OFF time, DG ON time will start and this cycle will continue until mains is
detected healthy. During any of the times, if mains is detected healthy both the timers are reset to zero
and load will shift to mains after taking return delay. This process continues in cyclic mode.
If genset is shut down or is unable to start because of any alarm present, then after clearing alarms if
mains is unhealthy, DG ON time will be taken first followed by DG OFF time.
Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit
represents mains contactor status and second digit represents genset contactor status, whereas
0 Contactor unlatched
1 Contactor latched
The AMF mode is activated when BTS monitoring, Cyclic and exerciser modes are disabled and Mains
Monitoring is enabled.
In this mode, if the mains is healthy then the genset remains in Stop condition. If after the Mains Detect
Delay, mains is found unhealthy, then controller will issue Start command and Genset will start
according to Start Sequence. When genset loading voltage and frequency are above the Minimum
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. During genset running condition, if the
mains is found healthy, Return To Mains Delay timer starts. If mains is found unhealthy during the
Return To Mains Delay, then Genset continues to run. At the end of this delay if mains is still healthy,
then genset contactor gets opened and mains contactor gets latched after the completion of Load
Transfer Delay. After opening genset contactor, Engine Cooling Time starts. Then at the end of
Engine cooling Time, controller initiates the stopping sequence by giving Stop command.
During start sequence, if the mains voltage recovers or any stop command or shutdown / warning alarm
occurs controller will not issue start command to genset. To start the genset it is necessary to clear all
the alarms manually and put the controller in Auto mode.
The AMF mode is only valid when BTS monitoring, Cyclic and exercise modes
are disabled and Mains Monitoring is enabled.
Exercise Mode
The GC2599 allows to configure two scheduled sequences to start and stop the genset on preconfigured
time.
The Exercise will occur when the controller is in the Auto mode with no shutdown or warning alarms. The
genset will run for pre-set duration. In this mode, load transfer on mains/genset is configurable.
Scheduled sequences can be configured to repeat daily, weekly or monthly.
If the controller is in Auto mode, Exercise will run at scheduled time for pre-set duration. Controller
will exit from Exercise mode, if the pre-set duration is expired or if Stop key is pressed while
scheduled sequence is running.
If the controller is in Manual mode when the scheduled sequence begins, genset will not be started.
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
This document is controlled when it is printed.
Page 56 of 80
SEDEMACTM
If the controller is switched to Auto mode during Exercise is running, genset will start and run for
remaining scheduled duration.
The genset controller will not respond to Remote start command in Exercise mode.
In AMF mode, if the mains is unhealthy or cut off or when the genset is running in Exercise mode,
genset will first run Exercise and then genset will continues to run in AMF mode. Load will be
transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF
mode when the mains become healthy.
If both exercises are scheduled at the same time, then Start time for second exercise will be
incremented by 1 min.
The Exerciser mode is only valid when BTS monitoring and Cyclic modes are
disabled and Mains Monitoring is enabled.
Remote Start/Stop
To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote
start/stop (Latched type input) and put the controller in the Auto mode. Also disable both BTS
monitoring and Cyclic mode.
In this mode, the genset can be commanded to start and stop by activating the preconfigured Remote
start/stop input. If Remote Start command is received, then controller will issue Start command and
Genset will start according to Start Sequence. When genset loading voltage and frequency are above
the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset
contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
This document is controlled when it is printed.
Page 57 of 80
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long as the genset is in running condition till the stop command is received. When Remote Stop
command is received the controller will open the genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping
sequence by giving Stop command.
It is recommended not to enable Mains Monitoring and Remote Start/Stop configuration simultaneously.
The Remote start/stop mode is only valid when BTS monitoring, Cyclic, exerciser
modes and Mains Monitoring are disabled.
Manual Mode
Module Operation in Manual Mode
Genset contactor latching status is represented by a digit in all the states of this SMD. Whereas
0 Contactor unlatched
1 Contactor latched
If Start Key is pressed in this mode, then controller will issue Start command and Genset will start
according to Start Sequence. When genset loading voltage and frequency are above the Minimum
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched if Auto Load Transfer is enabled. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received.
When Stop key is pressed, controller will open genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping
sequence by giving Stop command. If Stop key is pressed during Engine Cooling Time, controller skips
the Cooling Time and issues the stop command immediately.
Test Mode
In manual mode (while genset is OFF) if auto key is long pressed then controller goes in Test mode.
Test mode is almost same as manual mode. Only in test mode, irrespective of auto load transfer option
enabled or disabled, Genset contactor will not get latched. If Genset contactor latching key is pressed
then only genset contactor will get latched. Once the genset starts in test mode, Test mode timer
starts. After Stop key is pressed or this timer is over, controller will send the Stop command and genset
will stop according to stop sequence.
Paralleling Mode
The GC2599 controller offers the feature of electronic governing for engines with mechanical fuel systems.
In conjunction with the external Load Sharing Module, GC2599 controller can control speed of engine
and supports genset synchronisation and paralleling feature.
The Electronic speed governing (E-governor) system is especially applicable to engines used in genset.
This system provides precise, fast-acting control of engine speed. This system can be configured in
Isochronous mode or Paralleling mode. In paralleling mode of operation, the system maintains the speed
in accordance to the speed reference signal provided by supervisory control/Load Sharing Module (LSM).
Concept
Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then
connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset
must match within prescribed limits before they can be paralleled. By considering linear relation between
speed of the engine and frequency of the alternator output, the speed must be controlled until the genset
is paralleled with the grid or other genset with the help of electronic governor. A Load Sharing Module
controls the speed and the voltage of the genset by controlling the AVR and E-governor of the genset. To
control these two devices the LSM provides the DC analog voltage signal to the both devices. The analog
voltage signal is generally in the range of 0-5 V.
Mode Description
In case of paralleling mode operation of the genset, the E-governor module present in the GC2599
controller accepts speed reference (speed bias) signal in terms of 0-5 V analog DC voltage from the
supervisory LSM (Load sharing module).
Following is the stepwise procedure for configuring the GC2599 for paralleling operation.
Select the Governing Mode as Fixed speed. Select Set Speed Selection as Speed Bias
Provide 0-5 V analog signal from the LSM to GC2599 controller at terminal no. 23, as a speed
reference signal (Refer figure 22)
Figure 23: Pictorial reference for acknowledging & clearing the alarms
In case, if engine ON is detected without any start command given to GCU, it will
allow engine to stay ON and further act according to operating mode and
configuration.
In case of MCP Panels, since the Genset & Mains contactors are not
configured, the load sensed will be treated as load on the genset only
1. Generator rating
2. CT ratio
37 High Oil Press Detected Lube oil pressure is detected above the Warning
crank disconnect threshold when the
engine is off.
38 Maintenance Due Indicates that engine running hours has Notification
exceeded the pre-set hours limit or Warning
maintenance due date has occurred and
filter servicing is required.
39 Battery Charger Fail Indicates the battery is not getting charged None
by the charger Shutdown
Warning
Electrical Trip
Notification
40 Smoke Fire Controller has detected smoke / fire None
through its digital input Shutdown
Warning
Electrical Trip
Notification
41 Aux S2 / user defined name Auxiliary sensor S2s threshold being None
crossed Warning
Electrical Trip
Shutdown
Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Table 33: Troubleshooting
Sr.
Fault Possible Causes / Remedial Actions
No.
1 The controller does not Check the battery voltage.
power ON. Check the fuse on the battery supply.
Check continuity between battery +ve and controller
terminal # 2.
Check continuity between battery ground and controller
terminal # 1.
2 The controller screen Reset the controller power.
freezes or hangs up.
3 The controller fails to crank- Check the battery voltage.
start the engine. Enter the configuration mode in controller and verify the
configuration for the START output. Also, check that
START output is working correctly by measuring its
voltage o/p.
Enter the configuration mode in controller and verify the
configuration of CRANK DISCONNECT method. Verify
the configuration of LLOP SWITCH polarity. Also, ensure
that the lube oil pressure switch & sensor are working OK.
Check their wiring.
4 The Emergency Stop Check if the Emergency Stop switch is working OK.
Format No: SED-OHA-QF-06, Rev 01
NOTE: This document is a property of SEDEMAC Mechatronics Pvt. Ltd. It shall not be communicated to or copied by anyone without the written permission of the company.
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Sr.
Fault Possible Causes / Remedial Actions
No.
alarm comes up even when Check its wiring also.
the Emergency Stop is not Enter the configuration mode in controller and verify the
pressed. configuration of EMERGENCY STOP polarity.
5 The controller generates Check the respective switch/sensor and wiring.
unnecessary Shutdown Enter the configuration mode in the controller and verify
Alarms or Warning the respective threshold configuration.
Alarms
6 The controller reports To check if the controller's charging alternator terminal is
Charging Alt Fail alarm. working or not: disconnect the charging alternator wiring to
the controller's terminal # 10. Short the terminal # 10 to the
ground through a DC ammeter. Crank-start the engine. The
DC ammeter should indicate the current in the range 200 -
400 mA for ~30 seconds. If yes, the controller's chg
alternator terminal is working OK.
Disconnect and re-connect the charging alternator ind
connection to the controller's terminal # 10.
Check if the charging alternator is working OK or not.
7 A) The controller shows Enter the configuration mode in the controller and verify
genset ON while the configuration for the LLOP and LOP. Check their wiring
genset is at rest. also.
B) Fail To Stop alarm Ensure that the mains voltage wiring is not connected by
when genset is at rest. mistake to the controller's genset voltage terminals.
8 The controller issues Ensure that the controller's o/p terminal is not directly
unnecessary crank-start connected to the starter relay. The controller's o/p should
command immediately after be given to an intermediate relay which should in-turn
power on. power the starter relay. The controller can get permanently
damaged and will need to be replaced if this precaution is
not taken.
Check start-relay connection with the suitable controller
terminal.
Enter the configuration mode in the controller and verify
the configuration for START MODE and the START
RELAY o/p polarity.
9 The engine runs, but the Check for alternator voltage signal (R phase) is received by
controller shows genset to the controller terminal.
be OFF. Check if the LOP and LLOP are working OK. Also check
their wiring to the controller.
10 The controller displays Check wiring of the respective alternator phase voltage
incorrect PF value or kW or and the CT to the controller.
load current. Check the CT ratio (if kW or current reading is faulty).
11 The controller displays Check the wiring of the respective phase to the controller.
incorrect mains voltage or
incorrect main alternator
voltage.
12 Controller displays incorrect Check respective sensor and its wiring.
reading for any of LOP, Fuel Check SCP wiring.
Level, Engine Temp Enter the configuration mode in the controller and verify
sensors. the calibration for the respective
sensor in configuration.
Possible Issues in AUTO Mode
13 The controller displays Check wiring of the main alternators R-phase and neutral
incorrect engine RPM. to the controller.
Communication Protocol
The GC2599 genset controller supports a custom protocol based on MODBUS over a RS485
layer. The GC2599 genset controller implement a custom protocol based on the standard
MODBUS protocol. It operates in a slave mode, and responds to commands received from an
external MODBUS master. The transmission mode used by GC2599 controller is MODBUS RTU
(not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits, no parity bits
and 1 stop bit, Cyclic Redundancy Check (CRC).
Connection Details
The following section describe the connection details of RS485 MODBUS to SMPS MODBUS module.
On the GCU Pin 31 is represented as A, Pin 32 is represented as B and Pin 30 is represented as
ground.
Figure 24: RS485 MODBUS connection with the help of two core shielded twisted pair cable
Precautions
Keep the slave ID of the GCU controller and the SMPS controller same, take the slave ID from
the SMPS and configure the same ID in GCU.
Enable the GCU in the configuration of the SMPS after hardware connections are made, so the
SMPS can communicate with the GCU.
Connect the Pin # 31 & 32 (A & B) of the GCU to the pin # A & B of the SMPS respectively and
not with any other pin.
Connect the ground of the RS485 MODBUS module of the controller to the ground of SMPS. If
ground of the SMPS is not present, leave the ground terminal (Pin 30) of the controller open.
Use two core shielded cable for connection.
Use different colour wires for Pin # 31 & 32 (A & B) for easy detection and connection.
Route the Pin # 31 & 32 (A & B) wires properly ensuring they do not get short with any other
wires.
Do not use multi strand wires for the connection.
Supported Functions
This genset controller operates as a MODBUS slave that responds to certain commands (or
functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate
format. Supported functions and respective command-response structure is as shown below. If the
command received from the MODBUS master is other than the three functions mentioned below,
an exception message is generated.
Table 34: Details of function codes
Function Code MODBUS Name Description
Reads one or more 16-bit from the slave device of
03 Read holding register
read/write location
Reads one or more 16-bit from the slave device of
04 Read input register
read/write location
16 Write holding register Writes one or more 16-bit registers to the slave device
No of starts 58 1 -- Unsigned
No of trips 59 1 -- Unsigned
Alarm Status
Alarm 1 71
Alarm 2 72
Alarm 3 73
Alarm 4 74
Alarm 5 75
Alarm 6 76
Reserved -- -- 1/16-4/16
Alarm 7 77
Reserved -- -- 1/16-4/16
Alarm 8 78
Alarm 9 79
Alarm 10 80
Alarm 11 81
Alarm 12 82
Alarm 13 83
Alarm 14 84 --
Alarm 15 85 --
Alarm 16 86
Alarm 17 87
Input diagnostics 88
Output Diagnostic 89
Unimplemented -- -- 9/16
Unimplemented -- -- 8/16
Unimplemented -- -- 7/16
Unimplemented -- -- 6/16
Unimplemented -- -- 5/16
Unimplemented -- -- 4/16
Unimplemented -- -- 3/16
Unimplemented -- -- 2/16
Unimplemented -- -- 1/16
Dg status 90
Notes
Manufacturing Plant
G-1, MIDC, Phase-III Chakan
Industrial Area, Nighoje
Pune 410501, India
Manufacturing Plant
Survey No. 64/5, Off Sinhagad Road
Vadgaon Budruk, Narhe
Pune 411041, India