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Gensys Marine Technical Documentation PDF
Gensys Marine Technical Documentation PDF
Gensys Marine Technical Documentation PDF
April 2009
CRE Technology
130 Allée Charles-Victor Naudin
Zone des Templiers - Sophia Antipolis
06410 BIOT - FRANCE
Phone: + 33 (0)4.92.38.86.82 - Fax: + 33 (0)4.92.38.86.83
www.cretechnology.com - info@cretechnology.com
SARL au Capital de 300.000 Euros - RCS Antibes: 7488 625 000 15 N°TVA FR54 488 625 583
GENSYS MARINE – Technical documentation page 1/128
A40 Z1 9 0020 A-EN Technical documentation
Date Version Comments Par
1-04-2009 A Document based on GENSYS 1.0 technical documentation. JAM
You can download this documentation and the different documentation relating to GENSYS on our
web site: http://www.cretechnology.com/ .
NOTE :
Bureau VERITAS marine approval :
The control and monitoring functions must not be undertaken on the same module. The
engine securities (min oil pressure, over speed and oil absent) must not be handled by
the same module.
NOTE :
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury
and/or property damage.
Contact your CRE dealer for course training.
List of tables
Table 1 - LCD screen characteristics .................................................................................................... 11
Table 2 - Display Panel keys ................................................................................................................. 11
Table 3 - Service Panel keys................................................................................................................. 12
Table 4 - Control Panel keys ................................................................................................................. 13
Table 5 - M121 Control panel LEDs ...................................................................................................... 13
Table 6 – A40 Z1 Control Panel LEDs .................................................................................................. 13
Table 7 - Inputs/Outputs description...................................................................................................... 17
Table 8 – A40 Z1 User interface............................................................................................................ 18
Table 9 - Screensaver description......................................................................................................... 34
Table 10- Typical change over mode configuration .............................................................................. 38
Table 11 - Typical basic multi Generator configuration ......................................................................... 40
Table 12 - Typical basic configuration for GENSYS with parallel lines modules .................................. 41
Table 13 - Typical basic mains paralleling configuration....................................................................... 42
Table 14 - Paralleling with mains configuration..................................................................................... 45
Table 15 - GENSYS /GCR configuration............................................................................................... 46
Table 16 - Input functions ...................................................................................................................... 63
Table 17 - Wiring GENSYS Ù Auto Start Module ................................................................................ 79
Table 18 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus ................................. 105
Table 19 - Variables received by BROADCAST DATA via Inter GENSYS CANbus .......................... 106
Table 20 - CAN bus inhibition parameters........................................................................................... 110
Table 21 - CANopen configuration example ....................................................................................... 112
N.B.: in this manual, all mentions of the A40 Z0 should be considered as the A40 Z1.
1.2 Environment
Operating temperature
A40Z0 0 to 55°C
A40Z1 -20 to 70°C
A40Z2(GNSS) 0 to 55°C (UL certified)
A40B0,B1, B2, B3, B4, B5 5 to 55 °C (Bureau Veritas Marine agreement, Lloyds register)
Storage temperature -30 to +70°C
Humidity 5 to 95%
Tropic-proof circuits for normal operation in humid conditions.
Front panel: IP54 protection.
Back panel: IP20 protection.
Altitude: 2000m
1.3 Characteristics
Size 248x197x57mm (9.76x7.76x2.24in)
Weight 1.9kg (4.2oz)
Shift Used with other keys only (F1, F2, Not used.
I). Shift + I saves all parameters.
LED LED test: pressing this key will turn on all GENSYS LEDs. It is a simple test to
test check the LEDs and the keypad.
Auto Switches the system to automatic mode. The associated LED is ON when
AUTO mode is activated.
Semi Switches the system to Semi Auto (M121) or test (A40 Z1) mode. The
Auto associated LED is ON when TEST mode is activated.
Manu Switches the system to manual mode. The associated LED is ON when
MANU mode is activated.
Engine
Alternator
Engine
Alternator
The user can navigate through the different menus with the navigation bar and the / keys.
3.1.1 Navigation Mode
The navigation bar provides 5 contextual keys. Depending on the menu displayed, different icons may
appear above these keys, allowing the user to scroll up/down the pages or to select a link to a new
menu or parameter.
When the user selects a parameter and presses the ‘ ’ key, the browser switches to the ‘Input
mode’.
The 5 icons above contextual keys will change appearance depending on the type of parameter to
change (list of choice, label, numerical value, password...).
When in ‘Input mode’, the key will discard the parameter changes and return to the ‘Navigation
mode’. The key will confirm the parameter changes and return to the ‘Navigation mode’.
The browser displays a white pointer in front of each link or parameter of a menu. A black pointer will
indicate the active link or parameter. Figure 4- Browser link description shows these two pointers:
Label modification:
When the new parameter value is input, the user must press key to store and confirm the new
value.
3.1.3 Save parameters configuration
All GENSYS parameters used in configuration are stored in a FLASH memory. When a parameter is
changed by the user, the new value is stored in a RAM memory. This new value will be effective as
soon as it is entered, but it will be lost if the GENSYS power supply is cut or too low. To save the new
parameters in FLASH, you must use “SHIFT-I”. The user must press both + keys together.
This will start the backup sequence and store all parameters in the FLASH memory. Now, the new
parameters will be effective even after a power supply failure.
NOTE:
Due to the great number of parameters. The back-up procedure may take a few
seconds. It is thus essential to save parameters when the motor is stopped. To save all
parameters, the user must press at the same time on both + keys on the
GENSYS front panel. Otherwise, the new parameters will be lost when shutting down the
GENSYS.
menus. When the password page is shown on the LCD display, the user must first press on the
key (like for other parameters) to switch to the ‘Password Input mode’.
When all characters are entered, another press on the key will validate the password. If it is
correct, the main menu will appear on the LCD display. Otherwise, the password page will be
displayed again.
Default settings for the password are:
• Level 0: no password entered, just press "Enter" key.
• Level 1: 1.
• Level 2: Only for distributors.
The password of your level and those lower can be changed in the system menu.
Note: the menus might differ according to the security level of the password entered.
3.2 PC browser
GENSYS provides an efficient way of configuring your application thanks to its embedded Web server.
It is thus possible to access the different menus with a simple Web browser such as Netscape
Navigator or Internet Explorer. However, it is not recommended to be connected with the PC while the
engine is running.
Before connecting with the GENSYS you have to configure your computer as described in the next
chapter ". The next figure show a typical GENSYS menu accessed from a PC Web browser.
NOTE :
The user must press on both + keys at the same time on the GENSYS front
panel to save the parameters permanently. Otherwise, the new parameters will be lost
when shutting down the GENSYS.
A40W0
Figure 9 - GENSYS Ù PC
Data transfer takes place through a straight serial cable (with 9 wire DB9 connectors), as shown on
the figure above.
A few steps are required to configure a PC before controlling a GENSYS:
• Install the modem.
• Create a Dial-Up Networking Connection.
• Check the network properties.
• Set-up the internet security properties.
Communication between the GENSYS and the PC is carried out via a Dial-Up Network.
GENSYS MARINE – Technical documentation page 21/128
A40 Z1 9 0020 A-EN Technical documentation
The PC must be configured to communicate with a 19.2K bps modem with TCP/IP networking
enabled.
3.2.1.1 Check the network properties
Dial-Up Adapter and TCP/IP -> Dial-Up Adapter protocols must be present in the list. If they are not
there, create a new connection using the new connection wizard.
In the New Connection Wizard, select “connect to the network at my work place”. Then, click “Next”.
In the next page, select a 19 200 bps modem. Then, click “Next”.
In the connection name dialog box, in the “Company name” field write “GENSYS”. Click on “Next”
In the “Phone number to dial” dialog box, in the “Phone number” field, write: “123”. Then click “Next”.
Select “Yes, I have already installed the hardware”, and click “Next”.
In the next dialog box, under Manufacturers, Standard Model Types should be selected. Under
Models, select Standard 19200 bps Modem, then click Next.
In the next dialog box, select the Communications Port where GENSYS is connected as the port, and
then click Next.
In the Advanced parameters, in the “advanced options” tab, ensure that the modem is configured for 8
data bits, no parity, and one stop bit. Then click “OK”.
Click OK until you exit this dialog box.
Create a Dial-Up Networking Connection.
In the Control Panel, select Network Connection.
Double click on the “GENSYS” icon.
In the “General” tab, ensure that the selected modem is the modem installed in the previous step.
In the “Option” tab, in the dialling option, select “Display progress while connecting”.
In the “Networking” tab, select “PPP Windows 95/98/NT4/2000, Internet”. Select “Internet Protocol”.
Click on “Install”.
In the “General” tab, select “Use the following IP address” and write: 192.168.11.2. Then select
“Advanced”.
In the “DNS” tab, select “Append primary and connection specific DNS suffixes” and “Append parent
suffixes of the primary DNS suffix”.
In the “WINS” tab, select “enable LMHOSTS lookup” and in the NetBIOS setting, select “enable
NetBIOS over TCP/IP. Then, click OK.
=> =>
3.3 Screensaver
GENSYS has automatic screensavers. They only appear on the GENSYS LCD screen when you
press "Esc" in the password page or after an adjustable delay (GENSYS variable 1266). There are
four screensavers and the display depends on the mode and state of GENSYS:
Display in Manu
Screensaver Description Display in Auto mode
mode
4 customized lines
Customized
Customer Logo In Wait state (engine stopped). In other cases.
screen
Date and time
KW (in large font)
Voltage (in large font)
Generator When the generator breaker is When the generator
Frequency (in big font)
overview closed. breaker is closed.
Running hours (in large
font)
Crank Relay Output
Fuel Relay Output
Water Temp Digital
Input
Oil Pressure Digital
Input
Engine When you press Start
Emergency Stop In Start state and fault state.
overview or when in fault state.
Remote start
Nb of start attempts
Battery voltage (bar
graph)
Engine speed (bar
graph)
Frequency difference When the generator is
Synchronization (bar graph) ready and the
In Synchronization state.
column Voltage difference (bar generator breaker is
graph) opened.
GENSYS MARINE – Technical documentation page 33/128
A40 Z1 9 0020 A-EN Technical documentation
Phase difference
(column)
Frequency match (OK /
NOK)
Voltage match (OK /
NOK)
Phase match (OK /
NOK)
Table 9 - Screensaver description
To start the engine push the [Start] key and hold down until the oil pressure fault disappears. On the
front panel, the 2 LEDs above the generator should light up. The left hand LED indicates that a speed
greater than zero is measured, whereas the right hand LED indicates that a voltage other than zero is
measured.
If a speed regulator is connected to GENSYS, it is possible to increase the speed with the F1 key, and
decrease it with the F2 key.
If a voltage regulator is connected to GENSYS, it is possible to increase and decrease the voltage with
the SHIFT+F1 keys and SHIFT+F2 keys.
When the generator is synchronized, it is possible to close the breakers with the 0/I keys.
Important: The internal synch check relay is always active, i.e. it is impossible to close the breaker if
the conditions for closing are not met.
When the breaker is closed the corresponding LED on the front panel should light up.
As soon as the generator breaker is closed, the GENSYS is switched to droop mode for speed and
voltage, i.e. the speed and the voltage will decrease when the load increases.
To stop the engine, push the Stop key.
The generator starts with a remote start or in the case of mains failure. When the generator is ready
(voltage, frequency), the mains breaker is opened and the generator breaker is closed. Should the
mains return to normal conditions or remote start is off, after a programmed delay the generator
breaker is opened, the mains breaker is closed and the generator set is stopped.
Load sharing can be on a "base load" or "peak shaving" basis. Depending on the configuration, the
generator will stop either when there is a remote stop or when mains power returns to a stable level.
Speed
Nominal speed (1080 or 1081)
Idle speed (1079)
Crank drop out
(1325 or 1326 or 1327)
Start Stop
request request
Running timers Prelub Preglow Crank Crank rest Preglow Crank Warm up RPM stab Volt stab Safety on Cooling Rest
1145 1157 1135 1136 1157 1135 1139 1140 1141 1514 1142 1144
Warm up (2214)
(Terminal J6 to J15)
GENSET
GENSET
Power
Power
t t
MAINS
Power
OU
MAINS
Power
t
t
LOAD
Conso
LOAD
Conso t
t
GENSYS
Functions:
- Manual mode
- Auto mode
- RMS reasurements
- Test mode (three or single phase) Start/stop
- Nb of running hours - Electrical protections
Analog / logical inputs : (>V,<V,>f,<f,>Q, Alarms ... LV
>P,>I, ...) or
- Oil Pressure HV
- Water temp (100-
- remote start 480Vac)
- Emergency stop
- Genset breaker aux
- Mains breaker aux
- Pickup frequency
- Spares ...
Logical outputs:
Mains
- Crank
- Fuel solenoid LV
- Mains breaker or
HV
- Genset breaker
(100-
- Spares 480Vac)
Analog output:
Breakers
- analog signal to speed regulator management
Utility
For the generator to start when mains failure occurs, either a protection (mains or other) or a digital
input has to be configured as a "Mains electrical fault".
If remote start is on when mains are present the generator starts, GENSYS opens the mains breaker,
then closes the generator breaker and takes the load.
E0022 Mains voltage
400 V
triggered by a protection or
digital input set as "Mains
E2201 Mains electrical fault electrical fault"
Fastest mains
electrical fault
E1085
Mains back
Remote start on timer
E2002
terminal J3
Genset ready
E0003 Genset voltage
400 V
E1142 E1142
Cool E1459 Cool
Switchover
E2001 Generator CB down Switchover down
delay
E1459 delay
E1459
E1459
E2000 Mains CB Swithover
Swithover delay
delay
Second black
First black
First black
Second black
Utility
Variable
Variable number Variable label
value
1179 Gen. number 1 to n
1147 Nb of gen. N (>=2)
1148 Mains parallel No ch.over
1153 Mains regul X
1158 ILS compatible No
1177 Synchro mode Dynamic
1515 Deadbus manag. Yes
1258 Load/Unl. mode X
1020 MA kW <-> 20mA 0
1021 MA 0kW setting 0
ILS PowRcon
GENSYS 1 GENSYS 2 GENSYS n
Utility
Table 12 - Typical basic configuration for GENSYS with parallel lines modules
When GENSYS is in ILS compatible mode, the active power sharing is handled via the parallel lines.
You have to disconnect the AVR output (H2-H4) and have an external device control the reactive
power (CT droop...).
GENSYS
Mains
CPA2
Utility
400 V
Triggered by
fastest "Mains
E2201 Mains electrical fault electrical fault"
Remote start on
E2002
terminal J3
E1142
E1142
Cool
GE ready
GE ready
Cool
down
E2001 Generator CB down
Synchro
mains to GE
to Mains
to mains
There is only 1 black No black
START FOR EMERGENCY START FOR TEST
will only start if a mains protection or a digital input is programmed as or to transfert load from mains to GE.
"Mains electrical Fault".
Permanent:
When the remote start is on, GENSYS starts the generator, synchronizes and parallels with the mains,
then ramps up load until it reaches its set point. In base load mode (E1153), the generator has a
constant load and the mains take the utility load variations. If the utility load is less than the generator
set point, mains are in reverse power. In the peak shaving mode (E1153), the mains have a constant
load and the generator takes the utility load variations.
400 V
Triggered by
fastest "Mains
E2201 Mains electrical fault electrical fault"
Remote start on
E2002
terminal J3
Cool
E0003 Genset voltage down
400 V
E1142 E1152
Cool Unload
GE ready
GE ready
E1152
E1459 E1085 Unload
ramp E1151
E2000 Mains CB Swithover Mains back Load ramp
delay timer
Load ramp
Unload ramp
Synchro back
example)
to Mains
Synchronization bus
Réseau
PLC
Mains kW
CPA2
Utility
177 mm /
6.97 in
228 mm /
8.98 in
Figure 22 - Panel cut-out
Note: Cut-out must be cleaned of any metal dust before mounting.
7.2.2 Mounting:
To secure the GENSYS onto the panel, use the special kit provided with the module. The kit contains
4 screws, 2 brackets and 1 mounting tool.
If power and communication cables have to cross, they should do so at right angles.
Correct grounding is essential to minimise noise from electromagnetic interference (EMI) and is a
safety measure in electrical installations. To avoid EMI, shield communication and ground cables
appropriately.
If several GENSYS are used, all the power supply 0V (pin K3) must connected together with mini
10mm².
WARNING :
Please read the following recommendations to avoid any hardware damage to the
GENSYS CANBUS Driver (not isolated).
Note: If the K3 (0V) terminal is disconnected and the bus bar voltage is applied to the GENSYS,
there is the risk of getting AC voltage on the CANBUS terminals.
These isolators can be supplied by CRE Technology with the reference A40M0.
7.2.5 Vibrations:
In case of excessive vibration, the module must be mounted on suitable anti-vibration mountings.
7.2.6 Real time clock battery:
If the battery is disconnected, remove the rear panel and connect a 3V battery to the ST1 jumper
(+battery: ST1 up; -battery: ST1 down).
• Over speed
• Over voltage
• Emergency stop
• Oil Pressure
• Temp
How?
• Short-circuit the sensors.
• For over speed and over voltage, set the thresholds to 101%.
+ G9 Speed out
ESG offset (1077) +
G11 Speed
ref
ESG ESG
Terminal Terminal
Manufacturer Model Amplitude offset Remark
G9 (out) G11 (ref)
(1076) (1077)
E6 10% 0% B3
KG6 / System
E6 -25.00% 46.50% E3 NC
HEINZMANN
Voltage converter
PANDAROS to isolate the
24%
DC6 26% B3 A3 signal on the line.
(DC/DC) (advise)
GAIN OFFSET
0 0
255 0
255 255
0 255
Gain and Offset adjustment if you cannot obtain 400V on the AVR: Adjust the maximum voltage with
the AVR potentiometer, which is normally below 400VAC. Choose the best values for Gain and offset
to obtain the maximum deviation.
47R
AVR offset
(1104)
H4 AVR out -
BASLER DECS32-15-
xxx
DECS63-15- Use VAR control
xxx - - - - included in the
DECS125- DECS.
15-xxx
DECS300
VR63-4 240 240 VAR+ VAR- Remove the shunt
Aux input Aux input
DVR2010 100 0
MARATHON A B
ELECTRIC Replace with SE350
DVR2000 - - - -
or DVR2000E
Cosimat N+ 255 0 Pot + Pot -
AVK
MA329 155 0 A2(+) A1(-)
Remove the shunt
M8B 240 240 P Q
PQ
470nF capacitor
between 8 and M.
M8B400 0 0 8 6
MarelliMotori Don’t connect
shield.
470nF capacitor
between 6 and M.
M405A640 0 0 6 8
Don’t connect
shield.
Jumpers have to be
K65-12B 2 3
KATO 255 0 removed.
K125-10B Or 4 Or 7
Available soon
50kOhms in serial
MECC ALTE SPA UVR6 250 200 Pot + Pot -
with H2
Pot input
R449 253 255 Pot input - Remove the shunt
+
Pot input
R448 253 255 Pot input - Remove the shunt
+
LEROY SOMER
Pot input Pot input – Remove the shunt.
R221 100 241
+(6) (7) Pot ineffective
Pot input
R230 253 255 Pot input - Remove the shunt
+
Check synchronization
How?
GENSYS
J6: Input 1: Preheating (2273)
F6 / F7 F8 / F9
Figure 31 - Connections for water preheat, pre lubrication and pre glow
Auto mode
Pre-heat is activated if J6 is closed and if temperature is under the pre-set threshold (E0030 < E1154).
Note: The water temperature sensor is required in this instance.
Pre-lubrication will be activated when engine is in pre-start (E2057 = 1) if pressure is under the
threshold (E0029 < E1155). If the threshold (E1155) is 0, then pre-lubrication is active while the engine
is in pre-start (E2057 = 1). In the last case the oil pressure sensor isn’t required.
Pre glow is active when engine state is pre glow or start (E2057 = 12 or 2).
Manual mode
Preheat will be activated when J7 is closed. The water temperature sensor isn’t required.
Pre lubrication will be activated when J8 is closed. The oil pressure sensor isn’t required.
Pre glow will be activated when J9 is closed, when you push GENSYS start button, or when J10 is
closed.
GENSYS
F6 / F7
GENSYS
F1/F2 F3/F4
Fixed kW forced [E2258] Will force GENSYS to give constant power delivery. The
output governing system will maintain a fixed power output
from the genset. The “Power mode” (E2088) is forced to
Fixed kW (4).
kVAR sharing forced [E2259] The output to AVR will share reactive load with other
gensets, using the inter GENSYS CANbus. (E.g. to be used
in manual mode). The “AVR cont. mode” (E2090) is forced to
kVAR sharing (5).
Voltage Droop forced [E2656] Will force the GENSYS to apply Droop to the AVR command.
Set with [E1105]. The “AVR cont. mode” (E2090) is forced to
Voltage droop (1).
External manu mode request [E2261] Will put GENSYS into Manual mode. Will have the same
effect as the GENSYS "Manu" key.
Running with breaker open [E2661] Allow the engine to run in Auto mode without paralleling or
closing its breaker.
Select speed 2 [E2279] Will select the second speed set point.
Select volt 2 [E2280] Will select the second voltage set point.
Select KW 2 [E2281] Will select the second power output set point.
Select PNom 2 [E2513] Will select the second nominal power (active and reactive).
Preheating [E2273] Can be chosen if a coolant pre heating system is installed;
can be used in conjunction with a digital transistor output.
Will work in auto mode.
Manu fuel fill [E2252] To be selected for a manual fuel refill; to be used in
conjunction with digital outputs.
Man cool fill [E2253] To be selected for a manual coolant refill; to be used in
conjunction with digital outputs.
Manu oil fill [E2254] To be selected for a manual lubricant refill; to be used in
conjunction with digital outputs.
Heavy consumer request [E2766] To be selected to activate the "Heavy consumer control"
special sequence.
Horn [E2206] Can be used for external horn or flashing light relay; output
will activate whenever a protection triggers. The output will
have the same behaviour as the GENSYS front face LED. It
will be activated when a generator electrical fault [E2200],
mains electrical fault [E2201], alarm [E2202], fault [E2203] or
security [E2204] triggers, and while the GENSYS horn button
is pressed.
Fuel filling [E2229] Can be used for an external fuel pump in conjunction with
"Fuel low level" and "Fuel high level" or "Manu fuel fill"
functions of spare digital inputs.
Coolant filling [E2242] Can be used for a compressor in conjunction with "Coolant
high level" and "Coolant low level" or "Manu air fill" functions
of spare digital inputs.
Oil filling [2245] Can be used for oil level filling in conjunction with "Oil high
level" and "Oil low level" or "Manu oil fill" functions attributed
to spare digital inputs.
+f [E2341] The behaviour will change according to the mode. In Manual
-f [E2342] mode, if you program the +f function, the output will be
+U [E2343] activated when you press the GENSYS [+] key or if there is a
-U [E2344] “Manual +f request” [E2233]. Likewise for the other functions;
-f activates with [-] key or “Manual –f request [E2234]; -f
activates with [+]+SHIFT keys or “Manual +U request
[E2235]; -f activates with [-]+SHIFT keys or “Manual –U
request [E2236]. In Auto mode, these functions will control a
speed / voltage regulator requiring +/- contacts. You can
configure the no action range for the speed [E1598] and for
the voltage [E1599], the impulsion delay for the speed
[E1600] and for the voltage [E1601].
Damper [E2223] Will activate in stop sequence to stop the engine when
damping flap is fitted. Will be activated when there is an
engine fault [2046].
Generator stopped [E2240] Output will be active when genset is at rest. In Auto mode,
the output will be activated when the engine state [E2057] is
“Waiting” [0]. In Manu mode the output will be activated when
there is no speed [E0033].
F1 key [E2262] These keys are useful in Manu mode to control the speed
Shift + F1 keys [E2263] and the voltage.
F2 key [E2264]
Shift + F2 keys [E2265]
Manu mode [E2056] Output will be active when GENSYS is in manual mode.
Starter 2 [E2267] Will be active when a second engine starting system is
present and programmed in Configuration -> Start sequence
menu.
Starter 3 [E2268] Will be active when a third engine starting system is present
and programmed in Configuration -> Start sequence menu.
Ana1 threshold [E2269] Output will be active when the measurement of analogue
input 1 [oil pressure] is under the set value; it will not de-
activate until measurement is over [set value + hysteresis
value]. To be programmed and used with the following
parameters: “Oil threshold” [E1175], “Oil hysteresis” [E1176].
Ana2 threshold [E2270] Output will be active when the measurement of analogue
input 2 [water temperature] is over the set value; it will not
de-activate until measurement is under [set value minus
hysteresis value]. To be programmed and used with the
following parameters, “Wat temp thresh” [E1426], “Wat temp
hyst.” [E1427]
Ana3 threshold [E2271] Output will be active when the measurement of analogue
input 3 [1st spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 1 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 1 thresh.” [E1428], “Meas 1 hyst.” [E1429].
Ana4 threshold [E2272] Output will be active when the measurement of analogue
input 4 [2nd spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 2 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 2 thresh.” [E1430] and “Meas 2 hyst.” [E1431].
Available in Auto [E2525] Will activate when the genset has completed its start
sequence in auto mode - can be used for external logic. The
output will be activated when GENSYS is in Auto mode and
the power state [E2071] is not in fault [40, 100 or 255].
8.6.2 Polarity
For each of the five outputs, two options are possible:
• NE: normally energized; the output will de-energize when required, according to its function.
• ND: normally de-energized; the output will energize when required.
For « Normally closed » or « normally opened » inputs, wiring will be similar, only the software
requires modification.
GENSYS
F1 F2
-BAT
8.7.3 Parameters:
Calibration table for a normally closed input:
V1210 0 N Spare1 calib1 -32768 +32767
V1211 1 N Spare1 calib2 -32768 +32767
V1212 1 N Spare1 calib3 -32768 +32767
V1213 1 N Spare1 calib4 -32768 +32767
V1214 1 N Spare1 calib5 -32768 +32767
V1215 1 N Spare1 calib6 -32768 +32767
V1216 1 N Spare1 calib7 -32768 +32767
V1217 1 N Spare1 calib8 -32768 +32767
V1218 1 N Spare1 calib9 -32768 +32767
V1219 1 N Spare1 calib10 -32768 +32767
@*********************************;
@analog input to DI/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1 ;
@*********************************;
E2283:= E0031 ;
For normaly opened input, calibration table is similar, you must only
change equation by :
@*********************************;
@entree analogique en TOR/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1;
@*********************************;
E2283:= !E0031 ;
For Crank:
If E1989:= 0: The standard function applies, with E2018 to the A1 (crank) output.
If E1989 := 2xxx: One can create a new equation and switch to the A1 (crank) output. For this function,
write equations for the variable E2xxx.
Example 1:
Use the Crank Output to indicate an engine fault.
E1989:= E2217
Example 2:
Create a pulse to the A2 output (fuel)
E1710 is the time of the pulse (100 = 10 seconds)
E1916:= 2440;
BLOC
@example to create a pulse to the output A2 (fuel) pulse ;
TEST E2450 EQ 0 THEN
TEST E2019 EQ 1 THEN E2450 := 1 TEND
ELIF E2450 EQ 1 THEN
TEST E2451 GT E1710 THEN
E2450 := 2
ELSE INC E2451
TEND
ELIF E2450 EQ 2 THEN
BLOC
E2451 :=0;
TEST E2019 EQ 0 THEN E2450 :=0 TEND
BEND
TEND;
E2440 := E2450 EQ 1
BEND
When several generators are on the bus bar, one takes a central role with a fixed frequency of 50Hz.
The other generators determine load sharing using an integral so that each one has a perfect share.
The set point of the central frequency is the parameter E1080 (or E1081 if selected).
When the GENSYS starts, one genset is elected to be the master (the first one on the bus). The
master determines the central frequency and load sharing is without an integral. The other gensets
determine the load sharing with an integral, but without using the central frequency.
When you are in state E2071=29 (several generators paralleled with mains), the central frequency is
disabled.
9.2.2 Procedure
1. Download firmware 2.09 or later.
2. In manual mode, using F1 and F2, adjust the speed control output (G9-G11) to obtain the desired
frequency +/-2Hz from each genset.
3. Test that load sharing is working properly (default values inhibit the integral).
4. Activation of frequency centre with genset 1:
In Configuration/modification by variable number adjust E1476 to 2.
In Configuration/Active power regulation menu:
kW sharing GPI
G = 50 %(E1102)
P = 5 %( E1900)
I = 2 %(E1901)
Central Hz gain
G = 25% (E1902)
5. Adjust genset speed to 49Hz on speed governor (GENSYS in manual mode without load).
6. Switch to TEST mode. When the breaker is closed speed should go back to 50.00Hz within 5
seconds. Adjust the Hz central gain (E1902) to adjust the time if needed.
7. Repeat step 6 for all gensets.
8. Test the load sharing by changing the nominal frequency of one generator to 49Hz.
-> bus frequency should remain at 50 Hz and kW load sharing within 2% of that desired. The stability
of load sharing is adjusted with kW sharing GPI / I (E1901)
Remarks:
E1902 = stability of de-drooping (only activated in the master GENSYS, e.g. the one which closes its
breaker first). Adjust to recover 1Hz within 5 sec.
E1476 = 0 Ù Inhibition of central frequency; factory setting.
E1476 = with a high value, response time will be slower (recommended default value =2)
E1901 = Load sharing integral, is only active on the slave GENSYS units.
E1102 = Global gain of load sharing is obtained by multiplying the PI and the central Hz gain.
E2739 = 1 Ù I am the master (I control the frequency).
E2739 = 0 Ù I am a slave (I share load using the integral)
De-
Variable Disable
Label Description droop
number value
value
V1476 XXXXXX 2 0
not not
V2739 Master gen. Nb If 1 this GENSYS is the master.
used used
Warning:
When the CAN bus is not used, you have to disable load sharing (see table above).
In the case of a CAN bus failure where E1259 is not set at 6 (load sharing in droop
disabled), you also have to disable load sharing.
NB: For best results in sync it's important to set the GPID synch values high (80 to 200).
4. Start the engine with GENSYS in manual mode.
5. Engine should run near the nominal speed with deviation due to mechanical droop.
6. Put engine in Automatic mode. In this case the GENSYS should control the output until it
is running at the nominal speed, if a difference is present.
7. Set the frequency compensation for a recovery time of 10 sec for 0,5 Hz compensation
(E1874).
8. If the generator is changing the speed but over- or undershoots the nominal speed the
length of the E1873 pulse is too long. Make it a little bit shorter.
9. If it takes too long to reach the nominal speed the E1874 period is too long. Make this a
little bit shorter.
10. If you are not able to get the right compensation than the following needs to be checked:
- Does the potentiometer still turn if the GENSYS is sending an output signal.
- If not, the potentiometer is not able to control a sufficient speed range.
11. If each pulse causes overshooting it can be caused by the potentiometer motor running
on, even when the pulse is off. A shunt resistor over the motor input could solve this
problem.
12. Load the generator in island operation and the GENSYS in automatic mode, if possible
with full load.
13. Check if it still compensates the frequency according to the above specification (0,5 Hz in
10 sec).
14. If this is OK the Frequency compensation is set. (Repeat for all available engines)
15. Switch on one engine in auto mode and load it at 100 percent.
16. Disconnect the output to close the generator breaker of the next engine.
17. Start this engine in auto mode and wait until it shows in the information screen that it is
synchronizing. Simulate on the Generator aux input that the breaker is closed.
18. In the information screen you should see that the unit is in Load sharing mode.
19. Check the value of E2058: this should read as follows:
a. For the engine which is supplying the load, the value should be about – 6000.
b. For the engine which is not supplying the load, the value should be about + 6000.
20. If this value is lower than + 6000 or higher than – 6000 you have to increase the Load
sharing Gain.
21. If this value is higher than + 6000 or lower than – 6000 you have to decrease the Load
sharing Gain.
E1598 = DEADBAND
E2342 E1600
= pulse -Hz
DEADBAND=0.1Hz
E2342 E1873
= pulse -Hz
E1874
E2341 E1873
= pulse +Hz
E1874
Somation of both signals
E2342 E1873
= pulse -Hz
E1874
E2341 E1873
= pulse +Hz
K1 K2 K3 K4
C1 C2 C3 C4
K1 K2 K3 K4
Lower Volt
Raise Volt
Lower Hz
Raise Hz
Figure 35 - Pulse control
Parameters
Variable Value Description Menu
E1260 +f [E2341] C1 output Configuration/digital transistor output
E1261 -f [E2342] C2 output Configuration/digital transistor output
E1262 +U [2343] C3 output Configuration/digital transistor output
E1263 -U [2344] C4 output Configuration/digital transistor output
Summary:
• E1620 = 1.
• E2854 = Virtual Input 40 to allow the genset to return the load to the mains.
• E1699 = 1 : (E2584 ( VI 40) is “used by the equations)
E1846: Open breaker: selects the breaker that will be opened upon a "Mains electrical fault". Choose
between the "Mains" breaker or the "Generator" breaker or "both".
E1841: Fault start: allows the engine to start upon a "Mains electrical fault". You can select "Yes" to
start the engine or "No".
E1840: Start delay (0.0): is the delay between the "Mains electrical fault" and the engine start. It will
delay a digital or virtual input. In the case of an internal detection, this delay bypasses the delay of the
protection.
E1842: No load delay (60.0): is the time for which the engine runs without load when the generator
breaker is opened. If the delay is 0, the generator will never stop.
Default configuration
Start on fault and open generator on fault
This parameter is useful in permanent mains paralleling mode with "open generator breaker on mains
failure". It can be used if the generator nominal power is not high enough to take the load in island
mode.
In this case, the generator will provide power, but if there is a mains failure the generator will not take
the load alone, and opens its breaker.
In case the setup of the unit does not generate an engine start upon mains failure, it will run with no
load and stop after a preset time (E1842).
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Voltage bus
presence E2054
Start sequence
Timer before start on Mains back timer
Mains electrical fault
Production
request E2072
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Production
request E2072
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Power state
E2071 ParalleledFaultSync Paralleled Fault Sync ParalleledFault Sync ParalleledFault Sync ParalleledFault Stop
Generator CB
E2001
Generator electrical
fault E2200
Delay before re- Delay before re- Delay before re- Delay before re-
synchronization synchronization synchronization synchronization
Number of re-
synchronization
attempt = 3 Delay before reset of the
number of re-synchronization
attempt
0 1 0 1 2 3 4 0
NOTE :
Never use “No start on fault” in conjunction with "open mains on fault" in permanent
mode or no break change over mode.
Always use “No start on fault” when "generator breaker" or "both breakers" to open is
selected.
Remote start
Oil pressure
Crank Water temp
Pickup
Engine
M
Copy the following text and paste it in a new text file only.
You can download it to a GENSYS (level 1) as a starting point before commissioning.
CAUTION: this file is only a guide and is not enough to start a new application.
{PARAMETERS}
{INIT L1}
{END OF FILE}
E2585:=E2015;
E2514:=((E2514 OR ((E2015 EQ 1) AND (E2585 EQ 0))) AND ((E2514 AND
((E2015 EQ 1) AND (E2585 EQ 0))) EQ 0))
BEND
.
Don’t forget to set the input
V1276 1 N DI10 function +00000 +02999
Here the variable E2585 detects a rising edge on E2815.
Note: If E2197 is active, there will never be a Generator electrical fault (E2046).
Hardware:
Contacts for oil pressure and water temperature are no longer connected to J4 and J5 but to spare
configurable inputs.
In this example, the oil pressure and water temperature contacts are on J13 and J14.
Software:
The following equations must be downloaded to level 1 or 2
BLOC
@***************************************************************;
@Inhibition de la pression d'huile et de la temp eau ;
@***************************************************************;
@E2011 Entree logique 6 GENSYS inhibition securite ;
@E2012 entree spare 8 J13 pression d huile ;
@E2013 entree spare 9 J14 temperature eau ;
@E1274 fct entree spare 8 ;
@E1275 fct entree spare 9 ;
@E0033 vitesse ;
@E1712 param utilisateur: seuil de vitesse demarrage ;
@E1714 param utilisateur: seuil de vitesse arret ;
@E1456 Sens pression dhuile ;
@E1457 Sens temperature eau ;
@E2283 entree virtuelle 1 alarme inhibition ;
@***************************************************************;
100 - 480 V
See note 5
several generators
Surge
Pickup input
diverter
1-5A
See note 2
100 - 480 V
G8 G7 G10 K4 K5 H2 H4 H3 B2 B3 B4 B1 D6 D5 D4 D3 D2 D1 E6 E5 E4 E3 E2 E1 D8 D7 B6 B5 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15
Input 7
Input 8
Input 9
Input 10
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Oil pressure
Mains breaker IN
Gen Breaker IN
Water temp
Gen N
Remote start/stop
AVR out +
AVR out -
Gen I1-
Shield
Gen I3+
Gen I2+
Gen I1+
Gen 3-
Gen I2-
Shield 1
Gen L1
Gen L2
Gen L3
Actuator +
Pickup +
Actuator -
Pickup -
Mains L3
Mains L1
Mains I1 +
Mains I1 -
Mains Breaker NO
Gen Breaker NO
Gen Breaker NC
Mains common
Gen common
Mains Breaker NC
1 - NC 1 - NC 1 - NC 1 - NC
2 - NC 2 - CANL 2 - CANL 2 - Tx
3 - 0V 3 - 0V 3 - 0V 3 - Rx
+Alim GENSYS 4 - 0V 4 - NC 4 - NC 4 - DTR
5 - B (-) 5 - 0V 5 - 0V 5 - 0V
6 - A (+) 6 - 0V 6 - 0V 6 - DSR
Engine meas. 2 +
Engine meas. 1 -
Engine meas. 2 -
7 - NC 7 - CANH 7 - CANH 7 - RTS
Engine meas. +
Power supply +
8 - NC 8 - NC 8 - NC 8 - CTS
power supply -
9 - 0V 9 - NC 9 - NC 9 - RI
Emergency
DB9 female
0-20mA +
DB9 male DB9 male DB9 male
Parallel +
0-20mA -
Parallel -
relais out
Output 1
Output 2
Output 3
Output 4
Output 5
relay out
Shield
Shield
Shield
Crank
Fuel
stop
FUEL
load sharing
generator
-Alim
+Alim See note 2
- +
Battery Always present
See note 1 Not required
Synchronisation input
9.9.1 Schematic
PWM (%)
Offset = 70%
Amplitude = 30% 100
85
70
55
Specific applications
Meters preset
With this option you can set all the counters, and not only reset them.
Don’t forget to save the settings on the GENSYS [SHIFT] + [ i ].
P
+
Set Deviation
point
G I
-
D
Measure
G: global gain
P: proportional gain
I: integral gain
D: derivative gain
A generator can run in "Forced running" mode using a digital input or the "preferential" button on the
M121 model. Select a digital input with the function "Priority generator". Activate this input. The
generator starts, synchronizes, closes its breaker and stays on the bus bar until "Remote start/stop" is
de-activated.
If there are no generators in "Forced running" mode, the priority generator with "remote start" always
starts and closes its breaker on the bus bar, even if there is no load.
When all generators are stopped and have "remote start" activated, upon start-up the "Forced
running"" generators stay on the bus bar while the others coordinate stopping one by one.
How to determine the priority generator (which starts/stops) by using the variable "Load/Unl. mode"
(E1258):
-"Hours run" selected: the generator which has the least running hours has the priority to start, the
generator which has the most running hours has the priority to stop.
-"Digital in" selected: the generators start following a logical sequence ("Gen. number": E1179),
starting from the generator which is in "Forced running" mode (as shown below).
Note:
To force the start of a generator in load / unload mode, during commissioning for example, remote
start and digital input (in "Priority generator" mode) must be activated.
In "Hour run" mode, if a generator starts and goes past the hours run by a generator which is stopped,
the first one does not immediately stop and the second one immediately start. Coordination between
generators is activated only during a load or unload request, i.e. in the next start/stop on load request.
During a load request, only the stopped and available generators coordinate (auto mode selected; no
hard fault).
During an unload request, only the started generators coordinate.
GENSYS units in manual mode do not take part in start or load sequence.
1 2 3 4
ARBITRATION ORDER
Inhibited: [0]; the different GENSYS units installed on the power plant do not interact to start or
stop gensets according to the load demand.
Digital Input: [1]; if selected on all the GENSYS units installed on the power plant, the automatic
start/stop sequence will be done by the genset number, which is defined in the power plant
overview.
If a digital or virtual digital input of one GENSYS is set as priority generator, this GENSYS will start
first. The next to start will be decided by increasing genset number, which is defined in the power
plant overview settings menu. (E.g. if genset 2 has priority, then genset 3 will be the next to be
started upon increasing load, then genset 4; by decreasing load demand, genset 4 will be stopped
first, then genset 3...).
Load threshold [E1256]: Percentage of the genset nominal power (defined in the power plant
overview settings menu) at which GENSYS will ask another genset to start and share the load after
the following timer.
TM before load [E1257]: Timer for load sharing request.
Unload dep stp. [E1914]: Used to select the "unload dependant stop" sequence. Please refer to the
application note: A40Z090227.
GENSYS calculates the power that will remain on the bus bar (in % for each engine remaining) if it
decides to stop (and open its breaker). If this percentage is under the required threshold (E1915), then
GENSYS will stop. If not it will wait until threshold is reached.
Unload thresh. [E1254]: Only used if E1914 is set as NO: load dependent stop not used. It is the
percentage of the genset nominal power (defined in the power plant overview settings menu) at which
GENSYS will ask a genset to stop sharing the load after the following timer.
Unload dp. thrs [E1915]: Only used if the E1914 is set as YES: load dependent is used. GENSYS
calculates the power that will remain on the bus bar if it decides to stop. This is the threshold below
which GENSYS decides to stop. It is a percentage of the genset nominal power (defined in the power
plant overview).
TM bef. unload [E1255]: Timer used before deciding to reduce the number of gensets in load/unload
management.
This section describes the function which allows the Start/Stop of an engine on a power plant
depending on a KVAR threshold.
Procedure:
If KVAR (E0132) is higher than E1256 (in percent) OR if Kw (E0042) is higher than E1256 (in percent),
then GENSYS asks another engine to start (after a timer).
Summary:
E1619 = 1.
E1258 = 1, 2 or 3
E1254 and E1256 are KW and KVAR thresholds
E 1914 = 0
Variables used
E1619 Inhibit var = KVAR and KW auto start and stop (not only KW)
E1254 Unload threshold in %
E1256 Load threshold (to ask for KW help) in %
E1258 Load / Unload mode: (1=N° of GE, 2=hours run, 3=Custom(priority= E1617))
Examples that use Heavy Consumer Control: Using of a crane in a harbour, manoeuvring a ship in/out
of harbour using bow thrusters, etc …..
Procedure
To set the “Heavy Consumer Control” mode, go to the "Enhanced Configuration/Special
functions/Heavy Consumer control" menu. This can be accessed through the keyboard on GENSYS,
or with internet explorer as show below:
time
KW of Power Plant
200 KW
100 KW
time
100 KW
time
time
time
2
1
time
time
Procedure
To set the different thresholds and timers, go to the "Enhanced Configuration/Special functions Non
essential consumer trip" menu:
Using different thresholds and timers, you can create a fast standard protection:
Note: The settings of timer 1 and timer 2 are the same for overload and under frequency protection.
See diagrams below:
E2729 is activated
KW1
timer 1
E2729 is activated
KW2
timer 2
KW1
Min Hz 1 t
E2729 is activated
timer 1
Min Hz 2
Min Hz 1 t
E2729 is activated
timer 2
Min Hz 2
When the variable E2729 is activated, each trip output will activate after the same timer (E1894):
E2728:=1
E2727:=1 E2727:=1
E2729
1
To deactivate the outputs, it is necessary to reset the alarm “E2729” on the front panel.
10.1 Introduction
The core system of the GENSYS is based on a list of predefined variables.
The file named “40 Z0 9 0030.xls” gives an explanation of each of them.
The variable number always uses the same format.
The first digit is the type of variable:
• 0 Measurement or real time value (Ex: Voltage phase 1, CAN Bus Fault …)
• 1 Parameter to be stored in non-volatile memory (Ex: Genset number, Nominal power …)
• 2 General purpose variable (Ex: Alarms, PLC variables …)
•
The next 3 digits are the number of the variable.
All the parameters (Variable from 1000 to 1999) of the GENSYS are stored in a non-volatile FLASH
memory in the module. It is possible to download or upload these parameters with a computer allowing
the user to save, modify and reuse these parameters later.
All these values are stored in a text file. The following chapter describes the layout of that file.
Ex:
{PARAMETERS}
V1006 320 Gen nominal kW +00000 +65535
V1007 1.00 Gen PT ratio +00000 +65535
It is possible to modify the values directly in the text file before uploading it into the GENSYS. The user
must be sure that the modified value is within the minimum / maximum range. Failure to do so will lead
to an error message during uploading (Compilation result: VARIABLE).
It is also possible to write an incomplete parameter block (not all parameters are displayed in the list).
When uploaded, such a file will only modify the parameters which have been entered, the others
remain unchanged. This procedure can be used to upload an old text file into a newer GENSYS or to
activate special features independently.
The purpose of these blocks is to provide custom equations to the user which are run cyclically. These
equations are run every 100ms (PLC cycle time).
Non standard equations can be entered here to handle user defined features like thresholds,
Input/Output expansions, PID controls …
For further details on the programming language see the "PLC " chapter.
Note: It is strongly recommended not to add too many comments after the" End of File"
statement because the size of the file must not exceed 62Kbytes.
NOTE:
This file is a text ONLY file. Do not use word processors (like Microsoft© Word) to edit
this file: it would include layout information and corrupt the file. Use text editors only
(Notepad for example).
The file should not exceed 62Kbytes. If you try to transmit a bigger file to a GENSYS, it
will be rejected.
Note:
-Variables E1xxx/E4xxx are parameters stored in FLASH (non volatile memory). In level 2
and above, the user can allow the parameters to be written by PLC equations or via
MODBUS.
-Be very careful when modifying a parameter through equations, as unexpected behaviour
(due to an error in your equations for example) may damage your generator.
-It is advisable to include tests in the equations to verify that the engine is stopped prior to
changing a parameter. Otherwise, make modifications in the "INIT" block if possible.
These parameter modifications will not be saved in FLASH memory, i.e. parameters will
be reset to their previous value if power supply is turned OFF and then ON again, unless
the user saves them manually.
-Use document A53 Z0 9 0030 to get a complete list of all GENSYS variables.
-Variables E2xxx/E5xxx are outputs from the PLC; they can be read and written by PLC
equations without restrictions.
Each instruction is terminated by a semicolon (;) except before reserved words (BEND, ELIF, ELSE,
TEND). Init and program blocs are terminated by a dot (.).
Program PROG Starting point of PLC
INIT equations
. Starting point of INIT
equations
End of equations
Blocs BLOC Starting and ending points of
BEND a block of equations
Logical operators AND Logical operation used on a
OR whole variable (i.e. these are
XOR not bit to bit operators)
Unary operators ! Bit to bit complement
- Sign change
> Right shift
< Left shift
INC Increment
DEC Decrement
$ Hex value
Arithmetical operators + Addition
- Subtraction
* Multiplication
GENSYS MARINE – Technical documentation page 99/128
A40 Z1 9 0020 A-EN Technical documentation
/ Division
Bit operators ^ Rotation right
| Access one bit
# Bits mask
Affectation := Affectation
Comparison operators EQ Equal
NE Not Equal
GT Greater Than
LT Less Than
GE Greater or Equal
LE Less or Equal
Array [...] Array element
Tests TEST
THEN
ELIF
ELSE TEND
Comments @
The PLC equations only use 16 bit signed integer values. This means that all variables and data
should be between -32768 and +32767. This is an important point to keep in mind when comparing
values or doing calculations. For example, 20000*10 will produce a calculation overflow. For the same
reason, variables displayed with decimal digits are treated in the equations as if the decimal point
wasn’t there. For example, a power supply voltage of “24.5 V” will be treated as “245” in the equations.
Be careful when entering values which have digits after the decimal point. If you have one digit after
the dot, you have to multiply the number by 10. If you have two digits, multiply by 100.
For instance, the battery voltage measure (variable E0041), is from 0.0 to 6553.5, so you have one
digit after the dot. If you want to compare the battery voltage to 25.0 volts, you have to write:
TEST E0041 GT 250 THEN...
To know the number of digits after the dot, look in the “A53 Z0 9 0030-x.xls” file. In the 'Mini' / 'Maxi'
columns, the number of digits after dot appears.
Test examples:
TEST condition THEN instruction TEND;
Here is the standard pin out of a DB9 CAN connector compared with a GENSYS implementation:
GENSYS Standard
SHIELD GROUND
PIN 1 NC Cable Drain
PIN 2 CAN-L CAN-L
PIN 3 GROUND-1 CAN GND
PIN 4 NC free
PIN 5 GROUND-2 +24V POWER
PIN 6 GROUND-1 free
PIN 7 CAN-H CAN-H
PIN 8 NC free
PIN 9 NC 0V POWER
Note: GROUND-1 and GROUND-2 are each protected with a 47 ohms resistor.
CAN-BUS cable:
The CAN bus-BUS cable must be able to carry the CAN signals (CAN-L and CAN-H). These 2 signal
wires should be a 120 Ohm twisted pair (Ex: Belden's 3105A, 3082A-3087A (www.belden.com), LAPP
CABLE Unitronic bus DeviceNet or CAN (www.lappcable.com) or equivalent).
The CAN bus-BUS cable must be shielded, and must have a drain wire connected to the cable shield.
This drain connects to pin 1 of each connector. The connector housing must be connected to the
cable shield, and metallic shells should be used if possible.
For better results, a common GROUND should be used for all connected devices (this can be verified
easily with an ohmmeter, for example).
The total length of the cable must not exceed 250m for a CAN communication speed of 250kb/s. This
length may decrease with lower quality cables.
The last node on the CAN-BUS must have a 120-Ohm termination resistor plugged into its CAN
connector.
IMPORTANT:
2 2 2
3 3 3
R 4 4 4 R
5 5 5
7 7 7
9 9 9
G G
GENSYS1 GENSYS2
CAN1(COM2) CAN1(COM2)
A40W1
7m
G G G G
A40W2 A40W4 A40W2
7m 7m
A40W3
This fault only affects the working of a power plant with several GENSYS units (E1147 > 1).
In Auto mode, if there is a remote start and a CAN bus fault, the GENSYS starts and closes its
breaker after a delay that depends on the generator number (E1179), but only if the dead Bus
management is on (E1515 = 0) and there is no voltage on the bus bar.
Otherwise it will try to synchronize with the bus bar.
If the generator is paralleled to the Mains when a CAN bus fault occurs, and error control variable
E1259 is set to 6 (Droop mode + Alarm), speed control will be switched to droop and volt control will
be switched to power factor regulation. If the mains are not connected, both speed and voltage droop
is applied.
Note: If you need to disconnect a GENSYS from the inter GENSYS CAN bus, you must change
the number of generators (parameter E1147) on all other GENSYS units of the power
plant.
When the power plant is set to load/unload mode (Parameter E1258 set to "Hours run" or "Digital in"),
all generators will start using droop mode if a CAN bus error occurs.
GENSYS
Input 1 (E2006) N° 1
J6
E2006 E2752
E0552
CAN inter
GENSYS
GENSYS
N° 2
Input 1 (E2006) J6
E2006 E2752
E0536
To other GENSYS
GENSYS
Magnetic pick-up (E0033) N° 1
G7-8
E0033 E2762
E0562
CAN inter
GENSYS
GENSYS
N° 2
Magnetic pick-up (E0033) G7-8
E0033 E2762
E0546
To other GENSYS
To send value from GENSYS #1 to GENSYS #2, write this equation in GENSYS #1:
BLOC
@example to send digital input or analog input to each gensys oil pressure
input and speed;
E2752:=2006;
E2762:=33
BEND
To send value from GENSYS #2 to GENSYS #1, write this equation in GENSYS #2:
BLOC
@example to send digital input or analogue input to each gensys oil
pressure input and speed;
E2752:=2006;
E2762:=33
BEND
GENSYS #2:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
GENSYS #3:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
Important: Even if CAN bus inhibition is activated between GENSYS units (see below), broadcast data
is always sent and received on the inter GENSYS CAN bus.
Tie breaker
When the tie breaker is closed, all four GENSYS units should communicate with each other for power
management, so variables E2691 to E2694 should be set to 0 (zero) on every GENSYS unit (no CAN
inhibition).
When the tie breaker is open, generators DG1 and DG2 should communicate but ignore data from
DG3 and DG4. In the same way, generators DG3 and DG4 should communicate but ignore data from
DG1 and DG2. To do so, inhibition variables should be set as follows:
Feedback from the tie breaker can be connected to a GENSYS digital input and then used in custom
PLC equations to set or reset these inhibition variables.
11.5.1 How to set theses functions:
Special variables can be used to inhibit CAN bus variable use.
Each GENSYS is able to ignore (inhibit) all the others, depending to the state of the inhibition can
variable.
Note that this does not affect “BROADCAST DATA”, but only genset related functions.
5 - GND
WAGO
Note: Always group messages to/from one CANopen module. For example, do not use output
messages 1 and 3 with CANopen module number 1 and message 2 with CANopen
module number 2. It is preferable to use messages 1 and 2 with module number 1 and
message 3 with module number 2.
11.6.2 Read / write I/O
With the Info screen (view by pressing the info key), you can see the remote I/O:
• Digital inputs from 0157 to 0284
• Analogue inputs from 0285 to 0328
• Digital outputs from 2368 to 2431
• Analogue outputs from 2432 to 2439
To have the right variable associated to an input output, follow this rule: the lower variable number is
associated to the lower message number and the I/O nearest to the coupler.
Variable
Configuration Message number
number
Coupler 0159
number 2 5:
Second module : 0160
ID = 2 ; type digital ;
4 digital inputs
nb of Input = 4 0161
0162
Red "lamp"
This message is used to relay trouble code information that is of a severe enough condition that it
warrants stopping the engine. Variable E0403 contains the "Red lamp" value read from J1939. 0
means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Red lamp" message from the engine,
variable E1866 must be set (hard Shutdown is the default value).
-0: Disable
-1: Generator electrical fault
-2: Mains electrical fault
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown (default value)
-7: Help + Fault (Soft shut down)
-8: Help + Gen. Electrical fault
Amber "lamp"
This message is used to relay trouble code information that is reporting a problem with the engine
system where the engine need not be immediately stopped. Variable E0386 contains the "Amber
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Amber lamp" message from the engine,
variable E1865 must be set (disabled is the default value).
Protect "lamp"
This message is used to relay trouble code information that is reporting a problem with an engine
system that is most probably not electronic subsystem related. For instance, engine coolant
temperature is exceeding its prescribed temperature range. Variable E0363 contains the "Protect
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Protect lamp" message from the engine,
variable E1864 must be set (disabled is the default value).
-0: Disable (default value)
-1: Generator electrical fault
-2: Mains electrical fault
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
-7: Help + Fault (Soft shut down)
-8: Help + Gen. Electrical fault
Malfunction "lamp"
A message used to relay only emissions-related trouble code information. This message is only
illuminated when there is an emission-related trouble code active. Variable E0359 contains the
"Malfunction lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Malfunction lamp" message from the engine,
variable E1863 must be set (disabled is the default value).
Note: All the parameters are available in web pages in the System / Serial port / COM3 menu.
Please refer to J1939/71 standards to find the frame ID that fits your needs.
Note that there are no additional web pages to configure these custom RX frames. Please use custom
PLC equations to access custom RX variables. The variables are only accessible by equations.
Custom Tx Frame
If it is needed, a custom frame can be sent every 100ms by the system.
The Variable E2662 defines the size of the frame (from 0 to 8 bytes). A value of -1 switches off custom
TX frame transmission.
The Variables E2663, E2664, E2665, E2666 define the ID of the frame to be send sent (E2663 being
the least significant byte; E2666 is the most significant byte).
The Variables E2667 to E2674 contain the raw data to be sent (E2667 contains data byte 1).
Note that there are no additional web pages to configure the custom TX frame. Please use custom
PLC equations to access custom TX variables.
There are no additional web pages to configure this system; the variables are only accessible via
equations.
J1939 High
7 1
2 120 J1939 Low
2
3
GENSYS 1N4007
Batt Switched
4 EMS2
A2
Emergency
5
A3
Stop 6
7
8
+V Batt 8 poles
connector
Wiring on the serial port can be achieved using 2 wires, in point to point mode (1 master and 1 slave)
or in multi-drop mode (1 master and several slaves).
The following figure shows the wiring between the GENSYS and modem.
G G A40W4
G A40W4
G A40W4
A40W2
7m A40W3 7m A40W3 3 5 6
4 5 6 7 8
Supported functions:
04 Analogue reading
03 Register reading
The RTU address of the variables is the same as their number plus 1, converted into hexadecimal. For
example, variable 2000 (Mains break in) has for RTU address 07D1h (2001). See the Z090030.xls file
to locate the variable number.
Example: Here are two MODBUS RTU frames (request from a remote device and answer from
GENSYS). In this case GENSYS slave address is 5, and the request is to read variables E0000,
E0001 and E0002. The result is a function 04 request starting at address 1 (variable E000) and ending
at address 3 (variable E0002).
Request:
Fields Value (hex)
Slave address 05
Function 04
MSB start address 00
LSB start address 01
When you power up the GENSYS, the display does not work:
Check the bootstrap button on the back of GENSYS is off. Remove the power and change the position
of the bootstrap.
If there is no change, the module is defective and needs to be returned to CRE Technology.
+24V +24V
G1 G2
SYN SYN
GENSYS GENSYS
E5-E6 Gen. SYNCH E5-E6 Gen. SYNCH
ref CHECK ref CHECK
volt RELAY volt RELAY
Bus Bus
ref ref
volt volt
Mains
G
+24V +24V
Generator
Mains breaker
breaker NC
SYN SYN NC feedback
feedback
Warning:
Manual breaker opening.
When an external security device opens the breaker, the order has to be latched.
GENSYS needs the feedback.
Warning:
When a power plant has several generators, even if only one generator has a GENSYS,
the number of generators (E1147) must be equal or above 2. If it is 1, you may seriously
damage your generator.
Warning:
The engine, turbine, or other type of prime mover should be equipped with an over speed
(over temperature, or overpressure, where applicable) shutdown device that operates
independently from the prime mover control device.
CAUTION:
When a power plant has several generators, each GENSYS must have a different
number ("Genset number" variable: E1179). If two have the same number, there is no
conflict but there will be some operating problems.
Note:
To close the generator breaker the following conditions have to be met:
• Voltage must be in a window of 70% (parameter E1432) to 130% (parameter E1433) of the
nominal voltage (parameter E1107 or E1108)
• Speed must be in a window of 70% (parameter E1434) to 130% (parameter E1435) of the
nominal speed (parameter E1080 or E1081)
If the bus bar voltage is more than 10% of the nominal voltage, the generator has to be synchronizing
with the bus bar.
15.1 Options
Each of the following options can be selected and is password activated: contact your dealer for
procedure.
OPT1 PWM 500Hz for CATERPILLAR engine
OPT2 Mains paralleling option for single generator paralleled with the mains.
The most important paralleling functions are:
Phase shift
ROCOF
power management
15.2 Accessories
• A40W0 GENSYS to PC cable - DB9/DB9 - 3m.
• A40W1 CAN© inter GENSYS cable for 2 generators - DB9/DB9 - 120 Ohm termination resistor
included on both ends - 7m.
• A40W2 CAN© inter GENSYS cable for more than 2 generators or CANopen© I/O modules -
DB9/free wires - 120 Ohm termination resistor included on DB9 side - 7m.
• A40W3 DB9/Terminals connector to be used with more than 2 generators for double connection
(with screws).
• A40W4 Communication cable (RS485, CAN, RS232) - Price per meter.
• A40W5 DB9 termination resistor connector.
• A40W6 modem adaptor.
• A40W7 RS485 modem.
• A40X0 manual GENSYS test bench.
• A09Tx GCR: digital mains commander (x=0 for 100 VAC, x=1 for 230 VAC, x=2 for 400 VAC).
• A24Zx CPA : active power converter (x=0 for 100 VAC / 5 A, x=1 for 230 VAC / 5 A, x=2 for
400 VAC / 5 A, x=3 for 100 VAC / 1 A, x=4 for 230 VAC / 1 A, x=5 for 400 VAC / 1 A).
120R
120R
120R
WAGO
M F F F F
3m 7m 7m
120R
F
6 wires
F F
7m 7m
Temp : -30 -> +80°C
PVC : No resistance to fuel
WIRES
2 -- WHITE-BLUE STRIPE
7 -- BLUE-WHITE STRIPE
3 -- WHITE-GREEN STRIPE
4 -- GREEN-WHITE STRIPE
5 -- WHITE-ORANGE STRIPE
6 -- ORANGE-WHITE STRIPE
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