Document: MAN-6000 Series

Data: 04/99
Part No. 276-947

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 TABLE OF CONTENTS
1. SYSTEM OVERVIEW................................................................................................................................................................................................. 1
1.1. Scope of this Document................................................................................................................................................................................... 1
1.2. General Description.......................................................................................................................................................................................... 1
1.3. Information Displays......................................................................................................................................................................................... 1
2. FUNCTIONAL DESCRIPTION 6000 SERIES CONTROL SYSTEMS........................................................................................................................ 3
2.1 System Overview............................................................................................................................................................................................. 3
2.2 Generating set Parameter Displays.................................................................................................................................................................. 3
2.3 Control Features............................................................................................................................................................................................... 3
2.4 Control Functions............................................................................................................................................................................................. 4
2.5. Protective Features.......................................................................................................................................................................................... 5
2.6 Standard Auxilliary Equipment......................................................................................................................................................................... 5
2.7 Standard Options............................................................................................................................................................................................. 5
2.8. Communications Options................................................................................................................................................................................. 6
2.9 Hardware.......................................................................................................................................................................................................... 6
3. CONFIGURATION - OUTLINE OF SETPOINTS........................................................................................................................................................ 9
3.1 Configuration Menu.......................................................................................................................................................................................... 9
3.2 Shutdowns, Alarms........................................................................................................................................................................................ 10
3.3 Engine Control................................................................................................................................................................................................ 13
3.4 Synchroscope................................................................................................................................................................................................ 13
3.5 Real Load Control........................................................................................................................................................................................... 14
3.6 Reactive Load Control.................................................................................................................................................................................... 15
3.7 Process Control.............................................................................................................................................................................................. 16
3.8 Calibration...................................................................................................................................................................................................... 16
3.9 NetComm Dropouts........................................................................................................................................................................................ 18
3.10 6100 - Single Generating set, Automatic Mains Failure.................................................................................................................................. 18
4. RUN / GENERATING SET MANUAL RUN.............................................................................................................................................................. 19
4.1 Functional Description.................................................................................................................................................................................... 19
4.2. Prime Power Variant - Normal Switch Positions............................................................................................................................................. 19
4.3. AMF Variant - Normal Switch Positions.......................................................................................................................................................... 20
5. 6300 - AUTOMATIC SYNCHRONISING OF ONE GENERATING SET WITH MAINS............................................................................................. 21
5.1 Functional Description.................................................................................................................................................................................... 21
5.2. Base Load Operation...................................................................................................................................................................................... 21
5.3. Base Load Variant - Normal Switch Positions................................................................................................................................................ 21
5.4. Peak Shaving Operation................................................................................................................................................................................. 22
5.5. Peak Shaving Variant - Normal Switch Positions........................................................................................................................................... 22
5.6. Soft Transfer Variant - Normal operation:....................................................................................................................................................... 23
5.7. Soft Transfer Variant - Normal Switch Positions............................................................................................................................................. 23
6. AUTOMATIC SYNCHRONISING OF MULTIPLE GENERATING SETS WITH MAINS............................................................................................ 24
6.1. Functional Description.................................................................................................................................................................................... 24
6.2. Base Load Operation...................................................................................................................................................................................... 24
6.3. Base Load Variant - Normal Switch Positions................................................................................................................................................ 25
6.4 Peak Shaving Operation................................................................................................................................................................................. 25
6.5 Peak Shaving Variant - Normal Switch Positions........................................................................................................................................... 25
6.6 Soft Transfer Variant - Normal operation:....................................................................................................................................................... 26
6.7 Soft Transfer Variant - Normal Switch Positions............................................................................................................................................. 26
7. ALARM / EVENT INDICATION AND LOGGING....................................................................................................................................................... 27
8. REMOTE CONTROL AND MONITORING VIA A PC:.............................................................................................................................................. 27
8.1 System Outline................................................................................................................................................................................................ 28
8.2 Functional Description..................................................................................................................................................................................... 28
8.3 Hardware Specifications.................................................................................................................................................................................. 28
8.4 Equipment Supplied With Each Option:........................................................................................................................................................... 29
9. INITIAL STARTUP AND COMMISSIONING............................................................................................................................................................. 29
9.1 Test Procedure for Single Generating set Systems......................................................................................................................................... 29
10. TROUBLESHOOTING.............................................................................................................................................................................................. 32
10.1 Control Hardware and I/O................................................................................................................................................................................ 32
10.2 Engine Control / Sensing Parameters.............................................................................................................................................................. 32
10.3 Synchronisation............................................................................................................................................................................................... 33
10.4 Breaker Close / Open Control.......................................................................................................................................................................... 33
10.5 Real Load Control............................................................................................................................................................................................ 34
10.6 Reactive Load Control..................................................................................................................................................................................... 34
10.7 Sequencing...................................................................................................................................................................................................... 35
10.8 Mains / Bus Sensing........................................................................................................................................................................................ 35
10.9 Communications.............................................................................................................................................................................................. 35
11. DEFINITION OF TERMS........................................................................................................................................................................................... 36

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1. System Overview
1.1. Scope of this Document
This document is intended for use by any suitably qualified
person wishing to obtain technical information regarding the
configuration and setup of any of FG Wilson’s range of 6000
series control systems. It may also be used reference
document for those in the Sales, Engineering and Product
Support departments within FG Wilson. The information
contained herein is sufficiently detailed as to give the reader
insight into the operating modes of the 6000 Series Control
System and is designed to replace the Woodward GCP-1
manual for any of the FG Wilson range.
1.2. General Description
The 6000 Series Control System employs the 6000 Controller
as its core in addition to some ancillary components to realise
the range of 6000 Series Control Panels offered. Depending on
the requirements of the installation, the 6000 Series Control
System may be configured to operate in one of several modes:
6100, 6200 or 6300. It may also be configured to operate in the
6400 mode in conjunction with an external master control
section.
The control panel provides a means of starting and stopping the
generating set, monitoring its operation and output, and
automatically shutting down the set in the event of a critical
condition arising such as low oil pressure or high engine coolant
temperature.
Figure 1 shows typical diagrams of the 6000 Series Control
Panel. Addition of optional equipment will add items to the panel
so the panel fitted on the generating set may be slightly different
from the one shown. The following descriptions explain the
function of each item on both the panel and controller and each
display screen menu on the panels:
1. ALARM LAMP:
Fault lamp that illuminates to indicate that the protective
circuitry has sensed a fault condition. The lamp flashes
on an ALARM condition and lights continuously on a
SHUTDOWN condition. The specific nature of the fault is
detailed in the ALARM / EVENT LOG menu on the
STATUS screen.
2. ALARM RESET:
By pressing this pad the audible alarm is reset. Specific
faults are reset by pressing the ALARM RESET pad when
in the ALARM / EVENT LOG menu on the STATUS
screen.
3. ESC: Press this pad to exit from any menu.
4. COMMIT:
Use this pad to enter any menu or amended settings
(subject to security clearance).
5. “UP PAD”:
A pad to step upwards through the menu items or to
increase numerical values of parameters (subject to
security clearance).
6. “DOWN PAD”:
A pad to step downwards through the menu items or to
decrease numerical values of parameters (subject to
security clearance).
7. “LEFT PAD”:
A pad to move cursor to the left on numerical parameters
(subject to security clearance).
8. “RIGHT PAD”:
A pad to move cursor to the right on numerical parameters
(subject to security clearance).
9. “TUNEABLE PAD”:
A pad to move cursor into the tuneable screen.
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Figure 1: Diagram of Typical Control Panels
10. “STATUS PAD”:
A pad to move cursor into the status screen.
11. VOLTS RAISE / LOWER SWITCH:
A switch to manually control the generator voltage
(optional in 6100 Mode).
12. SPEED RAISE / LOWER SWITCH:
This switch manually controls the engine speed (optional
in 6100 Mode).
13. EMERGENCY STOP PUSHBUTTON:
A red lock-down pushbutton that immediately shuts down
the generating set and will inhibit start until the pushbutton
has been released by turning it clockwise.
14. CONTROL SWITCH:
A four position switch that provides a means of controlling
the generating set mode and function.
Position "1" - Off
Generating set is stopped and automatic starting is
disabled.
Position "2" - Auto
This is the normal position for automatic start up.
Position “3” - Test
Depending on exact configuration the generating set starts
and runs off load.
Position “4” - Run
Depending on exact configuration the generating set starts
and runs on load.
15. AUDIBLE ALARM:
Buzzer that sounds on sensing of a fault condition
depending on fault handling description.
16. BREAKER / CONTACTOR CLOSED:
Light to indicate generator breaker / contactor closed.
1.3. Information Displays
The 6000 Series Control Panel has two 4 line alphanumeric
LCD displays. The lines of information displayed on these
screens is split into two sections. All four lines of the upper
display and the top two lines of the lower display make up the
first section, outlined on the front panel in blue. The bottom two
lines of the lower display make up the second section, outlined
on the front panel in white. The white section is the tunables
section where all tuning of setpoints is carried out. The blue
section is used to display all status information.
All information on the status of the generating set is subgrouped
into the various display screens listed below:
• Control Overview - 3 x Phase kVar

• Engine Overview - 3 x Phase kVA

• Generator Overview #1 A B C
V 221 220 220
• Generator Phases A 250 248 251
• Synchroscope KW 58.2 58.2 58.2

• Alarm/Event Log Kvar 20.0 19.0 22.0

• I/O Status Kva 60.6 60.6 60.6

• Sequencing - Slip Frequency

Control Overview Screen Layout - Phase Angle Difference
- Unit Number - Voltage Differential
- Engine Status - Mains/Bus PT Selection
- Mains/Bus Volts Status - Dead Bus (Yes/No)
- Generator Output Status - Synchroniser Status
- Mode of Operation - Generator Voltage (A: )
- Control Status - Mains/Bus Voltage (U: )
- List of All Available Units SLIP PHASE VOLTS
**** **** ****
- Network Priorities of All Units on the Network MAINS/BUS: MAINS
UNIT 1 ALARMS 0 DEAD BUS: NO
ENGINE: OFF
MAINS ~ GEN - (Synchroniser status) IN SYNC
AUTO OFF A: 381 U: 380
Alarm/Event Log Screen Layout
UNIT NO: 1 2 3
PRTY: 1 2 3 - Number of Unacknowledged Faults
Engine Overview Screen Layout - Listing of up to Eight Most Recent Faults
- Engine Coolant Temperature UNACK FAULTS : 0
Faults Listing:
- Engine Oil Pressure OVERSPEED
- Battery Voltage 26-9 13:01

- Time LOW OIL PRESSURE

28-9 11:59 1.5
- Date
- Engine RPM I/O Status Screen Layout
- Generating set kW-Hrs - Status of Discrete Inputs 1-12 (‘*’ Denotes Active I/P)
- Generating set Run Time - Status of Discrete Output 1-12 (‘*’ Denotes Active O/P)
H2O OIL BATT - Volts Bias Output
67C 4.0B 27.9V
TIME DATE RPM - Speed Bias Output
12:00 26 09 1500
DI: 1 2 3 4 5 6 7 8 9 0 1 2
* * *
KW-HRS RUN TIME
DO: 1 2 3 4 5 6 7 8 9 0 1 2
831 25
* * *
Generator Overview Screen Layout
Volts Bias : 0
- 3 x Phase/Phase Volts Speed Bias : 0
- 3 x Phase Currents Sequencing Screen Layout
- Generator Power Factor - List of All Available Units
- Generator kW - List of All Running Units
- Load Status - Network Priorities of All Units on the Network
#1 A B C
V 381 379 380 - Unit Number of the Designated Master
A 250 248 251 - Address of Next Unit to be Sequenced On
Hz 50.0 kW 174.6
- Address of Next Unit to be Sequenced Off
PF 1.00 LAGGING
Generator Phases Screen Layout
0.96 (Load Control status) UNIT 1 2 3
- 3 x Phase/Neutral Volts OPER X X
PRTY 1 2 3
- 3 x Phase Currents MASTER UNIT 1
- 3 x Phase kW
NEXT ON: 3
NEXT OFF: 2
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 Automatic Mains Failure Control (handled externally in 6100 and
6200 Modes)
2. Functional Description 6000 Series Control Systems Alternator Output / Load Control
2.1 System Overview Import/Export Control (6300 Mode only)
The 6000 Series control system incorporates a microprocessor Automatic Proportional Real and Reactive Load Sharing (6200
based complete load control and engine management system and 6400 Modes)
and carries out all the functions necessary for engine control,
synchronising, real (kW) control, reactive (kVAR) control and Automatic Soft Load Ramping Facility (6200, 6300 and 6400
automatic generator sequencing. Protection is provided by the Modes)
control system against various fault conditions. VAR or Power Factor Load Control in Mains Parallel Operation
To simplify the variations in control capability the most common (6300 and 6400 Modes)
operating modes have been designated as follows:- Externally Adjustable VAR/PF Reference
6100 - Automatic mains failure (no paralleling). Externally Adjustable Baseload/Process reference
6200 - Automatic synchronising of multiple generating sets (up Soft Load Ramping
to 8 sets).
Soft load Transfer and Re-transfer Control (6300 and 6400
6300 - Automatic synchronising of one generating set with Modes)
mains (baseload, peak lopping and soft transfer).
Manual Voltage Control Facility (depends on configuration)
6400 - Automatic synchronising of multiple generating sets (up
to eight) with the mains (baseload and peak lopping). Manual Frequency Control Capability (depends on
configuration)
2.2 Generating Set Parameter Displays
Synchronising
AC Voltage Phase/Phase and Phase/Neutral
Automatic Phase Match Synchronisation
AC Phase Current
3-Mode operation (Run, Permissive and Check)
Output Frequency
Automatic Voltage Matching
Power Factor (Cos Phi)
Dead Bus Closing
Total and Per Phase kW
Synch Timer
Per Phase kVAr
Reclose Attempt Timer
Total and Per Phase kVA
Manual Synchronisation Capability (depends on configuration)
Total kWh to Date
Mains Sensing
% Voltage Difference between Bus and Generator (Single
Phase/Neutral) Over / Under Voltage
Bus/Generator Phase Angle Difference Over / Under Frequency
Bus/Generator Frequency Slip Load Surge Detection
Generator Run Time Programmable Loss of Mains Detection
Engine Coolant Temperature Loss of Mains Action Delay Timer
Engine Lube Oil Pressure Programmable Mains Stable Delay
DC Voltage Sequencing (6200 and 6400 Modes)
Single Phase/Neutral AC Bus Voltage Each unit in the system has an assigned priority
Generator AC Voltage within limits indication Master (Highest Priority Unit) sequences units on / off line as
Bus AC Voltage within limits indication required

2.3 Control Features Higher priority units are sequenced on in order of priority;
sequenced off in reverse of priority
Engine Control
‘Max System Load’ and ‘Min System Load’ setpoints determine
OFF/AUTO/TEST/RUN Control Switch percentage system load at which units are sequenced on or off
line
Emergency Stop Pushbutton (Latching)
Programmable sequence on and off delays
Multiple Attempt Crank Timer
Separate programmable time delay for overload (> 100%)
Multiple Crank Repeat Setpoint system load levels
Crank Repeat Timer
Crank Fail Alarm/Shutdown
Crank Cutout (RPM based)
Programmable Pre-Glow Timer 2.4 Control Functions
Automatic Cooldown Timer Engine Cranking
Remote Starting capability (method employed depends on The GCP-1 Control is designed to automatically control the
application) cranking functions of the engine generator set. In order to
safely control engine cranking the GCP-1 uses the following

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setpoints, as found in the Engine Control tuning menu of the
software:
 Preglow Time
 Crank Time
 Crank Cutout
 Crank Delay
 Crank Repeats
Starting Sequence:
Upon receiving a start command the following events occur:
1. The Preglow Output Energizes for the given preglow time
delay, and remains energized through the crank cycle.
2. After the preglow time expires, the Fuel Solenoid output
energizes.
3. 200 ms after the Fuel Solenoid output energizes, the
Crank output energizes.
At this point, the engine should be cranking at a certain RPM,
and receiving fuel. Typically a start would occur in these
conditions. To check if a start does occur, the GCP-1 monitors
the magnetic pickup from the engine. If the magnetic pickup
input indicates that the engine is operating above the Crank
Cutout speed, the GCP-1 will remove the Crank and Preglow
outputs, leaving the fuel solenoid energized. The engine state in
the control overview menu changes from “OFF” to “RUN”.
If for some reason the engine does not reach the crank cutout
RPM level, the GCP-1 will crank the engine for the Crank Time.
If the engine fails to rise above the crank cutout level in this
time, the GCP-1 will remove the Crank output signal, wait for the
Crank Delay, and if allowed by the number of Crank Repeats,
will crank the engine again. This sequence will continue until the
number of crank repeats is depleted, or until the engine speed
rises above the crank cutout RPM setting, whichever comes
first. If the number of crank repeats is depleted, the GCP-1 will
activate the Crank Fail Alarm Output based on this Alarm
setpoint’s configuration.
NOTE:
• The preglow output may stay energized between crank
attempts if the preglow time is greater than the sum of the
Crank Time and Crank Delay timers.
WARNING:
! Set Crank Repeats to zero when starting the engine for
the first time with the GCP-1. This will prevent starter
and ring gear damage to the engine if the MPU input to
the control should be faulty. Monitor Engine Overview
Status menu on the first start and confirm the RPM
readout during cranking. After a successful start is
made, the crank repeats may be set to the appropriate
value for the application.
Generator Voltage Control
The GCP-1 has the ability to control the voltage of the generator
set. This ability is used to control four separate operations which
require generator voltage adjustment :
1. Manual voltage adjustment
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2. Voltage Matching during Synchronization across the
generator or mains breaker Reactive load sharing between
multiple units on an isolated bus
3. Reactive load control while in parallel with the mains.
The generator voltage, or reactive load (depending on the
operation) is adjusted by injecting a voltage bias signal to the
Automatic Voltage Regulator. The GCP-1 can be set for +/- 1
VDC, +/- 3 VDC, and +/- 9VDC outputs. The span of the output
is selected by a dip switch located on the back of the GCP-1, as
SW-2, which is near the J5 connector. Here is a table showing
the dip switch settings, and resulting voltage bias output ranges
for those settings:
Dip Switches Voltage Bias Output Range
ON
SW2-5 +/- 1 VDC
SW2-4, SW2-1 +/- 3 VDC
SW2-4, SW2-3 , +/- 9 VDC
SW2-2
Select the proper voltage range input as recommended by the
AVR manufacturer.
Generator Voltage can be manually controlled from the Voltage
Raise and Voltage Lower Discrete inputs to the GCP-1. The
rate of change for manual voltage adjustment is set in the
Reactive Load Control tuning menu, at the Voltage Ramp Time
setpoint. The voltage ramp time is the amount of time it will take
for the GCP-1 to send a 0 to 100%, or 0 to -100% voltage bias
signal to the AVR.
When operating in the TEST mode, manual voltage
adjustment is only allowed through the voltage raise and
lower inputs. This allows testing of the Voltage Bias output,
and generator voltage levels prior to operation with load on
the generator.
When operating in Isoch mode, the GCP-1 does not allow
manual adjustment of the voltage, unless the Load Control
setpoint in the Configuration tuning menu is set for
“Droop”, or the VAR/PF Control Setpoint in the Reactive
Load Control tuning menu is set to “Disabled”. Using either
of these settings implies that a manual voltage control will
be used, and no automatic reactive load control functions
are active.
NOTE:
• It is highly recommended that the automatic reactive load
control in the GCP-1 be used for proper power conditioning
throughout the generator(s) load range. This is achieved by
setting the Load Control setpoint in the Configuration tuning
menu to Normal, or Soft Transfer (depending on the
application), and the VAR/PF Control setpoint in the
Reactive Load Control tuning menu to VAR or PF control
(depending on the application). For more details on these
functions see the Real Load Control and Reactive Load
Control sections of this manual.
The percent level of the voltage bias output can be monitored in
the I/O Display status screen of the GCP-1. This is a useful
point to monitor during initial start of the unit. By issuing Voltage
Raise and Lower inputs to the control while operating in the Test
Mode, confirmation of proper generator voltage levels at various
voltage bias points can easily be made. Typically the generator
voltage should change no more than +/- 10% for a +/- 100%
voltage bias output from the GCP-1.
All other modes of generator set operation rely upon the
Reactive Load Control functions of the GCP-1. See the
information in the “Reactive Load Control” section of the manual Per-Phase Overvoltage Shutdown
for more details on voltage and reactive load control.
Per-Phase Undervoltage Shutdown
Generator Real Load Control Overfrequency Shutdown
The GCP-1 Control has four core modes of generator load Underfrequency Shutdown/Alarm
control operation. These four modes are:
Alternator Loss of Excitation Alarm
 Droop
Load Surge Detection (while in Mains Parallel)
 Isochronous Load Sharing System Protection / Alarms
 Base Load Fail to Synchronise Alarm
 Process Control Mains Bus Overvoltage Alarm (Single Phase/Neutral)
The specific mode of generator control that the unit is in at any Mains Bus Undervoltage Alarm (Single Phase/Neutral)
given time can be monitored on the Control Overview Menu.
Mains Bus Overfrequency Alarm (Single Phase/Neutral)
A detailed description of each of these load control modes, and Mains Bus Underfrequency Alarm (Single Phase/Neutral)
the various operating states that will put the GCP-1 into each
respective load control operation can be found in section 3.5 of Up to 3 Spare Fault Channels
this manual. 2.6 Standard Auxilliary Equipment

Generator Reactive Load Control PBC5: 5A Battery Charger (fitted to all 6000 series systems)

When a small generator is paralleled with a Mains, the 2.7 Standard Options
synchronizer voltage matching function adjusts the generator PBC5: 5A Battery Charger (Standard on all Systems)
voltage to match that of the Mains. Voltage variations that may
occur in the Mains system after paralleling can cause large PSB3: 5A Battery Charger With Boost
changes in reactive current in the generator. The VAR/Power PBL5: 5A Battery Charger Low Voltage (Standard on all low
Factor Control provides closed loop control of either VARs or voltage Systems)
power factor when operating in parallel with another power
WH: Water Heater Contactor
system when that system can accept the reactive load.
WHL: Water Heater Contactor Low Voltage
Voltage adjustment, however, can only affect reactive power
when another system is available to accept the reactive load. FP2: DC Fuel Pump Controls
So the VAR/Power Factor control functions are automatically FP3: AC Fuel Pump Controls
switched to Power Factor sharing when either single or multiple
PML1: Oil Temperature Gauge
units are operating in isochronous load sharing mode on an
isolated bus. PPE1: Earth Leakage (not available on 6200)

The 6000 series controller is capable of operating in 3 modes of PPE2: Earth Fault
reactive load control:- WS1: Low Coolant Level (Standard on CV12 / Dorman)

 VAr Control FS1: Low Fuel Level Shutdown

 Power Factor Control FS2: Low Fuel Level Alarm
 VAr Sharing
LS1: High Lube Oil Temp
The Reactive Load Control function may also be disabled if
desired. This mode is used as standard in 6100 and 6200 Crank Attempt Counter
systems. PSB: Emergency Stop Button With Security Key

A more detailed description of each of the above operating PAT1: Terminals For Customer Supplied Remote Emergency
modes can be found in section 3.5 of this manual. Stop
PAC1: Set of Volt Free Contacts For Common Alarm
2.5. Protective Features
PRM1: Electronic Mains Sensing Unit (Phase Failure Unit)
Engine Protection
PSB2: Canopy Mounted Emergency Stop
High Coolant Temperature Pre-Alarm
AH1: Anti-Condensation Heater With Control Panel Mounted
High Coolant Temperature Shutdown
Auto control System and Contactor
Low Oil Pressure Pre-Alarm
FV1: DC Tank Base Mounted Solenoid Valve (For Use With
Low Oil Pressure Shutdown FS3 or FS4)

Overspeed Shutdown FS3: 2 x Tank Mounted Fuel Level Switches (High and Low)

Fail to Start Shutdown FS4: 4 x Tank Mounted Fuel Level Switches (High, Extra High,
Low, Extra Low)
Emergency Stop Operated
E1: Electronic Governor (Standard on 6200 and 6300 Systems)
Battery Overvoltage Alarm
WC1: Low Coolant Temperature Switch
Battery Undervoltage Alarm
2.8. Communications Options
Alternator Protection
PC1: Remote Monitoring (Hardwired)
Reverse Power Shutdown
PC2: Remote Monitoring and Control (Hardwired)

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TEL1: Remote Monitoring (Dial Up Link)
9 Mains Breaker Trip
TEL2: Remote Monitoring and Control (Dial Up Link)
10 Generator Breaker Trip
TEL3: Remote Monitoring and Control With Fault Alert Callback
(Dial Up Link) 11 Audible Alarm Relay

MOD1: Remote Monitoring and Control Utilising a ModBus The identification numbers associated with the discrete inputs
Communications Network and outputs are used in the I/O status screen of the GCP–1.
2.9 Hardware
AC Inputs
Discrete Inputs and Outputs
The GCP–1 receives AC inputs from the
The discrete inputs and outputs of the GCP–1 control are used
to interface external commands to specific control actions and generator, bus, mains and engine. They are as
operations, and to control external devices. follows:
The Discrete inputs are designed to be tied back into a switch Loc. Description Signal Burden
common on the GCP–1 when closed. Each switch input will sink
5 mA of current at 12 VDC when closed. J5-19 Generator PT phase A Line AC Voltage
Below is a list of the discrete inputs available to the GCP–1 J5-23 Generator PT phase A Neutral AC Voltage
control.
J5-18 Generator PT phase B Line AC Voltage
ID Description
J5-22 Generator PT phase B Neutral AC Voltage
Number
J5-17 Generator PT phase C Line AC Voltage
1 Mode Control Input #1 (Auto)
J5-21 Generator PT phase C Neutral AC Voltage
2 Mode Control Input #2 (Test)
J5-9 Generator CT phase A Current AC Current .067
3 Mode Control Input #3 (Run with Load) ohms
4 Volts Bias Raise J5-5 Generator CT phase B Current AC Current .067
ohms
5 Volts Bias Lower
J5-1 Generator CT Phase C Current AC Current .067
6 Speed Bias Raise ohms

7 Speed Bias Lower J5-10 Generator CT Neutral AC Current

8 Generator Circuit Breaker / Contactor J5-20 Mains/Bus PT phase A Line AC Voltage

Auxiliary J5-24 Mains/Bus PT phase A Neutral AC Voltage
9 Mains Circuit Breaker / Contactor Auxiliary J1-2 +Magnetic Pickup AC Freq.
10 Mode Control Input #4 (Process) J1-1 -Magnetic Pickup AC Freq.
11 High Engine Temperature Shutdown Contact DC Inputs and Outputs

Location Description Signal I/O

12 Low Oil Pressure Shutdown Contact
J5-12 + power supply 9-15 VDC (12V unit) Isolated
13 Emergency Stop Input
J5-8 - power supply 18-32 VDC (24V unit) Input
14 - 16 Spare Fault Channels 1 – 3 J5-2 + process signal 4-20 mA or 1-5 VDC 6 Watt
Below is a list of the discrete outputs available. All discrete J5-6 - process signal typical
outputs consist of double-pole relays rated at 10A at 120VAC, J1-17 + speed bias +/- 3 VDC Isolated
8A at 277VAC resistive. J1-13 - speed bias Output
J5-3 + voltage bias +/- 1, 3, or 9 VDC Isolated
J5-7 - voltage bias Output

Communication Ports
2 x serial communications ports are provided on the 6000 series
controller (1 x RS-485 and 1 x RS-422). Details of connections and
uses are given below.
ID Description
Number
Location Description Signal
1 Mains Breaker / Contactor Close
J8-2 - RS-485 communication line Intercontrol comms
2 Generator Breaker / Contactor Close
J8-1 + RS-485 communication line Intercontrol comms
3 Engine Preglow
J8-4 + 5VDC Isolated Supply
4 Fuel Control Solenoid
J8-5 - 5VDC Isolated Supply
5 Engine Crank
J8-3 + RXD RS-422 communication line Remote communications
6 Visual Alarm Relay
J8-6 - RXD RS-422 communication line Remote communications
7 Local Bus PT Connect
J8-8 + TXD RS-422 communication line Remote communications
8 Mains Bus PT Disconnect

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J8-9 - TXD RS-422 communication line Remote communications

Switch # Description Normal

Status
SW1-1 Not used N/A
SW1-2 Not used N/A
SW1-3 Not used N/A
SW1-4 Not used N/A
SW1-5 Oil pressure shunt resistor (100 ohms when on) OFF
SW1-6 Oil pressure shunt resistor (100 ohms when on) OFF
SW1-7 Water temp shunt resistor (100 ohms when on) ON
SW1-8 Water temp shunt resistor (100 ohms when on) ON
SW2-1 Voltage bias output scaling (ON for +/- 3VDC, OFF
OFF for others)
SW2-2 Voltage bias output scaling (ON for +/- 9VDC, OFF
OFF for others)
SW2-3 Voltage bias output scaling (ON for +/- 9VDC, OFF
OFF for others)
SW2-4 Voltage bias output scaling (OFF for +/- 1VDC, OFF
ON for others)
SW2-5 Voltage bias output scaling (ON for +/- 1VDC, ON
OFF for others)
SW2-6 Not used N/A
SW2-7 Not used N/A
SW2-8 Process input type selection ON
ON = 4-20 mA input, OFF = 1-5 VDC input (4-20
mA)
SW3-1 RS-422 Termination RxD+ ON
(end of
line
units)
SW3-2 RS-422 +5VDC pull-up ON
(end of
line
units)
SW3-3 RS-422 Termination RxD- ON
(end of
line
units)
SW3-4 RS-485 +5 VDC pull-up ON
(end of
line
units)
SW3-5 Not used N/A
SW3-6 Not used N/A
SW3-7 RS-485 Termination - ON
(end of
line
units)
SW3-8 RS-485 Termination + ON
(end of
line
units)

iii
Explanation of Dip Switches

J1 J2 EXPLANATION OF
SWITCHES
SW-1
8 water temp shunt resistor (100 ohms) when ON
7 water temp shunt resistor (100 ohms) when ON
6 oil pressure shunt resistor (100 ohms) when ON
5 oil pressure shunt resistor (100 ohms) when ON
4 not used
3 not used
2 not used
1 not used
on off
8
7
CONTRAST
6 ADJ. SW-2
5
4
3
8 process I/E: ON = 4-20 mA @250 ohms; OFF = 1-5 VDC @ 30Kohms
7 not used.
2
1 J5 6 not used. +/- 1 +/- 3 +/- 9
SW-1 5 voltage bias output
4 voltage VDC VDC VDC
scaling bias output
3 voltage
scaling bias output SW2-5 SW2-4 ON SW2-4 ON
2 voltage bias output
scaling ON SW2-1 ON SW2-3 ON
1 voltage bias output scaling
scaling SW2-2 ON

8 RS-485 Termination +
7 RS-485 Termination -
on
8
off 6 not used.
7 5 not used.
6 4 RS-485 +5VDC pull up.
5
4
3 RS-422 Termination RxD -
3 2 RS-422+5VDC pull up.
2 1 RS-422 Termination RxD +
J8 on
8
off
1

7 SW-2
6
5
4
3
2
1

SW-3

Connector Wiring Diagram

W
iringDiagramforGCP-1
Connector Connector Connector
J5 J1 J2

+ 12 - + 17 9
Speedbiasoutput Mainsbreakerclose(DO1) n.o.
12Vdcor24Vdc - 13 18
- 8 n.c.
- 1 27
Shieldtermination 4 MPUspeedinput
+ 2 8
+ 20 n.o.
Mains/BusAphasePT GeneratorBreakerClose(DO2)
+
- 24 5 17
Coolanttemperaturesensor n.c.
- 6 26
+ 19
GeneratorAphasePT Oilpressuresensor
- 23 + 9 7
EnginePreglow(DO3) n.o.
Auto/m
anual(DI1) 16
+ 18 16
n.c.
GeneratorBphasePT Testengine(DI2)
- 22 10 25
Runwithload(DI3) 34
+ 17 11
Voltageraise(DI4) FuelSolenoid(DO4) n.o.
GeneratorCphasePT 35
- 21 12
n.c.
Voltagelower(DI5) 36
GeneratorAphaseCT + 9 24
Speedraise(DI6)
GeneratorBphaseCT + 5 19 6
EngineCrank(DO5) n.o.
Speedlower(DI7) 15
GeneratorCphaseCT + 1 20
GeneratorCBaux(DI8) n.c.
CTNeutral - 10 15 24
MainsCBaux(DI9) 22 31
+ 2 n.o.
Processim port/export ProcessI/E(DI10) VisualAlarm(DO6)
(4-20m A/1-5Vdc) - 6 18 32
n.c.
Fault1(DI11) 33
+ 3 14
Voltagebiasoutput Fault2(DI12)
7 23 5
- n.o.
Fault1(DI11) LocalBusPTConnect(DO7)
8 13
NoConnect 11 n.c.
Fault2(DI12)
7 23
NoConnect 13
Fault1(DI11) 4
NoConnect 14 4
n.o.
Fault2(DI12)
3 14
NoConnect 15 MainsPTDisconnect(DO8) n.c.
21 22
NoConnect 16
1
MainsBreakerTrip(DO9) n.o.
10
n.c.
Connector 3
J8
2
+ 1 n.o.
RS-485Network GeneratorBreakerTrip(DO10)
- 2 11
ConnectorJ5is24-pinmaleTrimTriotype n.c.
(maleconnectoronPCboard) Shieldterm
ination 7 12

+ 3 28
ConnectorJ1is24-pinfem aleTrimTriotype RS-422RxD AudibleAlarm(DO11) n.o.
(femaleconnectoronPCboard) - 6 29
n.c.
+ 8 30
ConnectorJ2is36-pinfem aleTrimTriotype RS-422TxD
(femaleconnectoronPCboard) - 9 NoConnect 19

NoConnect 4 NoConnect 20
ConnectorJ8is9-pinm aleTrimTriotype
(maleconnectoronPCboard) NoConnect 5 NoConnect 21

1
3. Configuration - Outline of Setpoints
3.1 Configuration Menu
Security Code - 4 Levels of Access
• Operator: Access to Alarm Log and Network
Priority
• Supervisor: Allows access to Network Address and
Time Set in addition to above access.
• Technician: Allows access to all setpoints except
engine run time and calibration
• Factory: Allows access to all setpoints
value is out of range, and the engine will not operate until the #
symbol is cleared by entering the correct values.
CT Ratio (numeric : 5)
Scales sensed CT input for Amperage as seen at generator
Used for Load Sensing Algorithm (KVA,KW,KVAR,PF)
PT Ratio (numeric : 1)
Scales sensed PT input to Voltage Levels as measured at the
Generator
Used in Load Sensing Algorithm (KVA, KW, KVAR, PF)

Network Address (1 to 8) Used for Voltage Matching

Unique Address for Each Unit in the System Voltage Input (Wye L-N, Delta L-L)

Maximum of 8 units on network
Network Priority
Unique Priority for Each Unit in the System
Lowest Active Priority is considered Master
Maximum of 8 units on network
Sequencing effective from lowest to highest priority
“Set All” Function
When priority is reduced below 1, the value will change to “Set
All”. If the commit key is pressed when this value is on the
display, the display will change to represent all units in auto on
the network, and their priority. The network priority of any unit
can be changed by using the left/right and up/down keys n the
control. Once changes are made, the changes are committed
by pressing the commit key twice.
Number of Poles (numeric)
Determines Speed/Frequency Relationship
Used for Speed/Frequency Mismatch Alarm/Shutdown
Number of Teeth (numeric)
Determines RPM Scaling
Engine Speed Readouts/Alarms
Set for sensing/transformer used between generator and Gen
Part 6000.
Defines which calculations will be used for kW, KVA, KVAR,
etc.
Wye (Star) Generator or Transformer Connection
4 Wire - volts measured Line to Neutral
Delta Generator or Transformer Connection
3 Wire - volts measured Line to Line
Voltage Reference (numeric)
Operating Voltage of Generator per Generator Spec.
Used for Var/PF Sharing as the Reference that multiple
generators share reactive load to. This maintains the voltage
reference while in Power Factor Sharing or KVAR Control mode
on an isolated bus.
Load Control Mode
Normal: Standard setting for load control and VAR/PF functions
Soft Transfer: Standard load control and VAR/PF functions, but
unit will issue mains breaker open command while in process
control if process reference is reached, or while in base load
and base load reference is reached.
Droop: Manual Load and Voltage Control used primarily for
commissioning

System Frequency (50/60 Hz) Process Action (direct, indirect)

Used as a basis for generator waveform analysis
Defines typical operating frequency of generator
Rated Speed (numeric)
Synchronous Speed of Generator Set
Defines action of speed bias when unit is operating in process
control in parallel with the mains.
Direct action = Unit increases speed bias (fuel) to increase
process 4- 20 ma input
Indirect action = Unit decreases speed bias (fuel) to increase
process 4-20 ma input.

Used in Speed Calculation to determine “sample” period for Circuit Breaker Control (Breaker, Contactor)
MPU input Defines action of Generator and Mains closure command
Rated kW (numeric) Breaker issues momentary close signal, momentary open signal
Rated kW of Generator independently.

Rated kVA (numeric) Contactor issues continuous close signal. Removes this signal
to open contactor.
Used to determine Rated Current of Generator
Equation: I=KVA/Rated Voltage Breaker Close
Rated kVAr (numeric) Normally Open and de-
energised on mains and
Rated KVAR of Unit generator
Typically .6 x Rated KVA
Breaker Open
NOTE:-
Normally Open and
• Rated KVA must be less than or equal to the Voltage energised on generator
Reference x CT Ratio Primary. Normally Closed and
Rated kW must be less than or equal to the Rated KVA Contactor
de-energised on mains
Close/Open
Rated KVAR must be less than or equal to the Rated KVA
Any Values Falling out side of these ranges will appear on the Normally Open and
screen with a pound sign (#) next to them. This indicates the de-energised on generator

Normally Closed and

2 de-energised on mains

Check Mains Breaker (enabled, disabled)
Used to activate checking of mains c.b. aux. input when
enabled
If disabled, unit relies on other units with this setpoint enabled to
broadcast state of mains c.b. aux. contact over network
Operating Mode
Mains Parallel or No Mains Parallel
Mains Parallel will allow the unit to synchronise to the mains,
and carry load while in parallel with the mains as well.
No Parallel will allow the unit to operate with load until the mains
breaker is sensed as being open
All units operating in a load sharing system must be set for the
same parameter, i.e. mains parallel, or no parallel.
Number of Units (single, multiple)
Defines whether unit is part of a multiple unit system or not.
If single unit, there is no auto starting, auto sequencing, load or
pf sharing with other units under any circumstances. Unit
displays “single unit no sequencing” on sequencing screen.
If multiple unit, auto starting, auto sequencing, load and var/pf
sharing are active between all units in multiple. Unit displays
system-sequencing information on sequencing screen.
Auto Sequencing (enabled, disabled)
Enables or Disables Auto Sequencing for that unit
Can be used to disable sequencing for a particular unit in a
sequencing system if needed
RS-422 Protocol (Modbus, Servlink, Upload Setpoints)
Used to select between different types of communication
options as outlined below:
 ModBus
Utilises the industry standard ModBus protocol.
More details on ModBus communications
With the 6000 series system can be found in section xxxx
of this manual.
The controller must be re-booted if this option is selected to
initialise ModBus communications
 Servlink
Utilises the Servlink protocol.
This option is used in conjunction with the PC1, PC2,
TEL1, TEL2 and TEL3 communications options.
The controller must be re-booted if this option is selected to
initialise Servlink communications.
 Upload Setpoints
Used for uploading the stored setpoints from the controller
to a storage file on a PC compatible computer.
This option should not be used by any personnel other than
FGW commissioning personnel who have undergone the
appropriate training.
Modbus ID (numeric)
Used to uniquely identify each controller on a ModBus network
Any changes will not take effect until the controller has been re-
booted
Modbus Timeout (seconds)
Maximum time delay allowed between successive polls of the
slave controller by the master.
This should be set to greater then the polling period of the
ModBus master.
3
If this time is exceeded a link failure error will be logged.
Modbus Reset (True, False)
Used to reset all static ModBus error messages
3.2 Shutdowns, Alarms
Shutdowns and Alarms menu is used to configure the various
safety functions of the Gen Part 6000.
Each alarm setpoint can be set for:
 Disabled: Disables alarm indication and logging.
 Warning: LED on Control Flashes.
 Visual Alarm: LED Flashes, and Visual Alarm relay
energises.
 Audible Alarm: LED Flashes, Visual and Audible Alarm
relays energise.
 Soft Shutdown: LED Turns On, Visual and Audible
Alarm relays energise, Fuel Solenoid relay de-
energises. Unit soft unloads and cycles through cool
down timer when applicable.
 Hard Shutdown: Same as above, but immediately
opens generator breaker and de-energises fuel
solenoid.
The following alarms have ‘special’ functions:
 Mains Voltage High
 Mains Voltage Low
 Mains Frequency High
 Mains Frequency Low
 Load Surge
These alarms cannot be set to ‘Soft Shutdown’ or ‘Hard
Shutdown’ but may be set to the following two extra functions:
 Loss Of Mains
- Triggers an internal Loss of Mains condition
- No alarm indication triggered
 Loss Of Mains With Alarms
- Triggers an internal Loss of Mains condition
- Triggers an audible alarm
Load Surge (numeric %/sec)
Used only in Base Load or Process Control (Mains Parallel
Operations)
Set to trigger at a percent setpoint of total generator load shift
per second while operating in Mains Parallel
Instantaneous Trigger
Load Surge Alarm
Type of alarm triggered on Load Surge event
Can be set for Loss of Mains Detection
Mains Volts High Limit
Maximum mains bus voltage for mains to be considered stable
Mains Volts High Alarm
Type of alarm triggered on Mains Volts High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Volts Low Limit
Minimum mains bus voltage for mains to be considered stable
Mains Volts Low Alarm
Type of alarm triggered on Mains Volts Low event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency High Limit
Minimum mains bus frequency for mains to be considered
stable
Mains Frequency High Alarm
Type of alarm triggered on Mains Frequency High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency Low Limit
Maximum mains bus frequency for mains to be considered
stable
Mains Frequency Low Alarm
Type of Alarm triggered on Mains Frequency Low event
Can be set to Loss Of Mains / Loss of Mains with Alarms
If frequency is below Low Limit, generator is not considered
stable, and is unfit for breaker closure.
The controller will not allow speed biasing which will cause the
generator output frequency to go below this level even if the
alarm is disabled.
Generator Frequency Low Alarm
Type of alarm triggered on a Generator Frequency Low event
Speed / Frequency Mismatch
Compares generator frequency to engine RPM and alarms on
difference
Used to indicate loss of MPU, or Loss of Generator Field
Voltage

Loss of Mains (LOM) Action Delay Overspeed

Sets Time Delay for LOM Action to begin once Loss of Mains is Set for overspeed limit of engine
detected. Typically set for Hard Shutdown for safety
Typically Delay time From LOM to engine start command Typically Set for 10% above Rated Speed of engine
Voltage Range Alarm Overspeed Alarm
Type of alarm triggered once voltage bias signal to AVR Type of alarm triggered on a overspeed event
reaches +/- 100%
Overcurrent Level
Generator Volts High Limit
3 Phase Sensing
Sets maximum allowable generator voltage level
Set for Per Phase Overcurrent
Triggered of any individual phase
Over Current Detection begins when current exceeds rated
If voltage is above High Limit, generator is not considered current as determined by Voltage Reference and Rated KVA
stable, and is unfit for breaker closure. values in Configuration menu: (KVA/Voltage Ref)/3.
The controller will not allow voltage biasing which will cause the Uses Inverse Time Function as basis for overcurrent detection.
generator voltage to go above this level even if the alarm is This allows different levels of overcurrent based on time span.
disabled.
Per Phase
Generator Volts High Alarm amps Overcurrent Inverse Time Function
Overcurrent Trip Zone
Type of alarm triggered on a Generator Volts High event
overcurrent level
Generator Volts Low Limit
Sets minimum allowable generator voltage level 100% rated current
Triggered of any individual phase time
overcurrent
If voltage is below Low Limit, generator is not considered stable, delay
and is unfit for breaker closure.
The controller will not allow voltage biasing which will cause the Over Current Level
generator voltage to go below this level even if the alarm is
High Current, Short Duration
disabled.
Generator Volts Low Alarm amps
Overcurrent Trip Zone
Type of alarm triggered on a Generator Volts Low event overcurrent level
Voltage Alarm Delay
Delay between detecting a Generator Voltage High or Low
condition and activating the configured alarm time
overcurrent
Generator Frequency High Limit delay

Sets maximum allowable generator output frequency Overcurrent Level

If frequency is above High Limit, generator is not considered
Notice area of over current is the same
stable, and is unfit for breaker closure.
The controller will not allow speed biasing which will cause the
generator output frequency to go above this level even if the
alarm is disabled.
amps Overcurrent Trip Zone
overcurrent level
Generator Frequency High Alarm
Type of alarm triggered on a Generator Frequency High event
Generator Frequency Low Limit overcurrent time
delay
Sets minimum allowable generator output frequency
Overcurrent Delay

4
 Setpoint used in conjunction with the Overcurrent Level setpoint Active when generator is stable
to determine tripping time on an overcurrent condition
Sensed in Bar
Overcurrent Alarm
Approaching Low Oil Pressure Alarm
Type of alarm triggered on an Overcurrent event
Type of alarm triggered on an Approaching Low Oil Pressure
Reverse Power event
Reverse Power Condition begins when sensed kW on generator Approaching High H2O Temp
goes negative. Reverse Power
Sets the trigger point for the Approaching High H2O Temp pre-
Trip levels depend upon amplitude and duration of reverse alarm
power condition.
Uses Engine mounted temperature sensor
Reverse Power Delay
Active when generator is stable
Reverse Power also uses an inverse time function.
Sensed in ºC
Reverse Power
Approaching High H2O Temp Alarm
Minimum Reverse Power
Minimum reverse power level which can trigger a reverse power Type of alarm triggered on an Approaching High H2O Temp
alarm. Reverse power levels below this setpoint will never event
cause a reverse power alarm condition, regardless of duration.
See diagram above. Low H2O Temperature

Reverse Power Alarm Sets the trigger point for the Low H2O Temp alarm

Type of alarm triggered on a reverse power event. Uses Engine mounted temperature sensor

Loss of Excitation (LOE) Active when generator is stable

Set as a percentage of total KVAR load on the generator that Sensed in ºC
can be applied as a block reactive load to the unit. If control
senses changes in KVAR loads instantly applied greater than Low H2O Temperature Alarm
this value the LOE alarm triggers. Type of alarm triggered on an Approaching High H2O Temp
event
Used to indicate loss of field excitation to the generator
High Engine Temperature
Loss of Excitation (LOE) Alarm
Sets the type of alarm activated upon the application of the
Type of alarm triggered on an LOE event.
external High Engine Temperature volt-free signal.
Battery Voltage High Limit
Normally set to ‘Soft Shutdown’
Maximum permissible DC voltage supply to 6000 control
Set to ‘Hard Shutdown if combined with an external Low Coolant
Can be used to detect faulty charging circuit Level sensor
Battery Voltage High Alarm Only activated 15 seconds after the engine has reached the
Type of alarm triggered on a Battery Voltage High event crank cut-out speed

Battery Voltage Low Limit High Engine Temperature Timer

Minimum permissible DC voltage supply to 6000 control
Used to detect weak battery/failed charger
Automatically Disabled during engine cranking
Battery Voltage Low Alarm
Type of alarm triggered on a Battery Voltage Low event
High Oil Pressure Limit
Additional delay between the application of the external High
Engine Temperature volt-free signal and the activation of the
configured alarm type
Not active when engine not running
Low Oil Pressure
Sets the type of alarm activated upon the application of the
external Low Oil Pressure volt-free signal.

Sets the trigger point for the High Oil Pressure Alarm Normally set to ‘Hard Shutdown’

Uses Engine mounted pressure sensor Only activated 15 seconds after the engine has reached the
crank cut-out speed
Active when generator is stable
Low Oil Pressure Timer
Sensed in Bar
Additional delay between the application of the external High
High Oil Pressure Alarm Engine Temperature volt-free signal and the activation of the
Type of alarm triggered on a High Oil Pressure event configured alarm type

Approaching Low Oil Pressure Not active when engine not running

Sets the trigger point for the Approaching Low Oil Pressure pre- Emergency Stop
alarm
Sets the type of alarm activated upon the application of the
Uses Engine mounted pressure sensor external Emergency Stop volt-free signal.

5
Normally set to ‘Hard Shutdown’ Cool down Time

Emergency Stop Timer
Delay between the application of the external High Engine
Temperature volt-free signal and the activation of the configured
alarm type
Time allowed for cool down after coming off-line during a normal
stop sequence
Only activated if the generating set load has exceeded the Cool
down Limit

Always activated Cool down Limit

Spare Fault #1 kVA setpoint at which, when exceeded will cause the engine will
execute a cool down during a stop sequence
Sets the type of alarm activated upon the application of the
external Spare Fault #1 volt-free signal. Engine Run Time

Normally set to ‘Disabled’ Hours of run time on the engine

Spare Fault #1 Timer Increments in hours

Delay between the application of the external volt-free signal Retained in EE memory - retains value after power loss
and the activation of the configured alarm type
May be re-set or pre-programmed by anyone with level 3
Always activated security access

Spare Fault #2 MW Hours

Sets the type of alarm activated upon the application of the MW hours supplied by the generating set
external Spare Fault #2 volt-free signal.
increments in 0.1 MW hour steps
Normally set to ‘Disabled’
Retained in EE memory
Spare Fault #2 Timer
May be re-set or pre-programmed by anyone with level 3
Delay between the application of the external volt-free signal security access
and the activation of the configured alarm type
3.4 Synchroscope
Always activated
Synchroniser Mode
Spare Fault #3
 Permissive
Sets the type of alarm activated upon the application of the
- Acts as a synch check device.
external Spare Fault #3 volt-free signal.
- 6000 will not issue speed or voltage bias commands,
Normally set to ‘Disabled’ but if synchronisation conditions are within spec
(phase and voltage), control will issue a breaker close
Spare Fault #3 Timer command.
Delay between the application of the external volt-free signal  Check
and the activation of the configured alarm type
- Used for checking synchroniser prior to
Always activated commissioning
- 6000 control actively synchronises generator by
3.3 Engine Control issuing speed and voltage bias commands, but does
Preglow Time not issue breaker closure command

Time of preglow allowed prior to engine crank cycle  Run

Maintained through engine cranking - Normal operating mode

- Actively synchronises and issues breaker closure
Resets after every crank attempt command
- Control MUST be in RUN to operate as a dead bus-
Crank Time closing device.
Maximum allowable time for engine cranking - In multiple unit systems 6000 control MUST have
AUTO input active to enable dead bus closing
Crank Cut-out
Synchroniser Gain
Engine RPM level where crank command is cancelled
Sets Gain of synchroniser speed bias output
Crank Delay
Synchroniser Stability
Time between engine crank attempts
Sets Stability of synchroniser speed bias output
Crank Repeats
Both Gain and Stability are used to tune the synchroniser
Number of times the 6000 control will attempt to re-start the dynamic response.
engine. The number of actual cranking attempts = Crank
Voltage Matching
Repeats +1
Enables/Disables Voltage Matching feature of 6000 control
Crank Fail
Enables Voltage Window Setpoint
Type of alarm triggered once the generating set has completed
its full crank sequence and the engine has not yet started. Voltage Window

6
Overall percentage of error allowed between generator and bus,
or generator and mains
6000 control will not issue a breaker closure if error is greater
than voltage window
Maximum Phase Window
Maximum allowable phase angle deviation from phase matched
condition.
6000 Control will not issue breaker closure if phase angle
between generator and bus, or generator and mains exceeds
this window
Dwell Time
The period of time that the generator must be within the Max.
Phase Window for before the 6000 control will issue a breaker
closure
Longer dwell times will give typically give better stability after the
breaker closes
Shorter dwell times reduce amount of time required to
synchronise unit
C.B. Hold Time
Time in Seconds that Breaker/Contactor Close output is held
after breaker close command is issued
Close Attempts
Number of Close Attempts allowed while synchronising
Close attempt incremented if breaker does not send back
continuous CB aux. signal to 6000.
Reclose Delay
Time in Seconds before 6000 control attempts re-
synchronisation after failed closure attempt
Synch Reclose Alarm
Alarm setpoint if number of close attempts is depleted
Synch Timeout
Sets time allowed for synchronisation in seconds
Begins timing when synchroniser activates
Active for all gen and mains breaker open and close commands
from 6000 control
A setting of zero (0) seconds disables synch. time-out - infinite
synch time allowed
Synch Timeout Alarm
Sets alarm mode if synch time-out is exceeded
Dead Bus Closure
Enables/Disables Dead Bus Closing Feature
Only active in multiple unit systems. Dead bus closing is always
active in single unit configuration.
Unit must be within voltage and frequency high/low limits to be
considered for dead bus closure.
Dead Bus Closure uses Token Passing Scheme to assure that
only one unit in a networked system will close onto the dead bus
at any given time.
Multiple unit systems must have Auto switch input to allow dead
bus closing between networked units
3.5 Real Load Control
7
Load Control Gain
Sets gain response of load control
Active in load ramping and base load operations
Load Share Gain
Sets gain response of proportional load sharing
Active in load sharing operations
Load Stability
Sets stability response of load control
Active in load ramping and baseload operations
Load Derivative
Sets derivative response of load control
Active in load ramping and baseload operations
Load Control Filter
Low pass filter used to attenuate higher frequency transients for
better stability
Active in proportional load sharing, load ramping and baseload
control modes
Baseload
Load Level Generator will automatically ramp to when operating
in Base Load
Unload Trip
Load Level where Generator Breaker/Contactor open command
will be issued when 6000 control is off loading generator set
Load Droop
Percentage of kW droop used when 6000 control is operating in
a droop mode
Load Time
Time in Seconds for generator to load from unload trip level to
base load level. This rate is applied during any automatic
loading function, including ramping to load sharing
Unload Time
Time in Seconds for generator to unload from base load level to
unload trip level. This ramp rate is applied during any automatic
unload functions, including ramping from load sharing
Raise Load Rate
Percent Load per Second ramp rate used when the raise load
contact input is used during base load operation.
Lower Load Rate
Percent per Second Ramp Rate used when the load lower input
is active in base load control operation
Fast Xfer Delay
Time required for a transition in switching from Mains to
Generator operations, and from Generator to Mains operations.
This includes transition times between bus and mains sensing.
Mains Stable Delay
Period of time required for the mains to be declared stable
before transition from generator(s) to mains.
Generator Stable Delay
Period of time generator must be declared stable before
transition from Mains to Generator, as well as dead bus closing
Load High Limit Master begins sequencing next lowest priority unit off line if
system load is still above Min. Gen. Load setpoint at the end of
Maximum allowed load while operating in Base load or Process
the Max Stop Time Limit.
control modes
3.6 Reactive Load Control
Prevents overload of unit
VAr / PF Mode
High Limit Alarm
Can be set to one of three modes
Sets alarm mode when unit is at or above High Load Limit
 Disabled
Active during all load control operations
- Unit does not PF share, or control PF under any
Load Low Limit
circumstances
Minimum allowed load while operating in Base load or Process - This setting should be used for all 6100 and 6200
control modes systems

Prevents reverse current of unit  VAR Control

Low Limit Alarm - Unit PF shares in isolated bus load sharing mode
- Unit controls KVAR in Base Load and Process Control
Sets Alarm Mode when unit is at or below Low Load Limit Modes
Active during all load control operations  PF Control
Maximum Generator Load - Unit PF shares in isolated bus load sharing mode
% system load on all units with gen breakers closed, and on the - Unit controls PF in Base Load and Process Control
Modes
same network, in Auto,and in Load Sharing or Process control
modes, at which active master unit will begin timing to sequence VAr / PF Gain
next unit on line.
Controls Gain Response of unit in Var/PF control mode
Next Generating set Delay
NOT active in PF sharing mode
Period of time that will pass before master auto sequences an
Voltage Ramp Time
additional generator on line.

Delay is effective only in active master unit Ramp time from 0 to +/-100% voltage bias output

Rated Load Delay Controls response of units in PF sharing modes

Delay when system load exceeds 100%, before master starts
next generating set in sequence
Maximum Start Time
Time allowed by master to see next unit to be sequenced on line
in an “active” condition, i.e. started and ready to load.
Controls ramp time of voltage during synchronisation
Controls ramp time of voltage during manual voltage adjust
VAr / PF Share Gain
Not Active in any modes (reserved for future use)

This is determined by a flag, which indicates the unit is ready to

VAr / PF Stability
load, is sent over the network by the unit being sequenced on
by the master. Controls Stability Response of unit in Var/PF control mode

If master does not detect this flag within the Max. Start Time NOT active in PF sharing mode
allowed, it will go to the next lower priority unit and try starting it,
kVAr Reference
or if no other units are available, it will retry the start command
on the same unit. When KVAR control mode is selected, this references the
amount of KVAR the generator will produce while in Base Load
Minimum Generator Load or Process control modes
% of system load at which active master begins timing to
Can be set for generate or absorb levels of KVAR
sequence units off line
KVAR levels limited by Rated KVAR of unit
Master may have to wait until system load is below this level if
unit next in line to be sequenced off will cause the system load PF Reference
to increase above the Max Gen Load setpoint of the Master.
PF level that will be maintained by the generator while in Base
Reduced Load Delay Load or Process control modes.

Time in seconds which the active master waits before Can be set for leading or lagging power factor
sequencing units off line.
Scaled from 0 (unity) to - .5 (.5 leading) to +.5 (.5 lagging)
Delay is effective only on active master unit
PF Deadband
Lowest priority units are sequenced off line first
+/- deadband around PF reference point
Maximum Stop Time
set in PF
Time in seconds allowed by master for slave to sequence off
Active in PF and PF sharing modes
line
Can be used to stabilise units at low loads if needed

8
3.7 Process Control
Process Master Uses Process PID to control
Gain, Stability, Derivative, Filter, Droop
Slaves to the Process Master use Load Control PID Values to
track master system load reference
Load Gain, Stability, Derivative, and Filter
Process Gain
Sets system gain response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Stability
Sets system stability response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Derivative
Sets system derivative response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Deadband
+/- deadband around process reference point
Set in mA
Process Droop
Introduces negative feedback on the process reference as the
process input increases
Used to add stability to marginally stable processes
Process Filter
Low Pass Filter attenuates higher frequency transients on
process 4-20 mA input signal
The higher the filter is set, the more active the process control
will be to higher frequency process transients
The lower the filter is set, the less active, and more stable the
process control will be to higher frequency process transients
Process Reference
The reference point, in mA, at which the master will control the
process input.
Also used in Soft Transfer modes to set the level of process at
which the transfer from mains to generator will occur
Raise Rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a raise load contact input while
operating in process control mode
9
Lower rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a lower load contact input while
operating in process control mode
Process High Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process High Limit Alarm
Sets alarm mode when process High Limit is reached
Process Low Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process Low Limit Alarm
Sets alarm mode when process reference reaches the Low
Limit
Process Low Limit Alarm
Sets alarm mode when Process Low Limit is reached
3.8 Calibration
While each unit will be factory calibrated at Woodward prior to
shipment, there are bound to be some inputs/outputs affected
by external wiring and/or interfaces (relays, transformers, etc.)
that will require calibration at the site during commissioning.
The Calibration Menu allows calibration of all the analogue
inputs to the 6000 control, as well as the speed bias and voltage
bias outputs.
All calibration points in the 6000 control are used to make the
actual value of an input such as generator voltage, read out on
the respective display screen of the 6000 control, the proper
value of the signal being monitored.
Example:
380VAC measured line to line on the generator should read
380VAC in the line to line voltage measurement area of the
6000 control “generator overview” menu.
Any differences between the measured and actual values can
be corrected using the generator PT calibration points in the
calibration menu.
Process In Scale
Actual Input - 4-20 mA, or 1- 5VDC process signal from external
transducer.
Monitor the Pin (process in) reading in the Load Control Monitor
menu
Calibrate Process input scale until Pin reads accurately what
measured process signal is.
Engine must be in a test or run mode and operating to observe
the Pin value in the Load Control Monitor menu
Speed Bias Offset
Factory calibrated for 0VDC offset on +/- 3 VDC range.
All Woodward Speed controls operate with this bias output, so
no calibration should be required to operate with these controls
Calibration may be required for other manufacturer’s speed
controls.
Voltage Bias Offset
Factory set for zero Volts DC. Put 6000 control synchroniser in “check” mode in synchroniser
setup menu.
Dip Switch selectable +/- 1VDC, +/- 3 VDC, +/- 9 VDC range.
Start engine in run/load mode to a live bus (either paralleling to
Some regulators require a positive voltage bias offset because
another generating set, or the Mains).
they cannot receive a negative voltage bias command.
Monitor Synchroscope status menu. Observe and calibrate U:
6000 control will always reset to the voltage bias offset when off
volts reading until measured matches monitored.
line.
Synchroscope Offset
PT Phase A Scale
Calibrates phase angle error detection of 6000 control.
Calibrates PT phase A voltage input
Factory calibrated for zero phase angle error between bus and
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
A phase generator inputs
and adjust PT Phase A scale until these values match
measured generator voltage on A phase With synchroniser in “check” mode, and a live bus, monitor the
synchroscope menu of the 6000 control for “phase angle”.
PT Phase B Scale
Monitor Voltage across open gen contactor/breaker or panel
Calibrates PT phase B voltage input
synchroscope for phase angle error between generator and
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N) bus.
and adjust PT Phase B scale until these values match
Adjust synchroscope calibration for lowest voltage across gen
measured generator voltage on A phase
breaker, or 12 o’clock reading on panel mounted synchroscope.
PT Phase C Scale
Battery VCO Gain
Calibrates PT phase C voltage input
Sets slope of battery VCO over operating range
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
Analog inputs to VCOs (Voltage Controlled Osc.)
and adjust PT Phase C scale until these values match
measured generator voltage on A phase
Freq.
CT Phase A Scale
(Hz)
Calibrates CT Phase A sensing of 6000 control

Load generator and monitor gen. currents in phase overview

menu.

Measure actual gen. currents with clamp on ammeter, or panel Analog Input
ammeter.

Calibrate phase A CT reading in phase overview. Used for Batt Volts, Water Temp (Ain2) and Oil Pressure (Ain1)
CT Phase B Scale Voltage Controlled Oscillators
Calibrates CT Phase B sensing of 6000 control

Load generator and monitor gen. currents in phase overview Increasing offset
menu.
Freq.
Measure actual gen. currents with clamp on ammeter, or panel
ammeter.
Decreasing offset
Calibrate phase B CT reading in phase overview.

CT Phase C Scale
Analog Input
Calibrates CT Phase C sensing of 6000 control

Load generator and monitor gen. currents in phase overview

menu.

Measure actual gen. currents with clamp on ammeter, or panel

ammeter. Increasing gain

Calibrate phase C CT reading in phase overview.

If CT polarity is reversed, that phase will read negative kW

Decreasing gain
when loaded in the Phase overview menu.

If CTs are on the incorrect phases, then KVAR readings in

phase overview will be off. Battery VCO Offset
Bus PT Scale Sets level, or offset of Battery VCO over operating range
Similar to Gen PT scaling, but this scale is for single phase bus Battery Voltage is a linear increasing type VCO function
PT input to the 6000 control.
Ain1 VCO Gain

10
Oil Pressure sensor input
! If maintenance is to be carried out on the generating set
0-200 ohm sensor on engine is a direct, mostly linear VCO then the battery negative should be disconnected at the
function battery.

Sets slope of oil pressure input to VCO frequency AUTO / Auto Start Position

Ain1 VCO Offset  Generating set awaits an external (Volt Free) start signal
indicating a mains failure from the changeover system.
Sets level, or offset of oil pressure input to VCO frequency Upon receiving this signal the generating set will start and
assume any load on the local bus.
Ain2 VCO Gain
 The generating set will continue supplying the load until the
Sets slope of water temp. input to VCO frequency start signal is removed.
Ain2 VCO Offset  Upon removal of this start signal the generating set will
stop immediately.
Sets level, or offset of VCO frequency to water temperature
slope

Water Temp VCO Sensor without shunt NOTE:

Sensor with shunt

• All load transfer functions and mains failure detection are
handled by an external changeover system.

VCO Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into the

Freq. changeover system. The 6100 control system can be
programmed to perform the cooldown function itself if required
but must be requested prior to build.
TEST / Generating Set Test Position
Water Temperature  If selected the generating set will start and assume any
load on the local bus.
Shunt Resistor Switches 7 and 8 closed on SW-1 of 6000
control NOTE:

3.9 NetComm Dropouts
The number of lost or corrupted network communications
tolerated by the receiving unit.
Excess numbers of NetComm Dropouts on network due to
faulty wiring, improper shielding, or improper setup will result in
the unit experiencing the dropouts to flash intermittently in the
Sequencing Menu of the 6000 control. Typically set at 5 to 10
dropouts.
4. RUN / Generating Set Manual Run
Calibrated Unit
When set for true, indicates unit has been factory calibrated.
Requires level 4 security code to change.
3.10 6100 - Single Generating set, Automatic Mains Failure
Functional Description
In this mode of operation an external changeover system must
be used in conjunction with the 6000 Control System to handle
all mains sensing and load transfer functions providing a volt
free start signal.
Normal Switch Positions
OFF / Generating Set off
 If selected while engine is running the generating set will
stop immediately.
NOTE:
• The 6100 control system has no control over the load
• The 6100 control panel has no control over the load
transfer and so the generating set can carry out a test
without load by using this switch position only if the
changeover system used will not cause a load transfer
under these conditions.
 If the mains fails while the generating set is running and a
load transfer is initiated by the changeover system the
generating set will assume the load and run isochronously.
 Same as for ‘TEST’ position in this mode since the
generating set has no control over the load transfer.
6200 - Multiple Generating set, No Mains Parallel
4.1 Functional Description
In this mode of operation an external changeover system must
be used in conjunction with the 6000 Control System to handle
all mains sensing and load transfer functions providing a volt
free start signal. In this mode the generators only parallel with
other similarly equipped generating sets (up to a total of 8 sets).
Where there is a group of generating sets each set is given its
own unique identifying number (1-8). There are two main
operational variants within the 6200 operating mode, i.e. Prime
Power and Automatic Mains Failure (AMF). Depending on the
configuration set-up the generating sets may be started
manually, start automatically if a machine in the running group
fails, start automatically according to load demand (load
dependant sequencing) and, in the case of the AMF variant,
start automatically on a failure of the mains supply.

transfer, therefore the load should be removed from the
generating set before shutting down.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated
into the changeover system. The 6100 control system can
be programmed to perform the cooldown function itself if
required but must be requested prior to build.
 If selected while the engine is stopped will disable engine
starting.
WARNING:
4.2. Prime Power Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running the generating set
will ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on
the local bus the next available generating set in the
network may be sequenced on before the generating set
will initiate a stop sequence.

11
The 6200 control system has no control over the load transfer
to/from the mains and so this should not be used to initiate
a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into
the changeover system. The 6200 control system can be
programmed to perform the cooldown function itself if
required but must be requested prior to build.
 If selected while the engine is stopped will disable engine
starting.
WARNING
! if maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and no generating
sets are online the generating set will start and assume the
load.
 If selected while the engine is stopped with other
generating sets of only lower priorities online the
generating set will start, synchronise and close to the local
bus, soft load ramp then load share with the other
generating sets online. The generating set will now
assume master status and sequence the lowest priority
generating set offline if the system load is less than the
‘Min Gen Load’ setpoint. The generating set will continue
running online until a shutdown fault occurs or the control
switch is turned out of ‘AUTO’.
 If selected with at least one generating set of a lower
priority online the generating set will start, synchronise and
close to the local bus, soft load ramp then load share with
the other generating sets online. The lowest priority
generating set may now sequence offline automatically if
the system load is less than the ‘Min Gen Load’ setpoint on
the active master generating set. The generating set will
now revert to normal load dependant automatic sequencing
and will be brought on and offline by the active master
generating set as required.
 If selected with other generating sets of only higher
priorities online the generating set will go directly into auto
sequencing and will not start unless the system load is
greater than the ‘Max Gen Load’ setpoint on the active
master generating set. If this is the case the generating set
will start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The generating set will now revert to normal load
dependant automatic sequencing and will be brought on
and offline by the active master generating set as required.
TEST / Generating Set Test Position
 If selected while the engine is stopped the generating set
will start and run off load. The generating set will continue
to run off load until the control switch is turned out of
‘TEST’.
NOTE:
• During this time the generating set will be unavailable for
automatic sequencing and will never close onto the load.
RUN / Generating Set Manual Run
 If selected while the system is dead and no generating
sets are online the generating set will start and assume the
load.
 If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
12
The generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint. The
generating set will continue running online until a shutdown
fault occurs or the control switch is turned out of ‘RUN’.
 If selected with at least one generating set of a lower
priority online the generating set will start, synchronise and
close to the local bus, soft load ramp and then load share
with the other generating sets online. The lowest priority
generating set may now sequence offline automatically if
the system load is less than the ‘Min Gen Load’ setpoint on
the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
 If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The next lowest priority generating set online may be
sequenced offline if the system load is less than the ‘Min
Gen Load’ setpoint on the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
Prime Power Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’ position
on the control switch on startup. This will bring all generating
sets on line supplying the load and will allow the 6000 Control
System to initialise all load dependant sequencing correctly.
After approximately 2 mins of running all generating sets can be
placed in the ‘AUTO’ position for normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run.
As the load increases then the number of sets increase and vice
versa. The generating sets have a pre-set starting priority as
the load increases. As the load decreases they stop in reverse
order. The starting and stopping order sequence can be
changed by the operator at any time. Another feature in the
automatic mode is that if a generating set stops because of a
fault then the next generating set in the sequence starts up and
synchronises automatically to the load. When the faulty
generating set is repaired it will automatically take its place back
in the running sequence (see section on ‘AUTO’ switch
position). The 6200 mode requires that there must be a
minimum of one generating set running.
4.3. AMF Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running the generating set will
ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on
the local bus the next available generating set in the
network may be sequenced on before the generating set
will initiate a stop sequence.
The 6200 control system has no control over the load
transfer to/from the mains and so this should not be used
to initiate a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated
into the changeover system. The 6200 control system can
 be programmed to perform the cooldown function itself if
required but must be requested prior to build.
If selected while the engine is stopped will disable engine
starting.
WARNING
! If maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and no generating
sets are online the generating set awaits an external (Volt
Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will continue to run online for at least 5
minutes then revert to normal load dependant automatic
sequencing.
 If selected while the engine is stopped with other
generating sets of only lower priorities online the
generating set awaits an external (Volt Free) start signal
indicating a mains failure from the changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint. The
generating set will continue running online until a shutdown
fault occurs or the control switch is turned out of ‘AUTO’.
 If selected with at least one generating set of a lower
priority online the generating set awaits an external (Volt
Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
lowest priority generating set may now sequence offline
automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required.
 If selected with other generating sets of only higher
priorities online the generating set awaits an external (Volt
Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will go directly
into auto sequencing and will not start unless the system
load is greater than the ‘Max Gen Load’ setpoint on the
active master generating set. If this is the case the
generating set will start, synchronise and close to the local
bus, soft load ramp then load share with the other
generating sets online. The generating set will now revert
to normal load dependant automatic sequencing and will be
brought on and offline by the active master generating set
as required.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the external
start signal is not active the generating set will start and run
off load. The generating set will continue to run off load
until the control switch is turned out of ‘TEST’ or the
generating set receives the external start signal.
Upon receiving this signal the generating set will
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will continue to run online for at least 5
minutes then revert to normal load dependant automatic
sequencing.
13
 If selected while the engine is stopped with other
generating sets of only lower priorities online and the
external start signal active the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint. The
engine will continue to run until the control switch is turned
out of ‘TEST’ and will remain online until the external start
signal is deactivated.
 If selected with at least one generating set of a lower
priority online and the external start signal active the
generating set will start, synchronise and close to the local
bus, soft load ramp then load share with the other
generating sets online. The lowest priority generating set
may now sequence offline automatically if the system load
is less than the ‘Min Gen Load’ setpoint on the active
master generating set. The generating set will now revert to
normal load dependant automatic sequencing and will be
brought on and offline by the active master generating set
as required. The engine will continue to run until the control
switch is turned out of ‘TEST’ and will be sequenced on
and offline by the active master generating set as required.
 If selected with other generating sets of only higher
priorities online, the engine is stopped, with the external
start signal active and the system load less than the ‘Min
Gen Load’ setpoint the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the system
load becomes greater than the ‘Max Gen Load’ setpoint on
the active master generating set. If this is the case the
generating set will start, synchronise and close to the local
bus, soft load ramp then load share with the other
generating sets online. The generating set will now revert
to normal load dependant automatic sequencing and will be
brought on and offline by the active master generating set
as required. The engine will continue to run until the control
switch is turned out of ‘TEST’ and will be sequenced on
and offline by the active master generating set as required.
 If selected with other generating sets of only higher
priorities online, the engine is stopped, the external start
signal active and the system load greater than the ‘Max
Gen Load’ setpoint the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required. The engine
will continue to run until the control switch is turned out of
‘TEST’ and will be sequenced on and offline by the active
master generating set as required.
NOTE:
• If it is required to disable the generating set from going
online the local alternator output circuit breaker should be
placed in the open position.
RUN / Generating Set Manual Run
 If selected while the system is dead and no generating
sets are online the generating set will start and assume any
load on the local bus.
 If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint. The
generating set will continue running online until a shutdown
fault occurs or the control switch is turned out of ‘RUN’.
 If selected with at least one generating set of a lower
priority online the generating set will start, synchronise and
close to the local bus, soft load ramp and then load share
 with the other generating sets online. The lowest priority
generating set may now sequence offline automatically if
the system load is less than the ‘Min Gen Load’ setpoint on
the active master generating set.
 If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The next lowest priority generating set online may be
sequenced offline if the system load is less than the ‘Min
Gen Load’ setpoint on the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
AMF Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’ position
on the control switch on startup. This will bring all generating
sets on line supplying the load and will allow the 6000 Control
System to initialise all load dependant sequencing correctly.
After approximately 2 mins of running all generating sets can be
placed in the ‘AUTO’ position for normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run.
As the load increases then the number of sets increase and vice
versa. The generating sets have a pre-set starting priority as
the load increases. As the load decreases they stop in reverse
order. The starting and stopping order sequence can be
changed by the operator at any time. Another feature in the
automatic mode is that if a generating set stops because of a
fault then the next generating set in the sequence starts up and
synchronises automatically to the load. When the faulty
generating set is repaired it will automatically take its place back
in the running sequence (see section on ‘AUTO’ switch
position). The 6200 mode requires that there must be a
minimum of one generating set running.
5. 6300 - Automatic Synchronising of One Generating Set with
Mains
5.1 Functional Description
In addition to the automatic mains failure function (with soft load
retransfer), this variant can operate in base load mode, peak
lopping mode or soft load transfer mode. The operating mode is
pre-programmed at the factory and must be specified when
ordering.
In all variants the 6300 Control System must have full control of
both the generator and mains breakers with state feedback
provided for each by means of an auxiliary contact.
5.2. Base Load Operation
In this mode the generating set may be manually started. It will
automatically synchronise to the mains grid and take up load to
a pre-set value (usually the full output of the generating set). If
there is insufficient local load for the generating set then it will
export its excess power to the mains.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
14
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control
is disabled. If the mains fails during this time and the
mains breaker subsequently opens the control system will
not attempt to close the breaker until the control switch is
turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is
to be taken out of service for prolonged periods of time that
the maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close
the mains breaker on a short term mains failure.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains is
supplying the load, the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker and continue running offline.
NOTE:

• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a preset ‘Baseload’ level against the mains supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
WARNING:
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
5.4. Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set so that a minimum load is kept on the mains and
the rest is supplied by the generating set. This continues until
the generating set is at its maximum load then any further
loading is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the mains
until the control switch is returned to the OFF position or to the
AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.5. Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
 When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
15
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control
is disabled. If the mains fails during this time and the
mains breaker subsequently opens the control system will
not attempt to close the breaker until the control switch is
turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is to be
taken out of service for prolonged periods of time that the
maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close
the mains breaker on a short term mains failure.
! If maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
If selected while the engine is stopped with the mains supplying
the load the generating set will start, synchronise with the
mains, close the generator breaker and soft load ramp to a pre-
set import power level from the mains supply. The generating
set will maintain this import power level as the site load varies.
NOTE:

• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
5.6. Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set to the point where zero load is being supplied by
the mains then opens the mains breaker so assuming the full
site load. On removal of the time clock start signal the
generating set will resynch with the mains supply and perform a
soft load retransfer (closed retransfer) of the site load back to
the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or to
the AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.7. Soft Transfer Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control
is disabled. If the mains fails during this time and the
mains breaker subsequently opens the control system will
16
not attempt to close the breaker until the control switch is
turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is
to be taken out of service for prolonged periods of time that
the maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close
the mains breaker on a short term mains failure.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to the point where there is no load being imported
from the mains at which point the control system will open
the mains breaker and assume the full site load.
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6. Automatic Synchronising of Multiple Generating sets with
Mains
6.1. Functional Description
In addition to the automatic mains failure function (with soft load
retransfer), this variant can operate in base load mode, peak
lopping mode or soft load transfer mode. The operating mode is
pre-programmed at the factory and must be specified when
ordering.
This section describes the functionality of the ‘standard’ system
which consists of up to 4 generating sets paralleling with each
other onto a local generator bus and with a single mains supply.
This system is fitted with a mains breaker, feeder breaker and a
separate generator breaker for each generating set. For a
detailed outline of the system wiring consult the relevant
drawings and / or a member of the Electrical Drawing Office.
The Electrical Drawing Office should also be consulted if the
requirements of the proposed installation dictate changes in the
basic configuration of the system as this may require significant
modification to the control system philosophy.
6.2. Base Load Operation
In this mode the generating sets may be manually started either
by an external start signal starting all generating sets which are
in ‘AUTO’ or individually by selecting ‘RUN’ on the control
switch. Any generating sets told to run in baseload will
automatically synchronise to the mains grid and take up load to
a pre-set value (usually the full output of the generating set). If
there is insufficient local load for the generating sets then
surplus power over and above the site load will be exported to
the mains.
With the generating sets in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. In his case the system will open
the feeder breaker and attempt to start all generating sets
simultaneously. After all available generating sets have come
on-line and have closed to the local bus the feeder breaker will
close. The number of generating sets required to be on-line
before the feeder breaker will close can be customised for each
individual application. The generating set will perform a soft
load retransfer (closed retransfer) of the load back to the mains
supply on return of the mains.
6.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect from the local bus, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
and externally triggered starting functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable engine
starting.
17
WARNING:
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.3.4).
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’, the mains supply
goes outside specification or the external start signal is
received.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs. When the mains returns
the generating set will wait for the duration of the mains
stable delay timer then synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker and continue running offline.
 If an external start signal is received the generating set will
parallel to the mains supply and go into RUN mode (see
section 6.3.)
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a pre-set ‘Baseload’ level against the mains
supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6.4 Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock or externally applied run signal and run
in parallel with the mains supply. After synchronising with the
mains an external watt transducer provides a signal which is
representative of the loading applied to the mains supply. The
6400 uses this signal to adjust the load on the generating set so
that a minimum load is kept on the mains. This continues until
the generating set is at its maximum load after which any further
loading is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the mains
until the control switch is returned to the OFF position or to the
AUTO position with the external start signal removed.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
6.5 Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set from the local bus, cooldown
(if required) and stop.
NOTE:
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable engine
starting.
WARNING:
! if maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.5.).
TEST / Generating set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
18
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a preset import / export power level from the mains
supply. The generating set will maintain this import /
export power level as the site load varies.
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6.6 Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a preset time clock or externally applied start signal and
run in parallel with the mains supply. After synchronising with
the mains an external watt transducer on the mains provides a
signal of the load on the mains. The 6400 uses this signal to
adjust the load on the generating set to the point where zero
load is being supplied by the mains then opens the mains
breaker so assuming the full site load. On removal of the time
clock start signal the generating set will resynch with the mains
supply and perform a soft load retransfer (closed retransfer) of
the site load back to the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or to
the AUTO position with the external start signal removed.
NOTE:
• If only one generating set is turned into the RUN position
the site load may exceed the maximum generating set load
in which case the generating set will never reach the zero
load transfer point and will not disconnect the mains
supply.
With the generating set in the AUTO position the system
will operate in AMF Mode and will start and supply the site
load in the event of a mains failure. The generating set will
perform a soft load retransfer (closed retransfer) of the load
back to the mains supply on return of the mains.
6.7 Soft Transfer Variant - Normal Switch Positions
OFF / Generating set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set from the local bus, cooldown
(if required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site
load and the mains is dead the generating set will continue
supplying the site load until the mains returns or a
shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
 If selected while the engine is stopped will disable disable
engine starting.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains supplying the load the generating set will enter in
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.7.).
TEST / Generating set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise
to the mains, close the mains breaker, soft unload ramp,
open the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
19
with the mains, close the generator breaker and soft load
ramp to the point where there is no load being imported
from the mains at which point the control system will open
the mains breaker and assume the full site load.
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
7. Alarm / Event Indication and Logging
Fault conditions on the 6000 Series Control Panel are set as
warnings, alarms, soft shutdowns and hard shutdowns.
Warnings flash the ALARM light only, alarms energise the
audible alarm and flash the ALARM lamp, soft shutdowns
unload the generator, open the breaker and perform a cooldown
cycle if required. Hard shutdowns immediately open the breaker
and shut the generating set down. All alarms are logged with a
timestamp in the ALARM / EVENT LOG. These settings are
intrinsic to the setup parameters in the software and can only be
changed with suitable security clearance. When a hard
shutdown fault is sensed, the alarm lamp illuminates, the audible
alarm is energised and the generating set is automatically shut
down immediately. The audible alarm will remain energised until
the ALARM RESET pushbutton is pressed. The engine remains
locked out until the fault has been acknowledged. The alarm
lamp will flash until the enter ( ) pushbutton is pressed while in
the ALARM / EVENT LOG. This will acknowledge the alarm and
allow the generator to start but will not clear it from the log. The
alarm may be cleared from the log by pressing the ALARM
RESET pushbutton while in the ALARM/EVENT LOG subject to
technician level or higher security clearance. The possible fault
conditions available for sensing are dependant on the particular
operating mode of the generating set. See earlier section for a
list of all available alarms/shutdowns.
8. Remote Control and Monitoring Via a PC:
8.1 System Outline
The PC-Tools package is available in two main forms, which are
subdivided into 5 variants in total. A brief description of each is
given below:
 PC options:
PC1: This option offers monitoring of the 6000 series
system only via a direct hardwired connection to the control
system.
PC2: This option offers monitoring and control of the 6000
series system via a direct hardwired connection to the
control system.
 TEL options:
TEL1: This option offers monitoring of the 6000 series
system only via a standard telephone line.
TEL2: This option offers monitoring and control of the 6000
series system via a standard telephone line.
TEL3: This option offers monitoring and control of the 6000
series system via a standard telephone line with fault alert
callback.
The PC1 and PC2 options use a separate control box per
control system to interface between the RS-232 serial
communications port of the monitoring PC and the RS-422
communications network used by the 6000 series control
panels. The GP 6000 software in conjunction with the Servlink
software then utilises the information transmitted by this
communication path to allow users to monitor or control various
aspects of the 6000 series control panel from the computer.
The TEL1, TEL2 and TEL3 options also use a separate but
different control box per system to interface between the RS-
422 network used by the 6000 series control panels and the
telephone line.
Each 6000 series control system should have its own dedicated
communications path, e.g. one hard wired connection with one
PC1 interface panel per 6100 or 6300 panel with PC1option,
and one telephone line with one PC1 interface panel per 6200
or 6400 system with PC1 option.
Each control box requires a mains supply but does contain
battery backup to enable uninterrupted remote communications
even in the event of a mains and/or generator system failure.
The control box used with the TEL3 option differs from that used
with the TEL1 and TEL2 options in that it also incorporates the
fault callback unit. This control box will require two dedicated
telephone lines, one for data transfer and one for the recorded
The operator can now carry out any of the functions accessible
message callback facility.
by using the membrane keypad on the hardware control itself.
This is done by simply clicking on the appropriate button on the
front panel display, which will cause the 6000 series control to
8.2 Functional Description react in exactly the same manner as if the button was pressed
locally.
The GP 6000 software duplicates the front panel of the 6000
series hardware platform. All the monitoring information which In addition to the Monitoring version of the GP6000 software
can be obtained from the hardware can also be accessed by the there is also a version which gives the remote operator the
GP 6000 software in a format which is identical to that of the capability to simulate the operation of the control switch, panel
hardware. This makes the software mounted emergency stop button, and the speed/volts
raise/lower buttons. This version is used with the PC2, TEL2
very familiar to those accustomed to the 6000 controller keypad
and TEL3 options. An example of the front panel display for this
functions and LCD readout displays.
version is shown below:
There are two main information display sections within the GP
6000 software. These are the ‘Master Situation Monitor’ and the
‘Front Panel Display’. The ‘Master Situation Monitor’ displays
the essential information from up to eight of the individual control
panels in the system. The parameters displayed are:
 Network Address
 Network Priority
 Present kW loading of the generating set
 Alarm Status (ALARM or OK)
An example of a typical 3 generating set 6200 system display is
shown below:

As it can be seen, this version is identical to the monitoring only

In this example the Master Situation Monitor is showing an
alarm condition on generating set number 3. Highlighting
generating set number 3, and then clicking on the front panel
display icon in the lower right corner of the Master Situation
Monitor brings up the front panel display for generating set
number 3:
version with the exception of the added control buttons on the
right side of the display.
These control buttons not only allow the remote operator to
perform all the basic control functions but also indicate the
current state of these control inputs, i.e. if the panel mounted
emergency stop is locked on or has been released etc.
The control system works by acknowledging a change of state
of any of these switch inputs, whether triggered locally or
remotely, as the last valid control input. This means that there
is no overriding priority put on either the local or remote inputs,
and so it is quite conceivable that the local control switch could
be in the AUTO position but due to the remote operator pressing
the RUN button, the generating set will be operating in the RUN
mode. It should be noted however that the status as

20
indicated on the remote display will always match the
current operating mode of the controller.
The Emergency Stop control operates in a slightly different
manner however due to safety constraints. In this case the
local panel mounted emergency stop always has priority while
pressed. This prevents the remote operator from starting the
generating set if the local emergency stop button is still locked
on due to the occurrence of a dangerous or potentially
dangerous situation. Once the local emergency stop button has
been released the alarm can be reset and the generating set
started either locally or remotely.
It should also be noted that in the case of a 6100, or 6200
system that as all mains failure and load transfer functions are
performed by an external changeover system the PC2, TEL2
and TEL3. Options cannot be used to initiate a manual load
transfer/ re-transfer of the load to/from the mains supply.
8.3 Hardware Specifications
Communications:
RS-422 protocol
9600 Baud (fixed maximum)
No Parity
1 Stop Bit
Computer Requirements:
Minimum:
PC compatible running Windows 95 or Windows NT 4.0 and
above, 3 MB hard drive space.
Recommended:
100 MHz Pentium PC, 16 MB RAM, 3 MB hard drive space,
running Windows 95 or Windows NT 4.0 and above.
Modem Requirements (for TEL1, TEL2 and TEL3 options
only):
Remote PC end:
9600 Baud Capability (minimum)
8 Data Bits
No Parity
9. Initial Startup and Commissioning
1 Stop Bit
Recommended:
Multitech MT1932ZDX-K, MT2834ZDX-K, MT2834ZPX-Internal
US-Robotics Sportster 14.4 Vi Fax/Modem, Sportster 14.4
Fax/Modem, Sportster Voice 33.6 Fax/Modem, Courier Dual
Std, Courier HST.
Miracom Courier HST
Megahertz CC3144/CC4144 PCMCIA
Xircom PS-CEM28 range
NEC (AT&T) 14.4 Kbps Data/Fax Modem
Tornado FM144E
PC1 and PC2 communications path.
Standard RS-422 protocol communications.
Recommended cable: 6-core (3 x twisted pair), overall
screened, min core diameter of 0.5mm2.
Maximum length: 1km (special attention must be paid to cable
routing to minimise interference).
Connection Method: daisy chain (parallel looped) with PC
interface box at one end of the line - screen earthed at one
place only but interconnected.
TEL1, TEL2, and TEL3 communications path.
Hardwired RS-422 connection as in PC1, PC2 option.
21
Each TEL1 and TEL2 option requires one dedicated, analogue
telephone line.
Each TEL3 option requires two dedicated, analogue telephone
lines.
NOTE:
• Connection of the TEL1, TEL2 and TEL3 option interface
boxes to a digital telephone line, such as used on some
PBX switchboard systems, may result in permanent
damage to the interface system.
8.4 Equipment Supplied With Each Option:
PC1 Option
1 x PC interface box.
1 x 9-pin serial cable.
1 x GP6000 Monitoring Software package.
PC2 Option
1 x PC Interface box.
1 x 9-pin serial cable.
1 x GP6000 Monitoring and Control Software package.
TEL1 Option
1 x TEL1 interface box.
1 x GP6000 Monitoring Software package.
1 x Telephone cable (cable connectors fitted will depend on
country).
TEL2 Option
1 x TEL2 interface box.
1 x GP6000 Monitoring and Control Software package.
1 x Telephone cable (cable connectors fitted will depend on
country).
TEL3 Option
1 x TEL3 interface box with integral fault alert callback.
1 x GP6000 Monitoring and Control Software package.
2 x Telephone cables (cable connectors fitted will depend on
country).
9.1 Test Procedure for Single Generating set Systems.
Pre-Startup Instructions
 Check all electrical connections.
 Check engine oil and coolant level.
 Ensure that the control switch is in the OFF position.
 Power up the 6000 series control panel.
 The unit will carry out a RAM check after which it will
display the application code version installed in the unit.
Verify that this is the latest version. If not, download the
latest version. The unit should now display the ‘Control
Overview’ screen.
 Enter security code.
 Check all program setpoints.
 Set synchroniser to ‘Run’.
 Set ‘Load Control Mode’ to ‘Droop’.
 For multiple unit systems set ‘Number of Units’ to ‘Single’.
Ensure that the generating set is connected to a isolated bus or
load bank.
Start engine using the ‘RUN’ position on the control switch.
Check operation of Emergency stop button.
Re-start generating set by clearing Emergency stop fault while
control switch still in ‘RUN’.
Check the RPM reading on the ‘Engine Overview’ screen.
Set up electronic governor (if fitted).
Ensure that generator breaker closes.
Ensure that generating set is running in ‘Droop’ mode by looking
at the ‘Synchroscope’ screen.
Check that the Volts and Speed Bias outputs on the ‘I/O Status’
screen are both zero.
Check the generator output voltage on the load bank.
Calibrate the Line-Neutral voltages as seen on the ‘Gen Phases’
screen.
Adjust output voltage at AVR to specified voltage.
Verify operation of the Volts raise/lower switches (if applicable).
 Verify that ‘Volts Bias’ reading in ‘I/O Status’ screen
changes when raise/lower switches are pressed.
 Set ‘Voltage Ramp Time’ if necessary.
Verify operation of the Speed raise/lower switches (if
applicable).
 Verify that ‘Speed Bias’ reading in ‘I/O Status’ screen
changes when raise/lower switches are pressed.
 Set ‘Load Raise Rate’ and ‘Load Lower Rate’ if necessary.
If the 6000 series control panel is controlling the generating
set volts:
 Set AVR ‘Droop’ potentiometer to halfway.
 Set AVR ‘Trim’ pot to give +/- 10% output voltage swing for
+/- 100% voltage bias output (by using the Volts
raise/lower switches).
If Mains PT connected:
 Check mains voltage readout (U:) in ‘Synchroscope’
screen.
Calibrate if necessary.
Apply a small load to the generating set.
Check CT polarity by observing current readouts in the ‘Gen
Phases’ screen.
Load generating set to full load.
Check current readouts on ‘Gen Phases’ screen.
Calibrate current readouts if necessary.
Remove load.
Turn control switch to ‘OFF’.
Verify that generating set shuts down correctly.
Set ‘Load Control Mode’ to ‘Normal’.
Start generating set by turning the control switch to ‘RUN’.
Check operation of all shutdowns and alarms.
Load up generating set to full load and complete full load test.
Remove load and shut down generating set.
Test Procedure for Multiple Generating set Systems.
Test each individual unit in single generating set mode as
outlined above.
Connect all generating sets to common local bus.
Set up RS-485 communication lines.
 Connect proper RS-485 twisted pair, overall screened
cable of characteristic impedance of 120 ohms between all
generating sets in system.
 If RS-485, 120 ohm cable is not available standard twisted
pair, overall screened cable should suffice.
22
 Connect screen to panel earth at one end only ensuring
that the screen connection is carried right through to the
opposite end of the system.
 Ensure proper RS-485 termination by setting DIP switches
4, 7, and 8 on switch bank SW-3 (located beside J-8) are in
the ‘ON’ position on both units at the end of the
communication path.
 Ensure DIP switches 4-8 on switch bank SW-3 are in the
‘OFF’ position on all other units.
Ensure all control switches is in the ‘OFF’ position.
Power up all 6000 series panels.
Enter security code.
Set up all controllers as follows:
 Set synchroniser to ‘Check’ on all but first machine.
 Set synchroniser to ‘Run’ on fist machine only.
 Set ‘Number of units’ setpoint to ‘Multiple’.
 Set ‘Load Control Mode’ to ‘Normal’.
 Disable any Loss of Mains detection.
 Set up network addresses and priorities ensuring that
network addresses are all unique.
 Disable closure of all generating set breakers, except first
unit, by disconnecting the close signal from the control
panel.
Turn all control switches to Auto and verify network
communications:
 All generating sets in ‘AUTO’ should be shown in the
‘Control Overview’ screen after the ‘UNIT:’ prompt.
 If any controllers are missing from the display, check that
there is no duplication of network priorities, check all RS-
485 cable connections and that the end of line termination
resistors are set correctly (see above).
 If all of the above are correct, but any controllers are still
missing from the display, increase the ‘NetComm
Dropouts’ setpoint to 10.
 If communications still not correct, replace faulty controller
and repeat all previous setup procedures.
Turn all control switches back to ‘OFF’.
Turn control switch on first unit to ‘RUN’.
Verify that first unit starts and closes onto the bus.
Calibrate Synchroniser on all remaining units.
 Turn control switch on next unit to ‘RUN’.
 Change to the ‘Synchroscope’ screen.
 Verify that the ‘Mains/Bus’ sensing changes to ‘BUS’.
 Verify that the ‘Dead Bus’ display changes to ‘NO’.
 Verify the Bus Volts readout, ‘U:’ on screen, is correct and
calibrate if necessary.
 Verify synching by measuring volts across generating set
breaker.
 When satisfied that synchroniser is correct, shut down
generating set and repeat steps 1-7 for next unit.
Check synchroniser operation on next unit:
 Ensure that first unit is running and closed onto the bus.
 Apply a load of approx. 1/2 full load capacity of first
generating set.
 Turn the control switch on the next generating set to
‘RUN’.
 Confirm phase/voltage matching and synchroniser Take units off line one at a time ensuring that bus load does not
operation. exceed full load capacity of remaining units.

 Verify generating set breaker closure.  Verify unload ramping.

Check ‘Load Control’:  Verify unload trip.
 Verify load ramping operation.  Verify cooldown operation.
 Verify that ramp rate is reasonable. Carry any further application specific operational tests required.

 Reduce ‘Load Control Gain’ setting if unstable during

ramping.
 Verify that operating mode changes to ‘ISOCH’ when
ramping complete.
 Increase bus load to approximately 1/2 full load capacity of
all generating sets currently on-line.
 Verify real load sharing operation.
 Reduce ‘Load Share Gain’ if unstable during load sharing.
 Verify Var/PF sharing (if applicable).
 Reduce ‘VAR/PF Gain’ if unstable during Var/PF sharing.
Repeat Synchroniser and Load Control operational checks for
all remaining generating sets.
Once all sets are on line and correctly set up, increase load on
bus to full system load capacity.
Run on full load for 5-10 mins to verify long term stability.

23
10. Troubleshooting

10.1 Control Hardware and I/O

Problem Probable Cause Corrective Action

Unit does not power up No input power supply Check +12 Vdc or +24 Vdc power supply
Input power supply reversed Ensure proper polarity of power supply to
GCP-1
Discrete inputs don’t show active in I/O STATUS Faulty wiring of discrete input switches Verify wiring of discrete input switches
screen when switches are activated
Displayed generator voltages are very small Faulty wiring of generator Potential Verify wiring of generator Potential
Transformers(PT’s) Transformers(PT’s)
Generator PT inputs are improperly Calibrate the appropriate PT input
calibrated channel(s). See section 1.10 Calibration of
Control Inputs and Outputs
I/O STATUS shows relay(s) is energized, but action(i.e. Faulty wiring of relay output contacts Verify wiring of relay output contacts
alarm) does not occur
Generator voltage fluctuates or is unstable at no load AVR dynamics are improperly set up Tune the AVR dynamics for stable
on generator operation. See AVR manufacturer’s
instruction manual for more details
Voltages or currents displayed by GCP-1 are different GCP-1 PT inputs are inaccurately Calibrate the appropriate PT input
than measured parameter calibrated channel(s). See section 1.10 Calibration of
Control Inputs and Outputs

10.2 Engine Control / Sensing Parameters

Problem Probable Cause Corrective Action

Start command(i.e. test or run with load) does not start
engine
Starter motor stays engaged after engine starts
Engine starts, but starter re-engages while engine is
running
Engine speed is unstable when unit is at no load
When crank command is issued, GCP-1 loses power
and conducts a reset and RAM test
Configuration menu has not been
accepted or entered properly
An active alarm condition exists
Relay output contacts are not properly
connected to engine starter, fuel solenoid
Crank cutout set point in Engine control
menu is to large
Inadequate MPU signal to GCP-1 input
Inadequate MPU signal to GCP-1 input
Speed control dynamics are improperly set
up
Battery is too weak for the current demand
of the starter motor
Faulty wiring of power supply to the GCP-
1 control
Enter the configuration set points in the
Configuration menu such that all “*” and “#”
symbols are removed from the lower two
lines of the display. See section 1.3.4
Description of set points for more details.
Commit or reset alarm condition(s). See
section 1.3.2 Description of Screens
Verify wiring of relay output contacts
Set CRANK CUTOUT set point to
appropriate value. See section 1.3.4
Description of set points
Verify MPU wiring, and that adequate MPU
signal exists at input to GCP-1 control
Verify MPU wiring, and that adequate MPU
signal exists at input to GCP-1 control
Tune the speed control dynamics for stable
operation. See speed control
manufacturer’s instruction manual for more
details
Install a higher capacity battery or a more
efficient starter motor
Verify wiring of power supply to the GCP-1
control

24
10.3 Synchronisation
Problem Probable Cause Corrective Action

Unit never adequately matches phase Synchronizer Mode set point in
synchroscope menu set to PERMISSIVE
Synchronizer dynamics in synchroscope
menu are improperly set up
Synchronizer displays small phase difference, but Generator A phase PT input is L-L and bus
measured phase difference is large A phase PT input is L-N or vice versa
Bus and/or generator PT inputs are not A
phase
Synchronizer improperly calibrated
Synchronizer matches phase, but never closes Synchronizer Mode set point
breaker/contactor synchroscope menu is set to CHECK
Dwell time set point in synchroscope menu
is too large
Synchronizer displays matched phase, but measured Generator or bus PT is reversed polarity
phase difference is ~180 degrees, or when breaker (faulty wiring)
closes it crash parallels the set 180 degrees out of
phase
Unit won’t close to dead bus Multiple unit system with DEADBUS
CLOSING set point in configuration menu
set to DISABLED
Synchronizer set point is set to CHECK
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Tune synchronizer dynamics. See section
1.3.4 Description of Set points
Verify that Generator A phase PT input bus
A phase PT input are the same form (i.e. L-
N or L-L)
Verify that Bus and generator PT inputs
are A phase
Calibrate synchronizer. See section 1.10
Calibration of Control Inputs and Outputs
in Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Reduce Dwell Time set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify correct polarity of Generator and bus
PT inputs
ENABLE DEADBUS CLOSING set point in
configuration menu. See section 1.3.4
Description of Set points
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points

Synchronizer won’t voltage match
Synchronizer does not voltage match within spec.
VOLTAGE MATCHING set point
synchroscope menu is DISABLED
Generator A phase PT and/or Bus A
phase PT input(s) are inadequately
calibrated
Voltage matching tolerance set point in
synchroscope menu is too large
in ENABLE the VOLTAGE MATCHING set
point in synchroscope menu. See section
1.3.4 Description of Set points
Calibrate the Generator A phase PT and
Bus A phase PT inputs. See section 1.10
Calibration of Control Inputs and Outputs
Appropriately set the Voltage matching
tolerance set point in synchroscope menu.
See section 1.3.4 Description of Set points

10.4 Breaker Close / Open Control

Problem Probable Cause Corrective Action

When generator set is in synchronization, the Synchronizer set to CHECK Set synchronizer Mode to appropriate setting.
breaker never closes See section 1.3.4 Description of Set points

Contactor closes for a brief moment and then
opens
Breaker close relay stays energized when a close
Faulty wiring causing the relay output to not
make connection to the breaker
Dwell time set point in the synchroscope menu is Reduce Dwell time set point in the
too long
C B CONTROL set point in configuration menu
is set for BREAKER
C B HOLD TIME set point in synchroscope
menu is too short
Faulty wiring on C.B. aux contacts
C B CONTROL set point is set for
Verify wiring of the relay output contacts.
synchroscope menu. See section 1.3.4
Description of Set points
Appropriately set the C B CONTROL set point
in configuration menu. See section 1.3.4
Description of Set points
Increase C B HOLD TIME set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify wiring of C.B. aux contacts to GCP-1
input
Appropriately set the C B CONTROL set point

25
 command is given and never issues an open CONTACTOR in configuration menu. See section 1.3.4
command Description of Set points

10.5 Real Load Control

Problem Probable Cause Corrective Action

kW for a phase(s) reads negative.
Unit carries improper proportion of real load during
isochronous load sharing
Real load control is unstable when paralleled with the
mains source
Process control operation causes overload or reverse
power
Loading and/or unloading is too fast/slow
Engine speed/load has an instability that fluctuates very
quickly.
Current transformer(CT) has reversed
polarity
Rated kW set point in configuration menu
set at incorrect value
A proportional dc speed error exists on the
speed control unit (no-load speed not set to
match bus frequency)
Real load control dynamics in real load
control menu are improperly set up
PROCESS ACTION set point in process
control menu set for incorrect action
Load and/or unload ramp rates in the real
load control menu are set incorrectly
Speed control dynamics are improperly set
up
Verify/reverse polarity of current
transformer for effected channel(s)
NOTE: engine generator set must be off
to safely open circuit a current
transformer
Appropriately set Rated kW set point in
configuration menu. See section 1.3.4
Description of Set points
Adjust speed setting of speed control to
match the bus frequency. If unit is carrying
too little load, the speed setting needs
increased. If unit is carrying too much load,
the speed setting needs decreased.
Tune Real load control dynamics in real
load control menu. See section 1.3.4
Description of Set points
Appropriately set PROCESS ACTION set
point in process control menu. See section
1.3.4 Description of Set points
Appropriately increase/decrease the Load
and/or unload ramp rates in the real load
control menu. See section 1.3.4 Description
of Set points
Tune the speed control dynamics for stable
operation. See speed control
manufacturer’s instruction manual for more
details

10.6 Reactive Load Control

Problem Probable Cause Corrective Action

Phase power factors do not agree. Two of the three CT’s are connected to incorrect phase Verify CT’s are connected to the
phases are extremely far out of range inputs appropriate input terminals
NOTE: engine generator set must be off
to safely open circuit a current
transformer
Unit carries improper proportion of reactive load during Rated kVA set point in the configuration Appropriately set the Rated kVA set point in
isochronous load sharing menu is set at incorrect value the configuration menu. See section 1.3.4
Description of Set points
Generator A phase PT input(s) are Calibrate the Generator A phase PT
improperly calibrated input(s) of the generator set(s). See section
1.10 Calibration of Control Inputs and
Outputs
Reactive load control is unstable when paralleled with the Reactive load control dynamics in the Tune the Reactive load control dynamics in
mains source reactive load control menu are improperly the reactive load control menu. See section
set up 1.3.4 Description of Set points
Unit maintains a constant VAR load rather than a VAR/PF set point in the reactive load Appropriately set the VAR/PF set point in
constant power factor when paralleled with the mains control menu is set to VAR CONTROL the reactive load control menu. See section
source 1.3.4 Description of Set points
Unit maintains a constant power factor load rather than a VAR/PF set point is set to PF CONTROL Appropriately set the VAR/PF set point in
constant VAR when paralleled with the mains source the reactive load control menu. See section
1.3.4 Description of Set points
Multiple generator sets are unstable when VAR/PF VOLTS RAMP TIME set point in reactive Appropriately set the VOLTS RAMP TIME
sharing at light loads load control menu is not adjusted properly set point in reactive load control menu. See
section 1.3.4 Description of Set points
Droop Current Transformer not properly Verify the connection of the Droop Current
connected to AVR Transformer to the AVR. See AVR
manufacturer’s instruction manual for more
details

26
10.7 Sequencing
Problem Probable Cause
Unit number(s) does not show up in the sequencing switch in manual position
order in the sequencing screen/unit doesn’t auto
sequence
Automatic mode set point in the configuration
menu set to disabled
Unit has an active alarm
RS-485 Network not connected at unit(s)
RS-485 Network is inadequately terminated
When system load is large enough to require additional NEXT GENERATING SET DELAY set point in
gen-sets, more than one set is sequenced on line sequencing menu is too short
MAX START TIME set point in sequencing
menu is too short
When system load is small enough to take additional REDUCED LOAD DELAY set point in
sets off line, more than one set is sequenced off line sequencing menu is too short
MAX STOP TIME set point in sequencing
menu is too short
10.8 Mains / Bus Sensing
Problem Probable Cause
Unit(s) do not respond to loss of mains Shutdown/alarm set points for mains
sensing not set for LOSS OF MAINS
Unit(s) do not have an active auto switch
input
Unit does not recognize when mains are in spec. Set points for mains high/low frequency
and high/low voltage in shutdown/alarm
menu are set too tight for sensing when
mains are in spec
10.9 Communications
Problem Probable Cause
A unit number(s) does not show up in the sequencing RS-485 Network is inadequately
order in the sequencing screen terminated
RS-485 Network not connected at unit(s)
RS-485 network is connected with reverse
polarity at one or more units
If a unit with the network termination is powered down, +5Vdc power supply is not linked between
communications become unreliable or completely units (inadequate wiring)
cease
27
Corrective Action
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
ENABLE the Automatic mode set point in
the configuration menu. See section 1.3.4
Description of Set points
Commit or reset alarm condition(s). See
section 1.3.2 Description of Screens
Verify that the RS-485 network is
connected to all GCP-1 controls in system.
Verify that the RS-485 Network is correctly
terminated. See section 1.9.6 Inter-Control
Communications (RS-485)
Increase NEXT GENERATING SET
DELAY set point in sequencing menu. See
section 1.3.4 Description of Set points
Increase MAX START TIME set point in
sequencing menu. See section 1.3.4
Description of Set points
Increase REDUCED LOAD DELAY set
point in sequencing menu. See section
1.3.4 Description of Set points
Increase MAX STOP TIME set point in
sequencing menu. See section 1.3.4
Description of Set points
Corrective Action
Appropriately set mains high/low frequency
and high/low voltage set points in
shutdown/alarm menu. See section 1.3.4
Description of set points
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
Increase Mains high frequency and voltage
and decrease mains low frequency and
voltage set points in the shutdown/alarm
menu. See section 1.3.4 Description of Set
points
Corrective Action
Verify that the RS-485 Network is correctly
terminated. See section 1.9.6 Inter-Control
Communications (RS-485)
Verify that the RS-485 Network is
connected to the GCP-1 RS-485 input at
all units
Verify the polarity of the RS-485 network
on all units
Verify that the +5Vdc power supply is
linked between all units
11. Definition of Terms
AMF Automatic Mains Failure. The ability of a control to
detect, and take action on a mains failure
condition. The GCP–1, which has AMF
capabilities, can be programmed to sense a loss
of mains condition based on mains voltage,
frequency, or a sudden load surge on a generator
operating in parallel with the mains. The action
taken by the GCP–1 when it senses a mains
failure can be programmed for either an alarm
action, or a standby power action where all
generators start and tie to the load after the failed
mains have been isolated from that load.
Automatic A control mode used by the GCP–1 to activate
Control several automatic functions within the control.
These functions, which are dependent upon
program setpoints and system configuration, are
Loss of Mains detection, Automatic Sequencing,
and Automatic dead bus closing, Automatic
control also effectively connects those GCP–1
units in automatic to the Local Operating Network
(LON).
Auto Switch A discrete input to the control which will initiate
automatic operation of the GCP–1.
ATS Automatic Transfer Switch. A device which
isolates the mains upon a sensed fault in the
mains, or through manual operation. The ATS
selects a secondary power source, such as a
diesel generator to supply the load when the
mains have been isolated. The ATS will also re-
connect the load to the mains when they are re-
established and stable. The GCP–1 control has
ATS functions.
Audible An alarm condition used by the GCP–1 for various
Alarm alarm settings which will cause the audible alarm
relay output to energize when reaching or
exceeding the alarm parameters.
Automatic The automatic addition, or subtraction of
Sequencing generators to/from the load based on
predetermined load levels being crossed for
specific periods of time. Automatic sequencing is
a function of a multiple generator system which is
operating in load sharing mode isolated from the
mains, or process control mode in parallel with the
mains.
AVR Automatic Voltage Regulator. A device which
controls the field excitation of an AC generator in
such a way as to maintain a specific voltage level
over the operating load range of the generator.
The GCP–1 control biases the voltage setting of
the AVR to voltage match during synchronization
and to control reactive load during load share and
mains parallel operation.
Base A term used to describe a generator loading
Load condition in which the generator is paralleled to
another source of power, typically the mains, and
loaded to a fixed kW level. The generator
maintains this kW level regardless of load on the
Mains.
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Breaker A device used to connect one power source to a
load, or to another power source. Breakers can be
either manually or automatically operated, and will
usually contain overcurrent protection. The GCP–
1 controls motorized breakers by issuing a
momentary breaker close output to energize the
breaker coil, and a separate breaker open output
to shunt trip the breaker to open it.
Contactor A device used to connect one power source to a
load, or to another power source. Contactors are
typically automatic in operation, and are energized
for closure from an external source. The GCP–1
controls contactors by issuing a contactor close
output to close the contactor, and removing this
output to open the contactor.
Dead Bus The ability of a generator breaker control device to
Closing sense, and safely close onto a load which has no
other generators or sources of power tied to it.
Dead Bus Closing must not allow two generators
to attempt closure to the dead bus at the same
time, since an out of phase paralleling situation
would likely occur. The GCP–1 uses its Local
Operating Network to ensure safe dead bus
closing among all units tied to this network. The
units have a single dead bus token, which allows
the unit possessing it to close to the dead bus.
Only one token exists on the network, so there is
no possibility of multiple units closing to the dead
bus simultaneously. Dead Bus Closing is always
active in single unit configurations.
Droop A reduction in the reference of a controlled
parameter as the amplitude of that parameter
increases (negative feedback). The GCP–1 uses
Kilowatt Droop as a manual means of loading the
generator when paralleling to another generator,
or to the mains.
Dwell A term used to describe the amount of time
Time required during synchronization in which one
power source is within a specified phase angle
window of another source it is synchronizing to.
Hard A shutdown condition used by the GCP–1 for
Shutdown various alarm settings which will cause the unit to
immediately open its generator breaker if on load,
and shut down by immediately opening its fuel
solenoid output when reaching or exceeding the
alarm parameters.
Isochronous A term which is used to describe a generator set
which will maintain its frequency at a constant
level as the load on that generator changes. The
GCP–1 typically uses isochronous load control
when in load sharing, or when operating as a
single unit. This assures a constant frequency
under all generator loads which are within the
capacity of the generator.
Inverse Time A time delay used for over current and reverse
Delay power detection, which utilizes both time and
amplitude of the condition to determine the active
trip level. The inverse time delay accounts for
rapid high amplitude conditions to cause a trip, as
well as long duration low amplitude conditions.

Isolated Bus A bus which is electrically isolated from the mains.
KVA Kilovolt-Amps. The power rating of the generator
set KVA is determined by multiplying the rated
voltage of the generator by the rated current.
KVAR Kilovolt-Amps Reactive. Reactive load is
produced by a phase angle differential between
the volts and the amps of the generator. KVAR
can either be a product of inductive or capacitive
loads when operating on an isolated bus, or can
be produced by the generator when operating in
parallel with another power source such as the
mains.
kW Kilowatts. Watts are the product of the voltage of
the generator and the current, which is produced
within the voltage cycle. kW load is resistive in
nature.
Load Typically the kW load on the generator at any
given time.
Load Surge A condition in which a step load on the generator,
which is operating in a mains parallel mode (base
load or process) above a certain amplitude can be
used to trigger a Loss of Mains condition.
Loss of A condition in which the sensed mains PT input to
Mains the GCP–1 falls below certain voltage and/or
frequency setpoints for a given period of time.
Load Surge can also be used to detect a Loss of
Mains condition. The GCP–1 can be configured to
trigger a Loss of Mains (LOM) reaction to these
conditions, and provide on site power generation
to supplement the load until such time as the
mains return and are stable.
Mains To synchronize and close an operating generator
Parallel to the mains. The GCP–1 can be configured for
Mains Parallel operation.
Master The Highest Priority unit in an operating automatic
system. The Master Control controls load sharing,
VAR/PF sharing, sequencing, synchronization to
the mains, mains breaker closure/opening, and
multiple unit starting.
Manual A switch input to the GCP–1 which puts the
control in a manual operating mode. When in
manual, the GCP–1 does not communicate with
other units on the network, and if in a multiple unit
system, will not issue a dead bus closing
command. Being in manual also cancels any Loss
of Mains detection for that particular unit.
Network A unique address assigned to each unit, which is
Address operating in an automatic system. The network
address is that particular units “name” on the
network so that it can be properly identified by
other units operating on the same network.
Network A unique number assigned to each unit operating
Priority in automatic on the network. Network priority
defines the sequence in which units will be taken
on/off load when operating in an automatic
sequencing configuration (load sharing or process
control). Automatic sequencing will place units on
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load as required starting at the highest network
priority (lowest numerical value), and adding units
of lower priority (higher numerical value) as the
load on that system increases above certain
defined limits. Automatic sequencing will also
remove units from the load in a reverse order of
that used for sequencing units on load, that is from
lowest priority (highest numerical value) to highest
priority (lowest numerical value). In addition to all
this, the unit with the highest network priority on
the network is considered the master, and all
other units with lower priorities are slaves to that
master.
No Parallel An operating mode of the GCP–1 which will not
allow the generators to operate in parallel with the
mains under any circumstances. All transitions to
and from the mains are completed using an open
transition action.
Parallel To synchronize and close an operating generator
to another generator, or to the mains.
Power A right triangle which is used to determine the
Triangle amplitude relationship between KVA, KW, and
KVAR
A switch input which selects a mode of control
Control used while in parallel with the mains. When
operating in process control, the GCP–1 receives
a 4-20 mA, or 1-5 VDC input from an external
transducer. This transducer monitors a variable
which is affected by the generator operation.
Variables such as imported power to a site,
exported power to the mains, exhaust
temperature, and fuel gas pressure levels are
typical for monitoring with a transducer. The
GCP–1 uses an internal reference level for the
process input, and compares this reference to the
transducer input.The GCP then raises or lowers
the amount of load on the generator to maintain
the process transducer input to the referenced
value.
Proportional A mode of load control used by the GCP–1 while
Load Sharing operating multiple units on an isolated bus.
Proportional Load Sharing measures the total KVA
capacity of all the units on the bus and divides the
total KVA load on the bus by this capacity. This
value is then sent over the network as a load
reference for all units operating in parallel on the
bus. The result of this is the ability of various KVA
rated units operating at their respective proportion
of the total load on the bus. This allows consistent
load sharing among units of various sizes
throughout their entire operating load range.
Run With A discrete input to the GCP–1 which signals the
Load unit to operate the generator on load. The way that
the control puts the generator on load depends
upon software configuration, and the type of
system the GCP–1 is configured for.
Slave A GCP–1 with lower network priority (Higher
numerical value) than the master.
Soft A shutdown condition used by the GCP–1 for
Shutdown various alarm settings which will cause the unit to
softly unload and cooldown when reaching or
exceeding the alarm parameters.
Soft Transfer A Load Control Mode of the GCP–1 which allows
the unit, or group of units to transfer power from
 the mains to the on site generators. Upon
reaching either a base load reference, or process
control reference level, the GCP–1 will issue a
command to open the mains breaker. This results
in a complete transition of power from the mains to
the on site generators.

Synchronize To match the frequency, phase angle, and voltage

of a generator to another power source such as a
generator or the mains. This will allow a safe
smooth breaker closure of that generator to the
power source. The GCP–1 uses Phase and
Voltage Matching to ensure there is a minimum of
potential across the breaker prior to closure.

Test A discrete input to the GCP–1 which is used to

start the engine for test and initial start check out.
The test input is also used with the run with load
or process inputs, and a software setpoint, to put
the GCP–1 into a soft transfer mode.

VAR/PF The ability to control a level of VAR or PF on a

Control generator while in parallel with the mains. The
GCP–1 has VAR/PF control features which allow
the user to set a desired VAR or PF level on the
generator while in parallel with the mains. The
VAR or PF level is maintained by changing the
excitation level of the generator. This is
accomplished by changing the voltage reference
level of the AVR from the GCP1.

VAR/PF The ability to share the VAR and PF load on

Sharing multiple units operating on an isolated bus. Like
load sharing, the GCP–1 VAR/PF sharing
measures the VARs of the load on the isolated
bus, and divides this value by the total VAR
capacity of the generators tied to the load. A
proportional VAR/PF level is then maintained
between all units tied to the load based on their
rated VAR capacity.

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