SED MAN GC2599 002 Manual For GC2599 Controller

ABSTRACT
This manual is intended as

an information guide for
operating SEDEMAC's
GC2599 genset controller.
Doc #SED-MAN-GC2599-002
MANUAL FOR Date: 10-Jul-2018
GC2599: GENSET
CONTROLLER
Product Manual Version #0.00
Copyright
All rights reserved. No part of this publication may be reproduced, distributed or
transmitted by any means (including photocopying or storing in any medium by
electronic means or other) without the prior written permission of the copyright
holder. Any reference to trademarked product names used within this publication
is owned by their respective companies. SEDEMAC Mechatronics Pvt. Ltd.
reserves the right to change the contents of this document without prior notice.
For permission requests and applications to reproduce any part of this publication
should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
SEDEMAC Mechatronics Pvt. Ltd.

C9-10, C Block, MIDC Bhosari
Pune 411026, INDIA
Web Support:
Email: support@sedemac.com
Website: www.sedemac.com
Telephonic Support:
+91-20-67313500
+91-8551041888
+91-8551043888
+91-8551933888
+91-8551039888
GC2599 SEDEMAC
Safety Instructions
General Instructions
✓ This document includes important instructions that should be followed during installation and
maintenance of the generator set controller.
✓ For safety reasons, the manufacturer recommends that this equipment be installed and serviced by
an authorized service personnel. Follow all applicable state and local electrical codes.
✓ Efficient and safe operation of the controller can be acquired only if the equipment is correctly
operated, configured and maintained.
Note: Many accidents arise due to ignorance or illiteracy towards the elemental rules of safety and
precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions
to the operator, service personnel or the equipment.
• Highlights an essential element of a procedure to ensure correctness
• Indicates a procedure or practice, which could result in damage or

destruction of equipment, if not followed strictly
• Indicates a procedure or practice, which could result in injuring

personnel or loss of life, if not followed correctly
Electrical safety
✓ Electric shock can cause severe personal injury or death.
✓ Ensure the generator set must be grounded before performing any installation or service.
✓ Generators produce high electrical voltages direct contact with it can cause fatal electrical shock.
Prevent contact with terminals, bare wires, connections, etc., while the generator and related
equipment are running. Do not tamper with interlocks.
✓ To handle the maximum electrical current, sizes of wire gauge used for electrical connections and
wirings must be appropriate to which they will be subjected to.
In operation safety
✓ Before installing genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.
Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical
shock.
✓ Remove electric power supply before removing controller or touching other electrical parts.
✓ Use extreme caution when working on electrical components. High voltage can cause injury or death.
✓ Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
✓ Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
✓ Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. It may result in severe electrical shock.
Page | i
GC2599 SEDEMAC
✓ Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
✓ In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. Avoid direct contact with the
victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live
conductor. If the victim is unconscious, apply first aid and get immediate medical help.
Page | ii
GC2599 SEDEMAC
List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer their
respective description. This List Does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
BTS Base Transceiver Station
CHG Charging
CKT Circuit
CT Current Transformer
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
NC Normally Closed
NO Normally Open
OV Over Voltage
PFC Potential Free Contacts
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
RTC Real Time Clock
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
SMPS Switched Mode Power Supply
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
Page | iii
GC2599 SEDEMAC
Table of Contents
Introduction ......................................................................................................................... 1
Key Highlights of the Product .......................................................................................... 1
Product Features ............................................................................................................ 1
Specifications ...................................................................................................................... 3
Terminals ........................................................................................................................ 3
Power Supply Specifications ........................................................................................... 4
Genset Voltages and Frequency Measurements ............................................................ 4
Genset Current Measurements ....................................................................................... 4
Earth/Fan Leakage Measurements ................................................................................. 5
Mains Voltages and Frequency Measurements .............................................................. 5
Digital Inputs ................................................................................................................... 5
Analog Resistive Sensor Inputs ...................................................................................... 6
Analog Current/Voltage Inputs ........................................................................................ 6
Site Battery Inputs ....................................................................................................... 6
Magnetic Pick Up Inputs .............................................................................................. 7
Digital Outputs ............................................................................................................. 7
Actuator Outputs .......................................................................................................... 7
PFC Outputs ................................................................................................................ 8
D+ CHG ALT ................................................................................................................ 8
Sensor Common Point................................................................................................. 8
Deep Sleep Mode Feature........................................................................................... 9
Communication Ports ....................................................................................................... 10
Installation ......................................................................................................................... 11
Dimensions ................................................................................................................... 11
Mounting on Panel ........................................................................................................ 11
Terminal Pin Details ...................................................................................................... 13
Typical Wiring Diagram ................................................................................................. 15
Monitoring Mode................................................................................................................ 16
Description of Control Keys ............................................................................................. 20
Functions of Control Keys ............................................................................................. 20
Configuration Mode....................................................................................................... 21
Configurable Parameters .............................................................................................. 21
Modes selection in GC2599 .............................................................................................. 38
Start and Stop Sequence .............................................................................................. 39
Operation Modes ............................................................................................................... 41
Auto Mode .................................................................................................................... 41
Manual Mode ................................................................................................................ 48
Page | iv
GC2599 SEDEMAC
Load Sensing ..................................................................................................................... 52
Features ............................................................................................................................. 52
Auto Config Exit Mode ............................................................................................... 52
Load Histogram ......................................................................................................... 52
Alarms ................................................................................................................................ 53
Troubleshooting ................................................................................................................ 57
Communication Protocol .................................................................................................. 59
Connection Details..................................................................................................... 59
Precautions................................................................................................................ 59
Supported Functions.................................................................................................. 60
Communication Settings .................................................................................................. 61
Notes ......................................................................................................................................... 68
Page | v
GC2599 SEDEMAC
List of Figure
Figure 1: GC2599 genset controller's front fascia ........................................................................ 2
Figure 2: Connectors of 5.08 mm pitch ........................................................................................ 3
Figure 3: Connectors of 10.16 mm pitch ...................................................................................... 3
Figure 4: SCP connection ............................................................................................................ 6
Figure 5: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side) ....... 8
Figure 6: Dimensions of the GC2599 genset controller ............................................................. 11
Figure 7: Fixing clip and screw supplied along with controller .................................................... 12
Figure 8: Controller mounting on the panel using the fixing clips ............................................... 12
Figure 9: Rear view of the controller for terminal detail .............................................................. 13
Figure 10: Power circuit when used in the Auto Mains Failure Mode ......................................... 15
Figure 11: Control keys function ................................................................................................. 20
Figure 12: Configuration mode screen ....................................................................................... 21
Figure 13: Configuration mode authentication page screen ....................................................... 21
Figure 14: Saving setting screen ................................................................................................ 21
Figure 15: Mode selection screen .............................................................................................. 38
Figure 16: Flow chart of start sequence ..................................................................................... 39
Figure 17: Flow chart of stop sequence ..................................................................................... 40
Figure 18: SMD of site monitoring mode .................................................................................... 42
Figure 19: SMD of Cyclic mode ................................................................................................. 43
Figure 20: SMD of Auto Mains Failure mode ............................................................................. 44
Figure 21: SMD of Exerciser mode ............................................................................................ 45
Figure 22: Flow chart of remote start/stop mode ........................................................................ 46
Figure 23: SMD for night restriction mode.................................................................................. 47
Figure 24: SMD of Manual mode ............................................................................................... 48
Figure 25: Pictorial reference for starting the engine ................................................................. 49
Figure 26: Pictorial reference for stopping the engine ................................................................ 49
Figure 27: Analog voltage input terminals of GC2599 ................................................................ 50
Figure 28: Pictorial reference for acknowledging & clearing the alarms ..................................... 51
Figure 29: RS485 MODBUS connection with the help of two core shielded twisted pair cable . 59
Page | vi
GC2599 SEDEMAC
List of Tables
Table 1: Features list .................................................................................................................... 2
Table 2: Pitch connector details ................................................................................................... 3
Table 3: Power supply specifications ........................................................................................... 4
Table 4: Genset voltages and frequency measurements ............................................................. 4
Table 5: Genset current measurements ....................................................................................... 4
Table 6: Earth leakage measurements ......................................................................................... 5
Table 7: Mains voltages and frequency measurements ............................................................... 5
Table 8: Digital inputs ................................................................................................................... 5
Table 9: Analog resistive sensor inputs ........................................................................................ 6
Table 10: Analog current/voltage inputs ....................................................................................... 6
Table 11: Site battery inputs ......................................................................................................... 6
Table 12: Magnetic pick-up inputs ................................................................................................ 7
Table 13: Digital outputs ............................................................................................................... 7
Table 14: Actuator outputs............................................................................................................ 7
Table 15: PFC outputs ................................................................................................................. 8
Table 16: D+ CHG ALT ................................................................................................................. 8
Table 17: Sensor common point ................................................................................................... 9
Table 18: Communication ports .................................................................................................. 10
Table 19: Details of GC2599 terminals ....................................................................................... 13
Table 20: Screens of engine status and operating modes ......................................................... 16
Table 21: Control keys in different modes .................................................................................. 20
Table 22: List of configurable parameters .................................................................................. 21
Table 23: Digital input source selection ...................................................................................... 35
Table 24: LOP (Resistive) sensor calibration ............................................................................. 36
Table 25: Fuel level sensor calibration ....................................................................................... 36
Table 26: Engine / shelter temperature sensor calibration ......................................................... 36
Table 27: Auxiliary (S1/S2) resistive sensor calibration .............................................................. 36
Table 28: Auxiliary (S3/S4) current sensor calibration ................................................................ 36
Table 29: LOP (4-20 mA) sensor calibration .............................................................................. 36
Table 30: Auxiliary (S3/S4) voltage sensor calibration ............................................................... 36
Table 31: Load – RPM calibration .............................................................................................. 36
Table 32: Digital output source selection .................................................................................... 36
Table 33: Types of alarms actions and their descriptions ........................................................... 53
Table 34: Alarms and their causes ............................................................................................. 53
Table 35: Troubleshooting .......................................................................................................... 57
Table 36: Details of function codes ............................................................................................ 60
Table 37: RS485 MODBUS communication configuration setting .............................................. 61
Table 38: Command from MODBUS master for Function 4 ....................................................... 61
Table 39: Normal response from GC2599 slave for Function 4 .................................................. 61
Table 40: Register map .............................................................................................................. 62
Page | vii
GC2599 SEDEMAC
Introduction
This document presents information necessary for operating SEDEMAC's GC2599 genset
controller.
SEDEMAC’s GC2599 is a modern and feature rich genset controller with user-friendly HMI and full
graphics LCD. The GC2599 controller comes bundled with highly versatile software & extensive
I/O's and thereby supports a wide variety of industry standard features in diesel/gasoline genset
applications. A key feature in the GC2599 controller is load-based variable speed operation for
telecom tower gensets. The controller incorporates a built-in governor module that directly drives
SEDEMAC’s rotary actuators and helps save fuel consumption under part load conditions
prevalent in the telecom tower application. The governor module can also be configured to operate
in 0% droop fixed speed operation to support non-telecom applications with sensitivity to power
quality. GC2599 controller offers site battery monitoring feature by which there is significant
saving in fuel consumption. In the above feature shelter temperature monitoring feature is also
supported. Apart from this it also supports auto (AMF, remote start /stop modes, cyclic mode, Site
mode and exerciser mode), manual and test modes.
GC2599 controller offer unique features such as electronic governing for engines with mechanical
fuel systems. With a SEDEMAC's Rotary Actuator as an add-on for air / fuel charge control, these
controllers can subsume the electronic governing duty for the engine and offers tight speed
governing performance within ISO 8528: G3 class limits. The GC2599 controller's smart software
offers flexibility to configure each individual Input and Output for a specific function or application.
The powerful micro controller contained within the module allows for incorporation of a range of
complex features such as:
• LCD display
• True RMS Voltage and Current monitoring
• MODBUS RS485 based communication
• Monitoring of engine and alternator parameters
• Fully configurable inputs and outputs for range of functions
Key Highlights of the Product

• Auto (Site battery back up, AMF, remote start /stop, cyclic modes and exerciser mode), Manual
and Test modes
• Site battery monitoring
• Shelter Temperature Monitoring
• Electronic governor controller integration
• Real time clock
• Fuel theft alarm
• Cyclic timer
• RPM sensing using genset’s output frequency and MPU
• Backlit and full graphics display
• Night restriction option
• Earth leakage detection
• Auto Exerciser (2 Events)- Scheduler
Product Features
GC2599 is a very enhanced and feature rich genset controller. It has 9 digital inputs and 7 analog
inputs. Full features list is provided in below Table 1.
Page | 1
GC2599 SEDEMAC
Table 1: Features list
Features Spec / Remark
Digital Switch Input 9
Analog Resistive Inputs 5
Analog Current/Voltage Inputs 2
E-gov actuator output Y
Differential input (±60V DC) for Site battery voltage Y
Mains V-Input (AMF) Y
DG Alt V-Input, D+ CHG ALT I/O Y
Digital HSD including 2 PFCs 9
Event logs Y
USB port for PC based configuration Y
RS-485 for MODBUS communication Y
Operating Battery Supply Voltage (with -32V reverse protection) 8 to 32V DC
Operating Temperature Range (deg C) -20 to 65
Ingress Protection with Optional Gasket IP65
Sensor common Input with ±2V Sensing Range Y
Warning auto clear enable/disable Y
Fuel reference selection input Y
Figure 1: GC2599 genset controller's front fascia
Page | 2
GC2599 SEDEMAC
Specifications
Terminals
GC2599 controller host two types of terminal blocks as shown in Figure 2 and Figure 3 given below:
Table 2: Pitch connector details
Connector Male (on SM Part Female SM Part
Pitch Quantity
type controller) Number (mating part) Number
3-Pin 5.08 mm 5447366 SM0003213 5441977 SM0003292 1
4-Pin 5.08 mm 5447379 SM0003207 5448637 SM0003451 2
5-Pin 5.08 mm 5447382 SM0003205 5448640 SM0003293 1
6-Pin 5.08 mm 5441919 SM0003203 5441964 SM0003452 1
8-Pin 5.08 mm 5441935 SM0003201 5441951 SM0003294 1
9-Pin 5.08 mm 5447395 SM0003198 5448653 SM0003453 1
10-Pin 5.08 mm 5447405 SM0003196 5448666 SM0003501 1
4-Pin 10.16 mm 5474274 SM0003195 5453499 SM0001163 3
Figure 2: Connectors of 5.08 mm pitch
Figure 3: Connectors of 10.16 mm pitch
Page | 3
GC2599 SEDEMAC
Power Supply Specifications
Following table gives a brief overview of power supply specifications
Table 3: Power supply specifications
GCU connector terminal # 1 & 2 (Ground & Battery +Ve respectively)
Supply voltage range 8 to 32 V-DC (Suitable for 12/24 V-DC system)
Cranking drop out period 50 mS
Maximum reverse voltage protection -32 V-DC
Measurement accuracy (Battery Voltage) ±1% of full scale
Resolution 0.1 V
~ 0.4 A @ 12 V-DC (Excluding the current load for the
Maximum current consumption
high side driver output's)
Standby current consumption ~0.09 A @ 12V or 24V
Genset Voltages and Frequency Measurements

Following table gives a brief overview of genset voltages and frequency measurements
Table 4: Genset voltages and frequency measurements
GCU connector terminal # 54, 55, 56, 57 (N, B, Y, R respectively)
Measurement type True RMS
Phase to Neutral voltage reading limit 20 to 350 V-AC RMS
Phase to Phase voltage reading limit 20 to 606 V-AC RMS
±1% of full scale for Phase to Neutral
Measurement accuracy (Voltage) (P-P / P-N)
±1.5% of full scale for Phase to Phase
1 V-AC RMS for Phase to Neutral
Resolution (Voltage)
2 V-AC RMS for Phase to Phase
Frequency range 5 to 75 Hz
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For 1 phase genset application, it is mandatory to connect the genset phase and
Neutral cables to the genset controller's phase R and Neutral terminals respectively.
Genset Current Measurements

Following table gives a brief overview of genset current measurements
Table 5: Genset current measurements
47 & 46 (for phase B), 45 & 44 (for phase Y),
GCU connector terminal #
43 & 42 (for phase R)
Maximum CT secondary current rating 5A
Burden 0.25 VA
Measurement accuracy ±1.4% of full scale
Page | 4
GC2599 SEDEMAC
Earth/Fan Leakage Measurements
Following table gives a brief overview of earth leakage measurements
Table 6: Earth leakage measurements
GCU connector terminal # 48 & 49
Maximum CT secondary current rating 5A
Burden 0.25 VA
Measurement accuracy ±1.4% of full scale
Follow the recommended phase sequence while connecting the Current Transformer.
Mains Voltages and Frequency Measurements

Following table gives a brief overview of Mains voltages and frequency measurements
Table 7: Mains voltages and frequency measurements
GCU connector terminal # 50, 51, 52, 53 (N, B, Y, R respectively)
Phase to Neutral voltage 20 to 350 V- AC RMS
Phase to Phase voltage 20 to 606 V-AC RMS
±2% of full scale for Phase to Neutral
Measurement accuracy (Voltage)
±2.5% of full scale for Phase to Phase
1 V-AC RMS for Phase to Neutral
Resolution (Voltage)
2 V-AC RMS for Phase to Phase
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For 1 phase application, it is mandatory to connect the mains phase and neutral
Cables to the genset controller's phase R and Neutral terminals respectively.
Digital Inputs
Following table gives a brief overview of digital inputs
Table 8: Digital inputs
GCU connector terminal # 33, 34, 35, 36, 37, 38, 39, 40, 41
Number of inputs 9
Type Negative sensing (connect to ground for activation)
0.8 V-DC maximum (measured at the genset
Low level threshold
controller’s terminals and battery ground terminal)
8 V-DC minimum (measured at the genset
High level threshold
controller’s terminals and battery ground terminal)
Emergency stop, Remote start/ stop, etc. Please
Software configurable options
refer Table 23 for more details.
Page | 5
GC2599 SEDEMAC
Analog Resistive Sensor Inputs
Following table gives a brief overview of analog resistive sensor inputs
Table 9: Analog resistive sensor inputs
GCU connector terminal # 11, 12, 13, 14, 15 (LOP, Fuel, Temp, Aux1, Aux2)
Number of inputs 5
Type Ratio-metric sensing
Range 10 to 5000Ω
Open circuit detection Above 5.5 KΩ
Measurement accuracy ±2% of full scale (for range 50 to 1000Ω)
Figure 4: SCP connection
Analog Current/Voltage Inputs

Following table gives a brief overview of analog voltage/current inputs
Table 10: Analog current/voltage inputs
GCU connector terminal # 21, 23 (Aux3, Aux4)
Type Current/Voltage
Range 4mA to 20mA/0 to 5 V-DC
Accuracy ± 1.25% of full scale
For genset paralleling application, configure input Aux4 (Pin 23) to accept a 0-5 V-DC speed bias
signal generated by a LSM (Load Sharing Module)
Site Battery Inputs

Following table gives a brief overview of Site Battery inputs
Table 11: Site battery inputs
GCU connector terminal # 24, 25
Number of inputs 2
Type Differential
Page | 6
GC2599 SEDEMAC
Range ±60V
Resolution 0.1V
Accuracy ±2% of full scale (0 to +Ve max/ 0 to -Ve max)
Site battery run hours: In this feature, controller calculates the run hours for which the site runs on the
battery backup. Site battery run hours are incremented only when both the mains and genset
contactors are not latched and when site battery voltage is greater than low battery voltage threshold.
Magnetic Pick Up Inputs

The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine
speed sensing. The output of MPU is a sine-wave signal.
Table 12: Magnetic pick-up inputs
GCU connector terminal # 22
Type Single ended
Input voltage range 200mV to 45 V-AC RMS
The MPU (Magnetic Pick-Up) is an inductive sensor fitted on the engine flywheel for the engine speed
sensing. The output of MPU is a sine wave signal.
Digital Outputs
Following table gives a brief overview of digital outputs
Table 13: Digital outputs
GCU connector terminal # 3, 4, 5, 6, 7, 8, 9
Number of outputs 7
Type High side driver
Maximum current rating 5A (3 & 4), 1A (5, 6, 7, 8, 9)
Start relay, Fuel relay, Close genset contactor, close
Software configurable options mains contactor, Stop solenoid and many more.
Please refer Table 32 for more details.
1) Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID” directly to

the controller's output terminals and it is recommended to connect 3 & 4 to start &
stop.
2) Genset & mains contactor latching relays should be compiled against 4kVA surge
as per IEC-61000-4-5 standard.
Actuator Outputs
Following table gives a brief overview of actuator outputs
Table 14: Actuator outputs
GCU connector terminal # 17, 18, 19, 20
Type Stepper motor drive
Maximum current 1A each coil
Page | 7
GC2599 SEDEMAC
Figure 5: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side)
The Actuator outputs are used only for the SEDEMAC's Actuator, if installed. The SEDEMAC's
Actuator is a 4-wire Actuator that is used for creating an electronic governing application in case of
a mechanical fuel system engine. In diesel engines, the Rotary Actuator's shaft output gets
mechanically connected to the stop lever or the throttle lever of an in-line or rotary fuel injection
pump. In case of petrol or natural gas engines, the Rotary Actuator's shaft output gets connected
to the throttle/charge control valve.
PFC Outputs
Following table gives a brief overview of PFC outputs
Table 15: PFC outputs
GCU connector terminal # 26, 27, 28, 29
Number of outputs 2
Type Potential free
Maximum current rating 8A
Start relay, Fuel relay, Close genset contactor, close
Software configurable options mains contactor, Stop solenoid and many more.
Please refer Table 32 for more details.
• Recommended for genset contactor and mains contactor
D+ CHG ALT
Following table gives a brief overview of D+ CHG ALT
Table 16: D+ CHG ALT
Voltage range 0 to VBATT; VBATT = 8 to 30 V-DC
Excitation PWM (Current limited to 250mA)
Accuracy ±2% of full scale
*The charge fail is a combined input and output terminal. When the genset starts, the terminal provides
the excitation current to the charge alternator field winding. After the excitation is successfully done, the
controller reads the charging alternator's output voltage for monitoring its health. The action for charge
fail is configurable.
Sensor Common Point

The sensor common point (SCP) terminal (Pin # 16) of the controller should be directly connected to an
electrically sound point on the engine body. This point on the engine body should serve as a common
reference point for all analog sensors such as those for measuring lube oil pressure, engine
temperature and fuel level. The electrical cable used for the connection should not be shared with any
Page | 8
GC2599 SEDEMAC
other electrical connection. Such a wiring practice is strongly recommended to ensure that there is
negligible potential difference, if any, between the engine body and the controller's SCP terminal, and,
predictable and accurate analog sensor measurements are always available in a wide variety of field
conditions.
Table 17: Sensor common point
Range ±2V
Accuracy ±2% of full scale
Resolution 0.1 V
Deep Sleep Mode Feature

Deep Sleep Mode is a useful feature to prolong the battery life.
In this mode, normal functions of the controller are suspended, and controller is placed into its lowest
power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode.
When the controller wakes up, normal operations are resumed automatically.
The controller goes in Deep Sleep Mode when there is no user interaction for the pre-set Deep Sleep
Mode Delay.
GCU does not go to Deep sleep mode in following conditions:
• In auto (Site, cyclic, exercise and remote start/stop) modes
• Mains monitoring is enabled, and mains contactor configured as output
• MODBUS communication is enabled
Comes out of deep sleep mode by pressing either of following keys (not press & hold):
• Stop key
• Start key
• Auto key
• Ack key
Page | 9
GC2599 SEDEMAC
Communication Ports
Following table gives a brief overview of communication ports
Table 18: Communication ports
USB 2.0 Type B used for connection to PC running
USB
SEDEMAC Smart config.
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
RS485 Serial Port Termination resistor of 120Ω is provided between
output pin A & B
Common-mode operating range
Maximum distance of line is 1200m
GCU connector terminal # 30, 31, 32 (GND, A, B respectively)
Baud rate used is 250 kbps
CAN Packet size used is 8 bytes
Termination resistor of 120Ω is provided
Controller's terminal number for CAN 58, 59
The RS485 port on GC2599 genset controller supports a protocol based on MODBUS.
• Pin 30 should be connected to master’s isolated ground only

• Use two core shielded twisted pair cable for MODBUS RS485 connection.
• Keep pin 30 connection open if shielded cable is not available

• Do not connect pin 30 to battery -ve
Page | 10
GC2599 SEDEMAC
Installation
Dimensions
Figure 6: Dimensions of the GC2599 genset controller

Recommended mounting panel cut-out dimensions: 189 mm X 143 mm.
Mounting on Panel
To mount the controller into the panel, use the fixing clips provided along with the controller.
Follow the given steps:
Page | 11
GC2599 SEDEMAC
Figure 7: Fixing clip and screw supplied along with controller
Figure 8: Controller mounting on the panel using the fixing clips

• Insert the fixing clip into the slot provided on the side of the controller.
• Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is
properly fitted inside the slot provided on the controller.
• Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the
panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum
tightening torque is 0.19 N-m.
Over tightening of the screws may damage the controller casing.
Page | 12
GC2599 SEDEMAC
Terminal Pin Details
Following figure shows rear view of the GCU which has terminal details printed on it.
Figure 9: Rear view of the controller for terminal detail

Table 19: Details of GC2599 terminals
Mating connector
Pin # Name Description
part #
1 GND Power ground
2 BATT + Power supply positive
3 OUT A High side driver output – A
4 OUT B High side driver output – B
5 OUT C High side driver output – C BCP-508-10GN
6 OUT D High side driver output – D
7 OUT E High side driver output – E
8 OUT F High side driver output – F
9 OUT G High side driver output – G
10 D+ CHG ALT Input for charging alternator control
Analog input from Lube Oil Pressure
11 ANLG LOP / DIG J
Sensor/Digital Input J
Analog input from Fuel Level Sensor /
12 ANLG FUEL LEVEL / DIG K
Digital Input K BCP-508-6GN
Analog input from Engine Temperature
13 ANLG ENG TEMP / DIG L
Sensor / Digital Input L
Analog input auxiliary/Analog input from
14 ANLG AUX 1 / DIG M Shelter Temperature Sensor/Digital Input
M
Page | 13
GC2599 SEDEMAC
Mating connector
part #
15 ANLG AUX 2 / DIG N Analog input auxiliary/Digital Input N
16 SCP Sensor common point
17 GOV_ACT – OUT1 Output for the SEDEMAC Actuator
BCP-508-4GN
Analog input auxiliary /0-5V/4-20 mA
21 ANLG AUX 3/ DIG 0
(LOP) / Digital Input O
Input from engine speed sensor
22 MPU
(Inductive) BCP-508-5GN
Analog input auxiliary / 0-5V (Paralleling)
23 ANLG AUX 4 / DIG P
/ 4-20 mA/ Digital Input P
24 SITE ATT I/P Input 1 from Site battery
25 SITE BATT I/P Input 2 from Site battery
26 PFC OUT A Potential free output A (NC)
27 PFC OUT A COMM Potential free output A common BCP-508-7GN-
4PA
28 PFC OUT B Potential free output B (NO)
29 PFC OUT B COMM Potential free output B common
30 RS485- GND RS485 – GND
BCP-508-3GN
31 RS485- A RS485 – A
32 RS485- B RS485 – B
33 DIG IN A Input from switch – A
34 DIG IN B Input from switch – B
35 DIG IN C Input from switch – C
36 DIG IN D Input from switch – D
BCP-508-9GN
37 DIG IN E Input from switch – E
38 DIG IN F Input from switch – F
39 DIG IN G Input from switch – G
40 DIG IN H Input from switch – H
41 DIG IN I Input from switch – I
42 GEN CT IN R2 CT input 2 from Phase R
43 GEN CT IN R1 CT input 1 from Phase R
44 GEN CT IN Y2 CT input 2 from Phase Y
45 GEN CT IN Y1 CT input 1 from Phase Y BCP-508-8GN
46 GEN CT IN B2 CT input 2 from Phase B
47 GEN CT IN B1 CT input 1 from Phase B
48 GEN CT IN EL2 CT input 2 from Earth Leakage
49 GEN CT IN EL1 CT input 1 from Earth Leakage
50 MAINS V N Voltage input from Mains Neutral BCP-508-7GN-
51 MAINS V B Voltage input from Mains Phase B 4PA
52 MAINS V Y Voltage input from Mains Phase Y
Page | 14
GC2599 SEDEMAC
Mating connector
part #
53 MAINS V R Voltage input from Mains Phase R
54 GEN V N Voltage input from Gen Neutral
55 GEN V B Voltage input from Gen B
56 GEN V Y Voltage input from Gen Y
57 GEN V R Voltage input from Gen R
58 CAN L CAN Low
59 CAN H CAN High
BCP-508-4GN
60 RESERVED RESERVED
61 RESERVED RESERVED
Typical Wiring Diagram

The typical wiring diagram of GC2599 for Auto Mains Failure application
Figure 10: Power circuit when used in the Auto Mains Failure Mode
1) Genset & mains contactor latching relays should be compiled against 4kV
surge as per IEC-61000-4-5 standard.
2) Wiring drawing is for representation purpose only. Please refer wiring as per
given genset application drawing.
3) Relay cards that used with controller should have protection against reverse
battery voltages.
Page | 15
GC2599 SEDEMAC
Monitoring Mode
In monitoring mode, the screen will scroll automatically after a predefined time which can be
configured in configuration menu or one can use the “Navigation UP/DOWN Keys” to scroll/browse
the screens.
Table 20: Screens of engine status and operating modes
Product Info Manual mode
Auto mode Auto - SITE mode
Auto – Cyclic mode Auto - Exercise mode
Generator Voltage Genset Power Factor
(The “Y” and “B” phase will be visible only

if configured for 3 phase genset)
Page | 16
GC2599 SEDEMAC
Mains Voltage Mains Run Time
DG and Mains load status*
Load Apparent Power kVA Load Power KW
(The “Y” and “B” phase will be visible only if (The “Y” and “B” phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
Load Current Load Reactive Power kVAr
(The “Y” and “B” phase will be visible only if (The “Y” and “B” phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
*These 4 screens are common for DG and Mains
Cumulative energy screens
Generator energy Mains energy
Page | 17
GC2599 SEDEMAC
Engine screens
Engine lube oil pressure Engine fuel level
Engine temperature Shelter temperature
Auxiliary sensor
Engine Run Time SITE Run Time
Page | 18
GC2599 SEDEMAC
Engine Battery & Site battery voltage Engine speed
Alarm Histogram
Page | 19
GC2599 SEDEMAC
Description of Control Keys
1 5
6
2
7
3
4
Figure 11: Control keys function
1. Display 5. Menu Navigation up & down key
2. Mains contactor latching key 6. Genset contactor latching key
3. Start key 7. Auto/Manual/Test mode selection key
4. Stop/Config key 8. Acknowledgement key
Functions of Control Keys

Following table gives a brief overview of different functions of control keys
Table 21: Control keys in different modes
# Mode Key input Function
Start Starts the engine
Auto Enters Auto mode
1 Manual Stop Stops the engine when engine is running
Stop (long pressed) Enters configuration mode
Stop + Down (long pressed) Enters Programming mode
2 Auto Stop Stops the engine and enters Manual mode
Manual/Auto/
3 Up/Down Scrolls the screens/parameter
Configuration
4 Manual/Auto Ack Acknowledges and clears the alarm
5 Start Selects/saves the parameter
6 Configuration Up + Down (long pressed) Enters on event log page
7 Stop (long pressed)
Back to Manual mode
8 Deep sleep Stop/Start/Auto/Ack
9 Event log Up + Down (long pressed) Back to configuration mode
10 Programming Up + Down (long pressed) Controller enters in Manual mode
Page | 20
GC2599 SEDEMAC
Configuration Mode
To configure the controller please follow the below mentioned instructions:
• To enter the configuration mode press and hold “STOP” key, at least for 3 seconds. Following
screen will appear on the GCU
Figure 12: Configuration mode screen

• If you want to only view the configuration, press “STOP” key of the GCU. If you wish to change
the configuration, press “START” key of the GCU
Figure 13: Configuration mode authentication page screen

• The GCU will ask for password (4 digit). Enter the password by using up & down arrow key for
digit and “START” key for entering the digit. The 4 digits will start blinking individually as go on
selecting. Press “START” button as mentioned earlier to enter the right digit.
• After completion of parameter configuration, press and hold “STOP” key to exit from
configuration mode. Before existing from configuration mode controller will show the following
screen.
Figure 14: Saving setting screen
Configurable Parameters
Configurable parameters are listed in below table along with the range and value for the GCU
configuration. This will help to configure a GCU controller after entering the “write” mode.
* Level 2 names in sentence case are written how they display on Smart Config GUI and names in
bracket with capital case are written how they display on controller.
Table 22: List of configurable parameters
Level 1 (On
Level 0 Level 2 (On screen) * Possible Value
screen)
Power On Mode
Manual/Auto
Module General (POWER ON MODE)
(MODULE) (GENERAL) Power On Lamp Test
Enable/Disable
(POWER ON LAMP TEST)
Page | 21
GC2599 SEDEMAC
Level 1 (On
screen)
Deep Sleep Mode
Enable/Disable
(DEEP SLEEP MODE)
Load Histogram
Enable/Disable
(LOAD HISTOGRAM)
Auto-Clear Warning Alarm
Enable/Disable
(AUTO CLEAR WARNINGS)
Language
English/Chinese
(LANGUAGE SUPPORT)
Contrast
0 – 100 %
Display (CONTRAST)
(DISPLAY) Power Save Mode
Enable/Disable
(POWER SAVE MODE)
Communication Mode
None/MODBUS-SEDEMAC
(COMM MODE)
Slave ID
Communication 1 – 247
(MODBUS SLAVE ID)
(COMMUNICATI
ON) Baudrate 1200/2400/4800/9600/1920
(BAUDRATE) 0/38400/57600/115200
Parity Bit
None/Even/Odd
(PARITY)
Battery Monitoring
Yes/No
(BATTERY MON)
Site Battery Low Voltage Threshold
15.0 – 60.0 V
Monitoring (LOW BATT THRESHOLD)
(SITE BAT Battery Monitoring Delay
CONFIG) 5 – 300 sec
(LOW BATT MON DELAY)
Genset Run Duration
1 – 720 Mins
(GEN RUN DURATION)
Cyclic Mode
Enable/Disable
(CYCLIC MODE)
Cyclic Mode
Genset Off Time
(CYCLIC 1 – 720 Mins
(GEN OFF DURATION)
CONFIG)
Genset On Time
1 – 720 Mins
(GEN ON DURATION)
Auto Exercise
Enable/Disable
(EVENT 1)
Event Occurrence
Daily/Weekly/Monthly
Auto Exercise - (EVENT OCCURENCE)
Event 1 Event Day Runs Every day/Week
(AUTO (EVENT DAY) Days/1-28
EXERCISE – 1) Start Time 00 hr 00 Mins – 23 hr 59
(START TIME) Mins
Duration 00 hr 01 Mins – 99 hr 59
(GEN ON DURATION) Mins
Page | 22
GC2599 SEDEMAC
Level 1 (On
screen)
Load Transfer
Enable/Disable
(LOAD TRANSFER)
Auto Exercise
Enable/Disable
(EVENT 2)
Event Occurrence
Daily/Weekly/Monthly
(EVENT OCCURENCE)
Auto Exercise – Event Day Runs Every Day/ Week
Event 2 (EVENT DAY) Days/1-28
(AUTO Start Time 00 hr 00 Mins – 23 hr 59
EXERCISE – 2) (START TIME) Mins
Duration 00 hr 01 Mins – 99 hr 59
(GEN ON DURATION) Mins
Load Transfer
Enable/Disable
(LOAD TRANSFER)
Night Mode
Enable/Disable
(NIGHT MODE RESTRICT)
Night Mode Start Time 00 hr 00 Mins – 23 hr 59
(NIGHT MODE)
(START TIME) Mins
Night Mode Off Duration
1 – 1140 Mins
(GEN OFF DURATION)
Source
Refer Table 23
(SOURCE)
Polarity Close to Activate/Open to
Digital Input X (POLARITY) Activate
Inputs (DIG IN X) Action None/Warning/Electrical
(INPUTS) X= (ACTION) Trip/Shutdown/Notification
A/B/C/D/E/F/G/H
/I Activation Never/From Engine Start/
(ACTIVATION) From Monitoring On/Always
Activation Delay
1 – 180 Sec
(ACTIVATION DELAY)
Use Input As Not used/Dig In J/LOP
(SENSOR SELECTION) Sensor
(Dig In J) Source
Refer Table 23
(SOURCE)
(Dig In J) Polarity Close to Activate/Open to
(POLARITY) Activate
Analog Input 1
(Dig In J) Action None/Warning/Electrical
Analog Inputs (LOP RES / DIG
(ACTION) Trip/Shutdown/Notification
(INPUTS) J)
(Dig In J) Activation Never/From Engine Start/
(Dig In J) Activation Delay
1 – 180 Sec
(ACTIVATION DELAY)
(LOP) Low Level Shutdown
Enable/Disable
(SHUTDOWN)
(LOP) Low Level Shutdown 0 – 9.8 Bar
Page | 23
GC2599 SEDEMAC
Level 1 (On
screen)
Threshold
(SHUTDOWN THRESHOLD)
(LOP) Low Level Warning
Enable/Disable
(WARNING)
(LOP) Low Level Warning
Threshold 0.2 – 10 Bar
(WARNING THRESHOLD)
(LOP) Circuit Fault Action None/Warning/Electrical
(OPEN CKT ALARM) Trip/Shutdown/Notification
(LOP) Calibration Table for Lube
Refer Table 24
Oil Pressure
Use Input As Not used/Dig In K/Anlg In
(SENSOR SELECTION) Fuel LVL
(Dig In K) Source
Refer Table 23
(SOURCE)
(Dig In K) Polarity Close to Activate/Open to
(POLARITY) Activate
(Dig In K) Action None/Warning/Electrical
(Dig In K) Activation Never/From Engine Start/
(Dig In K) Activation Delay
1 – 180 Sec
(ACTIVATION DELAY)
(FLS) Low Fuel Level Shutdown
Enable/Disable
(SHUTDOWN)
(FLS) Shutdown Threshold
Analog Input 2 0 – 78 %
(FUEL LVL / DIG (FLS) Low Fuel Level Warning
K) Enable/Disable
(WARNING)
(FLS) Warning Threshold
2 – 80 %
(WARNING THRESHOLD)
(FLS) Fuel Tank Capacity
2 – 1000 Litres
(FUEL TANK SIZE)
(FLS) Fuel Theft Warning
Enable/Disable
(FUEL THEFT ALARM)
(FLS) Fuel Theft Alarm
Threshold 1 – 100 % per hour
(FUEL LVL THRESH)
(FLS) Circuit Fault Action None/Warning/Electrical
(FLS) Fuel Sensor Reference Battery Negative/Engine
(FUEL LVL REF) Body
(FLS) Calibration Table for Fuel
Refer Table 25
Level Sensor
Analog Input 3 Use Input As Not used/Dig In L/Anlg In
(ENG TEMP / (SENSOR SELECTION) Eng Temp
Page | 24
GC2599 SEDEMAC
Level 1 (On
screen)
DIG L) (Dig In L) Source
Refer Table 23
(SOURCE)
(Dig In L) Polarity Close to Activate/Open to
(POLARITY) Activate
(Dig In L) Action None/Warning/Electrical
(Dig In L) Activation Never/From Engine Start/
(Dig In L) Activation Delay
1– 180 Sec
(ACTIVATION DELAY)
(ETS) High Level Shutdown
Enable/Disable
(SHUTDOWN)
(ETS) Shutdown Threshold
27 – 300 deg C
(ETS) High Level Warning
Enable/Disable
(WARNING)
(ETS) Warning Threshold
25-298 deg C
(WARNING THRESHOLD)
(ETS) Circuit Fault Action None/Warning/Electrical
(ETS) Calibration Table for
Refer Table 26
Engine Temperature Sensor
Use Input As Not used/Dig In M/Auxiliary

Sensor/Shelter
(SENSOR SELECTION) Temperature
(Dig In M) Source
Refer Table 23
(SOURCE)
(Dig In M) Polarity Close to Activate/Open to
(POLARITY) Activate
(Dig In M) Action None/Warning/Electrical
(Dig In M) Activation Never/From Engine Start/
S1 Sensor (ACTIVATION) From Monitoring On/Always
(AUX S1 (Dig In M) Activation Delay
RES/DIG M) 1 – 180 Sec
(ACTIVATION DELAY)
(S1) Threshold Type Greater Than Threshold /
(THRESHOLD TYPE) Less Than Threshold
(S1) Shutdown
Enable/Disable
(SHUTDOWN)
(S1) Shutdown Threshold
0 – 1000 units
(S1) Warning
Enable/Disable
(WARNING)
(S1) Warning Threshold
0 - 1000 units
(WARNING THRESHOLD)
Page | 25
GC2599 SEDEMAC
Level 1 (On
screen)
(S1) Circuit Fault Action None/Warning/Electrical
(STS) High Temp Threshold
25-300 deg C
(SHELT TEMP THRESH)
(STS) Shelter temp hysteresis
1-100 deg C
(SHELT TEMP HYST)
(STS) Shelt Temp Monitoring
Delay 5 – 300 sec
(SHELT TEMP DELAY)
(STS) Shelt Temp Run Duration
1 – 720 sec
(GEN RUN DURATION)
(STS) Calibration Table
Refer Table 27
(Resistive)
Use Input As Not used/Dig In N/Auxiliary
(SENSOR SELECTION) Sensor
(Dig In N) Source
Refer Table 23
(SOURCE)
(Dig In N) Polarity Close to Activate/Open to
(POLARITY) Activate
(Dig In N) Action None/Warning/Electrical
(Dig In N) Activation Never/From Engine Start/
(Dig In N) Activation Delay
1 – 180 Sec
(ACTIVATION DELAY)
S2 Sensor
(AUX S2 RES / (S2) Threshold Type Greater Than Threshold/
DIG N) (THRESHOLD TYPE) Less Than Threshold
(S2) Shutdown
Enable/Disable
(SHUTDOWN)
(S2) Shutdown Threshold
0 –1000 units
(S2) Warning
Enable/Disable
(WARNING)
(S2) Warning Threshold
0 –1000 units
(WARNING THRESHOLD)
(S2) Circuit Fault Action None/Warning/Electrical
(S2) Calibration Table
Refer Table 27
(Resistive)
S3 Sensor/ Use Input As Not used/Dig In O/ Dig In
Digital Input O P/S3 Sensor/ S4 Sensor/0
(SENSOR SELECTION) – 5V Sensor/*LOP
(AUX S3 RES /
DIG O/*LOP) (Dig In O/ Dig In P) Source
Refer Table 23
And (SOURCE)
S4 Current (Dig In O/ Dig In P) Polarity Close to Activate/Open to
Sensor/ Digital (POLARITY) Activate
Page | 26
GC2599 SEDEMAC
Level 1 (On
screen)
Input P (Dig In O/ Dig In P) Action None/Warning/Electrical
(AUX S4 RES / (ACTION) Trip/Shutdown/Notification
DIG P)
(Dig In O/ Dig In P) Activation Never/From Engine Start/
(Dig In O/ Dig In P) Activation
1 – 180 Sec
Delay (ACTIVATION DELAY)
(S3/S4) Threshold Type Greater Than Threshold/
(S3/S4/LOP) Shutdown
Enable/Disable
(SHUTDOWN)
(S3/S4/LOP) Shutdown
Threshold 0 –1000 units
(S3/S4/LOP) Warning
Enable/Disable
(WARNING)
(S3/S4/LOP) Warning Threshold
0 –1000 units
(WARNING THRESHOLD)
(S3/S4/LOP) Circuit Fault Action None/Warning/Electrical
(S3/S4/LOP) Calibration Table Refer Table 28 for S3/S4 &
(Current) Refer Table 29 for LOP
(0-5 V Sensor) Threshold Type Greater Than Threshold/
(0-5 V Sensor) Shutdown
Enable/Disable
(SHUTDOWN)
(0-5 V Sensor) Shutdown
(0-5 V Sensor) Warning
Enable/Disable
(WARNING)
(0-5 V Sensor) Warning
(WARNING THRESHOLD)
(0-5 V Sensor) Circuit Fault
Action None/Warning/Electrical
Trip/Shutdown/Notification
(OPEN CKT ALARM)
(0-5 V Sensor) Calibration Table
Refer Table 30
(Voltage)
Output X Source
Refer Table 32
(OUTPUT X) (SOURCE)
X=A/B/C/D/E/F/ On Activation
G Energise/De-energise
Outputs (ON ACTIVATION)
(OUTPUTS) Source
Output PFC-X Refer Table 32
(SOURCE)
(PFC X)
On Activation
X=A/B Energise/De-energise
(ON ACTIVATION)
Page | 27
GC2599 SEDEMAC
Level 1 (On
screen)
Crank Hold Time
1 – 15 sec
(CRANK HOLD TIME)
Crank Rest Time
Cranking 2 – 60 sec
(CRANK REST TIME)
(CRANKING
TIMER) Manual Start Delay
0 – 300 sec
(MANUAL START DELAY)
Auto Start Delay
0 – 300 sec
(AUTO START DELAY)
Safety Monitoring Delay
10 – 60 sec
(SAFETY MONITOR DELAY)
Mains Detect Delay
1 – 300 sec
(MAINS DETECT DELAY)
Alternator Detect Delay
1 – 30 sec
(ALT DETECT DELAY)
Warm-Up Delay
0 – 60 sec
(WARM-UP DELAY)
Start / Stop
Return To Mains Delay
(START / STOP 0 – 600 sec
(RETN-TO-MAINS DELAY)
TIMER)
Timers Engine Cooling Time
(TIMERS) 0 – 300 sec
(ENG COOL TIME)
Stop Action Time
10 – 120 sec
(STOP ACTION TIME)
Additional Stopping Time
0 – 120 sec
(ADDN STOPPING TIME)
Load Transfer Delay
1 – 60 sec
(LOAD TRANSFER DELAY)
Power Save Mode Delay
5 – 1800 sec
(PWR SAVE MODE DELAY)
Screen Changeover Time
1 – 1800 sec
(SCRN CHNGOVER TIME)
Deep Sleep Mode Delay
General 5 – 1800 sec
(DEEP SLP MODE DELAY)
(GENERAL
TIMER) Sounder Alarm Time
1 – 300 sec
(SOUNDER ALARM TIMER)
Test Mode Timer
1 – 720 min
(TEST MODE TIMER)
Auto Exit Config Mode
10 – 1800 sec
(AUTO EXIT CNFG MODE)
Alternator Present
Yes/No
(ALT PRESENT)
Alternator Number of Poles
Generator 2/4/6/8 Poles
Configuration (NUMBER OF POLES)
(GENERATOR)
(ALT CONFIG) AC system
1 Phase/3 Phase
(ALT AC SYSTEM)
Min Healthy Voltage 50 – 350 V Ph - N
Page | 28
GC2599 SEDEMAC
Level 1 (On
screen)
(MIN HEALTHY VOLT)
Min Healthy Frequency
10 – 75 Hz
(MIN HEALTHY FREQ)
Phase Reversal Detection
Enable/Disable
(PHASE REVERSAL DETECT)
Phase Reversal Action None/Warning/Electrical
(PHASE REVERSAL ACTION) Trip/Shutdown/Notification
Auto Load Transfer
Enable/Disable
(AUTO LOAD TRANSFER)
Alternator Wave Detection
Enable/Disable
(WAVEFORM DETECT)
Under-voltage Shutdown
Enable/Disable
(UNDER VOLT SHUTDOWN)
Under-voltage Shutdown
Threshold 50 – 295 V Ph-N
(UV SHUTDOWN THRESH)
Under-voltage Warning
Enable/Disable
(UNDER VOLT WARNING)
Under-voltage Warning
Voltage
Threshold 55 – 300 V Ph - N
Monitoring
(UV WARNING THRESHOLD)
(VOLT
MONITOR) Over-voltage Shutdown
Enable/Disable
(OVER VOLT SHUTDOWN)
Over-voltage Shutdown
Threshold 105 – 350 V Ph - N
(OV SHUTDOWN THRESH)
Over-voltage Warning
Enable/Disable
(OVER VOLT WARNING)
Over-voltage Warning Threshold
100 – 345 V Ph - N
(OV WARNING THRESHOLD)
Under-frequency Shutdown
Enable/Disable
(UNDER FREQ SHUTDOWN)
Under-frequency Shutdown
Threshold 10.0 – 59.0 Hz
(UF SHUTDOWN THRESH)
Under-frequency Warning
Frequency Enable/Disable
Monitoring (UNDER FREQ WARNING)
(FREQ Under-frequency Warning
MONITOR) Threshold 11.0 – 60.0 Hz
(UF WARNING THRESHOLD)
Over-frequency Shutdown
Enable/Disable
(OVER FREQ SHUTDOWN)
Over-frequency Shutdown
(OF SHUTDOWN THRESH)
Page | 29
GC2599 SEDEMAC
Level 1 (On
screen)
Over-frequency Warning
Enable/Disable
(OVER FREQ WARNING)
Over-frequency Warning
(OF WARNING THRESHOLD)
CT Ratio
0 – 8000 / 5
(LOAD CT RATIO)
Over-current Action None/Warning/Electrical
(OVER CURR ACTION) Trip/Shutdown/Notification
Current Over-current Threshold
Monitoring 5 – 10000 Amp
(OVER CURR THRESHOLD)
(CURRENT
MONITOR) Over-current Delay
1 – 600 sec
(OVER CURR DELAY)
CT Correction Factor 0.900 – 1.100
CT Location On Alt Output Cable/On
(CT LOCATION) Load Cable
Current Monitoring ERTH Curr Mon/
(FAN / EARTH MON) FAN Curr Mon
Current CT Ratio
0 – 8000 / 5
(CT RATIO)
High Current Action None/Warning/Electrical
Earth/Fan
(HIGH CURR ACTION) Trip/Shutdown/Notification
Current
Monitoring High Current Threshold
(EARTH CURR 0.1 – 10.0 A
(HIGH CURR THRESH)
MON)
Current Delay
5 – 60 sec
(CURR DELAY)
Low Current Action None/Warning/Electrical
(LOW CURR ACTION) Trip/Shutdown/Notification
Low Current Threshold
0.0 – 9.9 A
(LOW CURR THRESH)
Generator Rating
0 – 8000 kW
(GEN RATING)
Over-load Action None/Warning/Electrical
(OVERLOAD ACTION) Trip/Shutdown/Notification
Over-load Threshold
50 – 150 %
(OVERLOAD THRESHOLD)
Load Monitoring
Over-load Monitoring Delay
(LOAD 1 – 600 sec
(OVERLOAD MON DELAY)
MONITOR)
Unbalanced Load Action None/Warning/Electrical
(UNBAL LOAD ACTION) Trip/Shutdown/Notification
Unbalanced Load Threshold
5 - 200 %
(UNBAL LOAD THRESHOLD)
Unbalanced Load Delay
1 - 600 sec
(UNBAL LOAD DELAY)
Mains Configuration Mains Monitoring Enable/Disable
Page | 30
GC2599 SEDEMAC
Level 1 (On
screen)
(Mains) (MAINS (MAINS MONITORING)
CONFIG) Mains AC System
1 Phase/3 Phase
(MAINS AC SYSTEM)
Phase Reversal Detection
Enable/Disable
(PHASE REVERSAL DETECT)
Phase Reversal Action
None/Notification
(PHASE REVERSAL ACTION)
Partial Healthy Detection
Enable/Disable
(MAINS PARTIAL HEALTHY)
Under-voltage
Enable/Disable
(UV ENABLE)
(UV) Trip
50 – 298 V Ph - N
(UV TRIP)
Voltage (UV) Return
52 – 300 V Ph - N
Monitoring (UV RETURN)
(VOLTAGE Over-voltage
MON) Enable/Disable
(OV ENABLE)
(OV) Trip
102 – 350 V Ph - N
(OV TRIP)
(OV) Return
100 – 348 V Ph - N
(OV RETURN)
Under-frequency
Enable/Disable
(UF ENABLE)
(UF) Trip
10.0 – 59.0 Hz
(UF TRIP)
Frequency (UF) Return
Monitoring 11.0 – 60.0 Hz
(UF RETURN)
(FREQUENCY
MON) Over-frequency
Enable/Disable
(OF ENABLE)
(OF) Trip
26.0 - 75.0 Hz
(OF TRIP)
(OF) Return
25.0 - 74.0 Hz
(OF RETURN)
Start Attempts
1–9
(START ATTEMPTS)
Disconnect on Oil Pressure
Sensor Enable/Disable
Crank (DISCONN ON LOP SENS)
Engine Disconnect
(ENGINE) (CRANK Pressure Sensor Monitoring
DISCONN) Threshold 0.5 – 10.0 bar
(DISCONN LOP SENS)
Monitor Pressure Sensor Before
Crank Enable/Disable
(MON LLOP BEF CRANK)
Page | 31
GC2599 SEDEMAC
Level 1 (On
screen)
Monitor Pressure Switch Before
Crank Enable/Disable
(MON LOP BEF CRANK)
Disconnect on Oil Pressure
Switch Enable/Disable
(DISCONN ON LLOP SW)
Pressure Switch Transient Time
0.0 – 3.0 Sec
(LLOP SW TRANS TIME)
Crank Disconnect At Alt
Frequency 10 – 70 Hz
(ALT FREQUENCY)
Crank Disconnect At Engine
Speed 150 – 4000 RPM
(ENGINE SPEED)
Disconnect On Charging Alt
Voltage Enable/Disable
(DISC ON CHG ALT VOLT)
Charging Alt Disconnect Volt
Threshold 5.0 – 30.0 V
(CHG ALT THRESHOLD)
Engine Speed Sense Source
Alternator frequency/MPU
(SPEED SENSE SOURCE)
Flywheel Teeth
1 – 300
(FLYWHEEL TEETH)
Under-speed Shutdown
Enable/Disable
(UNDER SPEED SHUTDOWN)
Speed Under-speed Threshold
0 - 3600 RPM
Monitoring (UNDER SPEED THRESH)
(SPEED Under-speed Delay
MONITOR) 1 - 60 Sec
(UNDER SPEED DELAY)
Over-speed Threshold
700 - 4000 RPM
(OVER SPEED THRESH)
Over-speed Delay
1 - 20 Sec
(OVER SPEED DELAY)
Gross Over-speed Threshold
100% - 200%
(GROSS OS THRESHOLD)
Low Battery Voltage Action None/Warning/Electrical
(LOW VOLT ACTION) Trip/Shutdown/Notification
Low Battery Voltage Threshold
8.0 – 31.0 V
Battery (LOW VOLT THRESHOLD)
Monitoring Low Battery Voltage Delay
5 – 1800 Sec
(BATTERY (LOW VOLT DELAY)
MONITOR) High Battery Voltage Action None/Warning/Electrical
(HIGH VOLT ACTION) Trip/Shutdown/Notification
High Battery Voltage Threshold
9.0 – 32.0 V
(HIGH VOLT THRESHOLD)
Page | 32
GC2599 SEDEMAC
Level 1 (On
screen)
High Battery Voltage Delay
5 – 1800 Sec
(HIGH VOLT DELAY)
Charging Alternator Fail Action None/Warning/Electrical
Charging (FAIL ACTION) Trip/Shutdown/Notification
Alternator Charging Alternator Fail
Monitoring Threshold 0.0 - 35.0 V
(CHARGE ALT (FAIL THRESHOLD)
MON) Charging Alternator Fail Delay
5 – 60 sec
(FAIL DELAY)
Preheat Timer
1 – 900 sec
(PREHEAT TIMER)
Preheating Engine Temperature
Enable/Disable
(PREHEAT) (ENG TEMP EN)
Engine Temperature Threshold
10 – 300 °C
(ENG TEMP LIMIT)
Alarm Action
Notification/Warning
Maint Alarm (ACTION)
(MAINT ALARM) Due At Engine Hours
Maintenance 10 – 65000 Hrs
(MAINTENANCE) (DUE AT ENGINE HOURS)
Alarm Due Date
Alarm Due Date
(ALARM DUE 1-31/Jan-Dec/2016-75
(ALARM DUE DATE)
DATE)
Actuator Application As E-Governor/As
(ACTUATOR APPLICATION) Start/Stop Device
Actuator Speed
1 – 10 * 25 Hz
General (ACTUATOR SPEED)
(GENERAL) Actuator Direction Clockwise/Anti clockwise to
(ACTUATOR DIRECTION) Stop
Governing Mode Fixed Speed/Variable
(GOVERNING MODE) Speed
Recovery Mode
600 – 3000 RPM
(RECOVERY THRESHOLD)
Rotary Actuator Low Voltage Recovery
(ROTARY 0 – 300 Volt Ph-N
(LOW VOLTAGE REC)
ACTUATOR)
Low Load Entry Limit
0 – 100 %
(LOW LOAD ENTRY LMT)
Low Load Exit Limit
Variable Speed 0 – 100 %
(LOW LOAD EXIT LIMIT)
(ECONOSEEK)
Recovery Time
10 – 300 sec
(RECOVERY TIME)
Low Saturation Voltage
0 – 300 Volt Ph-N
(LOW SATURATION VOLT)
RPM Stepup Rate
1 – 50 RPM/sec
(RPM STEP UP RATE)
RPM Stepdown Rate 1 – 50 RPM/sec
Page | 33
GC2599 SEDEMAC
Level 1 (On
screen)
(RPM STEP DOWN RATE)
RPM vs Load Calibration Table Refer Table 31
Set Speed Selection Fixed Speed (0%

Droop)/Speed Bias Inp (0-5
(SET SPEED SELECTION) V)/Load Based Droop
Droop
0–4%
(LOAD DROOP)
Target Speed
500 – 4000 RPM
(TARGET/RECOVERY SPD)
Proportional Gain (Kp)
0 – 1000
(PROPORTIONAL GAIN)
Generator EGov Integral Gain(Ki)
Configuration 0 – 2000
(INTEGRAL GAIN)
(GEN EGOV
Derivative Gain(Kd)
CONFIG) 0 – 1000
(DERIVATIVE GAIN)
Friction Setoff
0 – 1000
(FRICTION SETOFF)
Gain Schedule Trigger
0.0 – 100.0 %
(GAIN SCHEDULE TRIGER)
Loading Factor
0 – 1000
(LOADING FACTOR)
Unloading Factor
0 – 1000
(UNLOADING FACTOR)
Target Speed
500 – 4000 RPM
(TARGET/RECOVERY SPD)
Proportional Gain (Kp)
0 – 1000
(PROPORTIONAL GAIN)
Integral Gain(Ki)
0 – 2000
(INTEGRAL GAIN)
Engine EGov Derivative Gain(Kd)
0 – 1000
Configuration (DERIVATIVE GAIN)
(ENGINE GOV Friction Setoff
CFG) 0 – 1000
(FRICTION SETOFF)
Gain Schedule Trigger (GAIN
0.0 – 100.0 %
SCHEDULE TRIGER)
Loading Factor
0 – 1000
(LOADING FACTOR)
Unloading Factor
0 – 1000
(UNLOADING FACTOR)
Cranking Steps
50 – 5000
Engine Start (CRANKING STEPS)
Strategy Initial Low Speed Delay
0 – 180 sec
(ENG START (INIT LOW SPEED DELAY)
STRGY) Initial Low Speed
500 – 1800 RPM
(INIT LOW SPEED)
Page | 34
GC2599 SEDEMAC
Level 1 (On
screen)
PID Trigger Speed
20 – 2800 RPM
(PID TRIGGER SPEED)
Ramp Up Time
1 – 180 sec
(RAMP UP TIME)
PID On Time
1 – 180 sec
(PID ON TIME)
Start Stop
Device
Running Steps
Configuration 0 – 500
(RUNNING STEPS)
(START STOP
DEVICE)
0 – 9 for each digit and A –
Id (ENG SR NO) ############
Z for each alphabet
(ID)
(PASSWORD 1) #### 0 – 9 for each digit
(PASSWORD 2) #### 0 – 9 for each digit
Table 23: Digital input source selection

# Source (On screen)
1 Not used
2 User Configured
3 Low Fuel Level Switch (Low Fuel LVL switch)
4 Low Lube Oil Pressure Switch
5 High engine temperature switch (High Engine Temp Switch)
6 Low Water Level Switch (Low Water LVL Switch)
7 Emergency Stop
8 Remote Start / Stop
9 Simulate Start
10 Simulate Stop
11 Simulate Auto
12 Close genset/open mains contactor (Close Gen/Open Mains Switch)
13 Close mains/ open genset contactor (Close Mains/Open Gen Switch)
14 Simulate Mains
15 V-Belt Broken Switch
16 Mains Contactor Latched
17 Genset Contactor Latched
18 Battery Charger Fail
19 Smoke Fire
20 Remote Alarm Mute
21 Remote Alarm Acknowledge
22 Stop and Panel Lock
23 External Panel Lock
24 Generator Load Inhibit
25 Mains Load Inhibit
Page | 35
GC2599 SEDEMAC
Table 24: LOP (Resistive) sensor calibration
Resistance(Ω) Pressure (Bar)
0 – 5000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)
Table 25: Fuel level sensor calibration

Resistance(Ω) Fuel level (%)
0 – 5000 (R1 - R10) 0 - 100% (V1-V10)
Table 26: Engine / shelter temperature sensor calibration

Resistance(Ω) Temperature° C
0 – 5000 (R1 - R10) -25 - 300° C (V1-V10)
Table 27: Auxiliary (S1/S2) resistive sensor calibration

Resistance(Ω) Monitoring Parameter (User configuration)
0 – 5000 (R1 - R10) 0.0 – 1000.0 (V1-V10)
Table 28: Auxiliary (S3/S4) current sensor calibration

Current(mA) Monitoring Parameter (User configuration)
4 – 20 (I1 - I10) 0 – 1000 (V1 – V10)
Table 29: LOP (4-20 mA) sensor calibration

Current(mA) Bar (Bar)
4 – 20 (I1 - I10) 0 – 10 (V1 – V10)
Table 30: Auxiliary (S3/S4) voltage sensor calibration

Voltage(V) Monitoring Parameter (User configuration)
0-5 (I1 - I10) 0 – 1000 (V1 – V10)
Table 31: Load – RPM calibration

Load (%) RPM
0 – 130 (L1 - L11) 400 – 4000 (R1 – R11)
Table 32: Digital output source selection

# Output source (On screen)
1 Disable
2 Sounder Alarm
3 Battery Over Voltage (Battery Over Volt)
4 Battery Under Voltage (Battery Under Volt)
5 Charging Alternator Shutdown (Charge Alt Shutdown)
6 Charging Alternator Warning (Charge Alt Warning)
7 Close Genset Contactor (Close Gen Contactor)
8 Close Mains Contactor (Close Mains Contactor)
9 Mains Failure
10 Common Alarm
11 Common Electrical Trip
12 Common Shutdown
Page | 36
GC2599 SEDEMAC
13 Common Warning
14 Cooling Down
15 Digital Input A (Dig In A)
16 Digital Input B (Dig In B)
17 Digital Input C (Dig In C)
18 Digital Input D (Dig In D)
19 Digital Input E ((Dig In E)
20 Digital Input F (Dig In F)
21 Digital Input G (Dig In G)
22 Digital Input H (Dig In H)
23 Digital Input I (Dig In I)
24 Digital Input J (LOP Resistive)
25 Digital Input K (Anlg In Fuel LVL)
26 Digital Input L (Anlg In Eng Temp)
27 Digital Input M (Aux Sensor 1)
28 Digital Input N (Aux Sensor 2)
29 Digital Input O (Aux Sensor 3)
30 Digital Input P (Aux Sensor 4)
31 Emergency stop
32 Stop Solenoid
33 Fail To Start
34 Fail To Stop
35 Fuel Relay
36 Generator Available (Gen Available)
37 R Phase Over Voltage Shutdown (R Phase OV Shutdown)
38 R Phase Under Voltage Shutdown (R Phase UV Shutdown)
39 Y Phase Over Voltage Shutdown (Y Phase OV Shutdown)
40 Y Phase Under Voltage Shutdown (Y Phase UV Shutdown)
41 B Phase Over Voltage Shutdown (B Phase OV Shutdown)
42 B Phase Under Voltage Shutdown (B Phase UV Shutdown)
43 Gen Over Current
44 High Engine Temperature (High Engine Temp)
45 Low Fuel Level (Low Fuel LVL)
46 Low Lube Oil Pressure (Low LOP)
47 Mains High Voltage (Mains High Volt)
48 Mains Low Voltage (Mains Low Volt)
49 (Res) Oil Pressure Open Circuit
50 Open Generator Contactor (Open Gen Contactor)
51 Open Mains Contactor
52 Over Frequency Shutdown (Over Freq Shutdown)
53 Over Speed Shutdown
54 Gross Over Speed Shutdown
Page | 37
GC2599 SEDEMAC
55 Start Relay
56 Temp Sensor Open Circuit
57 Under Frequency Shutdown (Under Freq Shutdown)
58 Under Speed Shutdown
59 Maintenance Due
60 Stop Mode
61 Auto Mode
62 Manual Mode
63 Preheat Output
64 Calling For Scheduler Run
65 Stop and Panel Lock
66 External Panel Lock
67 Fail To Close Generator
68 Fail To Close Mains
69 Loading Volt Not Reached
70 Loading Freq Not Reached
71 MPU Loss
Modes selection in GC2599
Figure 15: Mode selection screen

Page | 38
GC2599 SEDEMAC
Start and Stop Sequence
Start and stop sequence is described below with flow chart. It explains the behaviour of the controller
when it receives start and stop command.
Start Sequence
Figure 16: Flow chart of start sequence

Once the start command is received by the controller/controller enters Start Wait State. After Start
Delay (Manual or Auto Start Delay) is over, if Preheat Output is configured then controller will enter
Preheating State. If Preheat output is not configured, then controller will directly enter Crank Hold State
and will activate Start Relay output. In case of Preheat output configured, controller will enter Crank
Hold State after Preheat time is over or Preheat temperature threshold is reached. If Crank is not
disconnected and Crank Hold time is over, then controller enters Crank Rest State. In Crank Rest, also
if Crank is not disconnected and Crank Rest time is over, then controller enters Crank Hold State for
next cranking attempt. If Crank is disconnected by any means in the Crank Hold OR Crank Rest States
then controller will enter ENGINE ON state. If Maximum cranking attempts are done, then controller will
raise the Fail to Start alarm.
Page | 39
GC2599 SEDEMAC
Stop Sequence
Figure 17: Flow chart of stop sequence

Once the Stop command is received, controller enters Stopping State where it starts the Stop Action
Time and activates Stop Solenoid output. If controller detects engine OFF by all the means even before
Stop action time is over, then controller will enter by skipping stop action time. Once Additional Stopping
Time is over, controller will enter ENGINE OFF State and will deactivate Stop Solenoid output. If Engine
is not detected OFF before Stop Action Time, then Fail to Stop alarm will be raised.
Page | 40
GC2599 SEDEMAC
Operation Modes
• Auto mode
• Manual mode
• Test mode
• Paralleling mode
Auto Mode
To enter Auto mode press “AUTO” key.
• Site Battery monitoring mode (fuel saving mode)
• Cyclic mode
• Auto Mains Failure (AMF)
• Remote start/stop
• Exerciser mode
Site Battery Monitoring Mode

This mode enables the controller to monitor the health of the Site battery and Shelter temperature and
accordingly control the power sources (Mains / Genset) to keep the battery charge within the specified
threshold.
This mode also supports partial healthy condition of mains source. Partial healthy is a state in which
mains is not considered as failed even if one or two-phases are unhealthy. The mains keep supplying
power through the available phase/s. Mains failure occurs only when all the three phases fail. Upon
Mains failure genset shall receive start command only if either of following conditions occur
a) Site Battery voltage level has reached below its lower limits.
b) Shelter temperature has exceeded its upper threshold limits.
c) If either of a) or b) occur when source is partially healthy.
Page | 41
GC2599 SEDEMAC
Figure 18: SMD of site monitoring mode

Contactor latching status is represented by 0 and 1 digit in all the states in SMD. First digit represents
mains contactor status and second digit represents genset contactor status, whereas
0 – Contactor unlatched
1 – Contactor latched
In this mode if the Site battery condition is healthy, Shelter temperature is below “High Shelter Temp
threshold” and mains is unhealthy, the controller keeps both the contactors (Genset and Mains) open
and waits till the Site battery gets discharged. Once the Site battery becomes unhealthy or Shelter temp
is detected high, the controller then gives a start command to the genset. Then Genset will Start
according to Start Sequence. When genset loading voltage and frequency are above the Minimum
Healthy thresholds, Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. Then genset will run for DG run
Duration. According to the factor which triggered DG start (Site battery voltage Low OR Shelter Temp
High), Run duration (Site low Run duration OR High Shelter Temp run duration) will be taken. After the
duration is over or mains becomes healthy during the DG Run duration, controller will open genset
contactor. If shelter temp run duration is over and the temp is not below Low Temp Threshold, then
genset will continue to run for the set duration. After opening genset contactor, Engine Cooling Time
starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving
Stop command.
It is recommended to keep mains monitoring enable in this mode. Also, it is

recommended to use shelter temperature only when site monitoring is enabled.
Page | 42
GC2599 SEDEMAC
Cyclic Mode
Figure 19: SMD of Cyclic mode

This mode is used for running the genset for a pre-specified time for a cycle of max 12 hours each. The
time of genset to be kept ON & OFF is configurable.
Mains is being monitored in this mode. Load is on mains when mains is healthy. If mains is detected
unhealthy, controller gives a start command to the genset. Then Genset will Start according to Start
sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds,
then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking
Load Transfer Delay. Engine run hours will start incrementing if the genset is in running condition till
the stop command is received. After completion of the ON time or if mains become healthy during ON
time, controller will open the genset contactor. After opening genset contactor, Engine Cooling Time
starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving
Stop command. When genset is off, controller will start DG off time.
After completion of DG OFF time, DG ON time will start and this cycle will continue until mains is
detected healthy. During any of the times, if mains is detected healthy both the timers are reset to zero
and load will shift to mains after taking return delay. This process continues in cyclic mode.
If genset is shut down or is unable to start because of any alarm present, then after clearing alarms if
mains is unhealthy, DG ON time will be taken first followed by DG OFF time.
Page | 43
GC2599 SEDEMAC
Auto Mains Failure (AMF)
Figure 20: SMD of Auto Mains Failure mode

The AMF mode is activated when Site monitoring, Cyclic and exerciser modes are disabled, and Mains
Monitoring is enabled.
In this mode, if the mains is healthy then the genset remains in Stop condition. If after the Mains Detect
Delay, mains is found unhealthy, then controller will issue Start command and Genset will start
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. During genset running condition, if the
mains is found healthy, Return To Mains Delay timer starts. If mains is found unhealthy during the
Return To Mains Delay, then Genset continues to run. At the end of this delay if mains is still healthy,
then genset contactor gets opened and mains contactor gets latched after the completion of Load
Transfer Delay. After opening genset contactor, Engine Cooling Time starts. Then at the end of
Engine cooling Time, controller initiates the stopping sequence by giving Stop command.
During start sequence, if the mains voltage recovers or any stop command or shutdown / warning alarm
occurs controller will not issue start command to genset. To start the genset it is necessary to clear all
the alarms manually and put the controller in Auto mode.
Page | 44
GC2599 SEDEMAC
The AMF mode is only valid when site monitoring, Cyclic and exercise modes are
disabled, and Mains Monitoring is enabled.
Exercise Mode
Figure 21: SMD of Exerciser mode

The GC2599 allows to configure two scheduled sequences to start and stop the genset on preconfigured
time.
The Exercise will occur when the controller is in the Auto mode with no shutdown or warning alarms. The
genset will run for pre-set duration. In this mode, load transfer on mains/genset is configurable.
Scheduled sequences can be configured to repeat daily, weekly or monthly.
• If the controller is in Auto mode, Exercise will run at scheduled time for pre-set duration. Controller
will exit from Exercise mode, if the pre-set duration is expired or if Stop key is pressed while
scheduled sequence is running.
• If the controller is in Manual mode when the scheduled sequence begins, genset will not be
started. If the controller is switched to Auto mode during Exercise is running, genset will start and
run for remaining scheduled duration.
Page | 45
GC2599 SEDEMAC
• The genset controller will not respond to Remote start command in Exercise mode.
• In AMF mode, if the mains is unhealthy or cut off or when the genset is running in Exercise mode,
genset will first run Exercise and then genset will continues to run in AMF mode. Load will be
transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF
mode when the mains become healthy.
• If both exercises are scheduled at the same time, then Start time for second exercise will be
incremented by 1 min.
The Exerciser mode is only valid when site monitoring and cyclic modes are
disabled, and Mains Monitoring is enabled.
Remote Start/Stop
Figure 22: Flow chart of remote start/stop mode

To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote
start/stop (Latched type input) and put the controller in the Auto mode. Also disable both Site monitoring
and Cyclic mode.
In this mode, the genset can be commanded to start and stop by activating the preconfigured Remote
start/stop input. If Remote Start command is received, then controller will issue Start command and
Genset will start according to Start Sequence. When genset loading voltage and frequency are above
the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset
contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as
long as the genset is in running condition till the stop command is received. When Remote Stop
command is received the controller will open the genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping
sequence by giving Stop command.
It is recommended not to enable Mains Monitoring and Remote Start/Stop configuration simultaneously.
Page | 46
GC2599 SEDEMAC
The Remote start/stop mode is only valid when site monitoring, cyclic, exerciser
modes and mains monitoring are disabled.
Night Restriction Mode

In night restriction mode, user can set a particular time in 24 – hour cycle, and then select the time
duration for which you want to restrict DG run in any circumstances. Night restriction mode commands
to turn off the genset at preconfigured time. This time is of 24 – hour cycle and repeated on daily basis.
It also keeps the genset in OFF state for the preconfigured time duration. Genset is restricted to start if
start command is received by any means during “Night Mode OFF Duration”.
If genset needs to start in night restriction mode, then follow the below instructions:
• Press and hold “STOP” key for minimum three seconds and enter in edit mode of configuration
of genset controller.
• Select the “Module” and navigate to “Night Mode” parameter.
• Enter in Night mode and disable the ‘Night Mode” or change the “Night Mode OFF Duration”
time period.
• Save the parameters and come out of configuration mode.
• Start the genset in Auto/Manual mode
Figure 23: SMD for night restriction mode
Page | 47
GC2599 SEDEMAC
Manual Mode
Module Operation in Manual Mode
Figure 24: SMD of Manual mode

Genset contactor latching status is represented by a digit in all the states of this SMD. Whereas
Page | 48
GC2599 SEDEMAC
Starting the Engine
Press the START key

to crank the engine.
Figure 25: Pictorial reference for starting the engine

If Start Key is pressed in this mode, then controller will issue Start command and Genset will start
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched if Auto Load Transfer is enabled. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received.
When Stop key is pressed, controller will open genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping
sequence by giving Stop command. If Stop key is pressed during Engine Cooling Time, controller skips
the Cooling Time and issues the stop command immediately.
Stopping the Engine
While engine is running,

press STOP key to stop
engine. To stop engine
immediately press STOP
key twice.
Figure 26: Pictorial reference for stopping the engine
Page | 49
GC2599 SEDEMAC
Test Mode
In manual mode (while genset is OFF) if auto key is long pressed then controller goes in Test mode.
Test mode is almost same as manual mode. Only in test mode, irrespective of auto load transfer option
enabled or disabled, Genset contactor will not get latched. If Genset contactor latching key is pressed,
then only genset contactor will get latched. Once the genset starts in test mode, Test mode timer
starts. After Stop key is pressed or this timer is over, controller will send the Stop command and genset
will stop according to stop sequence.
Paralleling Mode
The GC2599 controller offers the feature of electronic governing for engines with mechanical fuel
systems. In conjunction with the external Load Sharing Module, GC2599 controller can control speed of
engine and supports genset synchronisation and paralleling feature.
The Electronic speed governing (E-governor) system is especially applicable to engines used in genset.
This system provides precise, fast-acting control of engine speed. This system can be configured in
Isochronous mode or Paralleling mode. In paralleling mode of operation, the system maintains the
speed in accordance to the speed reference signal provided by supervisory control/Load Sharing
Module (LSM).
Concept
Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then
connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset
must match within prescribed limits before they can be paralleled. By considering linear relation
between speed of the engine and frequency of the alternator output, the speed must be controlled until
the genset is paralleled with the grid or other genset with the help of electronic governor. A Load
Sharing Module controls the speed and the voltage of the genset by controlling the AVR and E-governor
of the genset. To control these two devices the LSM provides the DC analog voltage signal to the both
devices. The analog voltage signal is generally in the range of 0-5 V.
Mode Description
In case of paralleling mode operation of the genset, the E-governor module present in the GC2599
controller accepts speed reference (speed bias) signal in terms of 0-5 V analog DC voltage from the
supervisory LSM (Load sharing module).
Following is the stepwise procedure for configuring the GC2599 for paralleling operation.
• Select the Governing Mode as Fixed speed. Select Set Speed Selection as “Speed Bias”
• Provide 0-5 V analog signal from the LSM to GC2599 controller at terminal no. 23, as a speed
reference signal (Refer Figure 27)
Figure 27: Analog voltage input terminals of GC2599

Page | 50
GC2599 SEDEMAC
Configure Analog Aux4 Sensor as “Not Used” for paralleling mode.
Acknowledging & Clearing the Alarms

Press the “Ack” key to acknowledge the alarm in any mode.
Press the
Ack key
Figure 28: Pictorial reference for acknowledging & clearing the alarms
In case, if engine ON is detected without any start command given to GCU, it will
allow engine to stay ON and further act according to operating mode and
configuration.
Page | 51
GC2599 SEDEMAC
Load Sensing
In Manual and Auto mode, the load sensing is done with following configuration:
The GCU senses the load (on Mains / Genset) depending upon “Generator Contactor Latched” and
“Mains Contactor latched” inputs (if configured) and their real-time status.
In case if the inputs are not configured, the GCU will sense the load depending upon the outputs ‘’Close
Genset Contactor’’ and ‘’Close Mains Contactor’’ or ‘’Open Mains Contactor’’ and ‘’Open Genset
Contactor” being configured and depending upon their real-time status. These outputs are set through
facial keys or Contactor controlling inputs (such as ‘’Close Genset/Open Mains’’ or ‘’Close Mains/Open
Genset’’).
In case of MCP Panels, since the “Genset & Mains” contactors are not configured, the
load sensed will be treated as load on the genset only
For Mains load sensing, two configurations are mandatory.
1. Mains monitoring must be enabled.

2. CT location in panel and in GCU configuration must be “On Load Cable”.
Features
There are some silent features that helps in saving power and other monitoring purpose.
Auto Config Exit Mode

In this mode, the controller comes out of Configuration Mode automatically when there is no user
interaction for the pre-set Auto Config Exit Mode Delay.
Controller saves all configuration parameter changes and exit the configuration mode.
Load Histogram
Load Histogram displays an engine run hour spent in different regimes. This mode helps user to
monitor the duration of genset running on specific percentage of load. The load percentage is
calculated based on following parameters:
1. Generator rating
2. CT ratio
Page | 52
GC2599 SEDEMAC
Alarms
When Shutdown alarm occurs controller commands genset to stop. The controller will not issue the
start command if the Shutdown alarm left unacknowledged.
When an electrical trip alarm occurs, the controller opens the genset contactor first and then it
commands the genset to stop. The controller will not issue the start command if the Electrical trip
alarm left unacknowledged.
If the warning alarm occurs in between the genset running condition, then the controller will not
issue the stop command. But if the warning alarm left unacknowledged when the genset is in stop
condition, then the genset cannot be started. Warning alarm gets auto cleared when condition gets
cleared only if auto warning clear is enabled in config file or through UI.
Notification alarms get auto cleared.
Table 33: Types of alarms actions and their descriptions
Alarm
# Description
Actions
Load is taken off from the genset and the genset is immediately stopped by
1 Shutdown
skipping Engine Cooling Time.
Load is taken off from the genset, engine cooling timer begins, after which
2 Electrical trip
genset is stopped.
Warning alarms serves to draw operator's attention to an undesirable condition
3 Warning without affecting genset's operation.
The genset cannot be started without acknowledging the warning alarms
Controller will display message on the display screen and will not affect genset
4 Notification
start stop operation.
Table 34: Alarms and their causes

Sr.
Alarms Causes / Indication Actions
No.
None/
Low Oil Pressure Indicates that the oil pressure measured is below
Shutdown/
(Sensor) the pre-set threshold
Warning
None/
1
Shutdown/
Low Oil Pressure Indicates that the oil pressure measured is low
Warning/
(Switch) through switch
Electrical Trip/
Notification
None/
Shutdown/
LOP Res Sensor- Ckt The oil pressure sensor is detected as not being
2 Warning/
Open present
Electrical Trip/
Notification
Indicates that the engine temperature is above the None/
High Eng Temp (sensor) pre-set threshold. This condition is detected only Shutdown/
when engine is on. Warning
None/
3
Shutdown/
Indicates that the engine temperature measured is
High Eng Temp (Switch) Warning/
high through switch
Electrical Trip/
Notification
Page | 53
GC2599 SEDEMAC
Sr.
No.
None/
Shutdown/
The temperature sensor is detected as not being
4 Eng Temp - Ckt Open Warning/
present
Electrical Trip/
Notification
Indicates that the amount of fuel level is below the None/
Low Fuel level (Sensor) pre-set threshold. This condition is detected only Shutdown/
when engine is on. Warning
None/
Shutdown/
Indicates that the amount of fuel level measured is
Low Fuel level (Switch) Warning/
low through switch
5 Electrical Trip/
Notification
None/
Shutdown/
Fuel level - Ckt Open Fuel level sensor is detected as not being present Warning/
Electrical Trip/
Notification
The fuel consumption has exceeded the pre-set
6 Fuel Theft Warning
threshold
None/
Shutdown/
Indicates that radiator water level is below the pre-
7 Low Water Level Switch Warning/
set threshold
Electrical Trip/
Notification
Shelter Temp - Ckt Shelter Temperature sensor is detected as not
8 Notification
Open being present
None/
Shutdown/
Auxiliary sensor S2 is detected as not being
9 Aux S2 - Ckt Open Warning/
present
Electrical Trip/
Notification
None/
Auxiliary Input (for e.g. Shutdown/
Configured auxiliary input has triggered longer
10 Aux_A - P) /user Warning/
than pre-set duration
defined name Electrical Trip/
Notification
When emergency stop switch is pressed and
11 Emergency Stop Shutdown
immediate shutdown is required.
It is detected that genset is still running after
12 Fail To Stop Shutdown
sending stop command
Indicates that genset has not started after the pre-
13 Fail To Start Shutdown
set number of Start Attempts
Indicates that genset (R) Phase voltage has Warning/
14 R Phase Over Voltage
exceeded the pre-set over voltage threshold. Shutdown
Indicates that genset (Y) Phase voltage has Warning/
15 Y Phase Over Voltage
exceeded the pre-set over voltage threshold Shutdown
Page | 54
GC2599 SEDEMAC
Sr.
No.
Indicates that genset (B) Phase voltage has Warning/
16 B Phase Over Voltage
exceeded the pre-set over voltage threshold Shutdown
Indicates that genset (R) Phase voltage has fallen Warning/
17 R Phase Under Voltage
below pre-set under voltage threshold. Shutdown
Indicates that genset (Y) Phase voltage has fallen Warning/
18 Y Phase Under Voltage
below pre-set under voltage threshold Shutdown
Indicates that genset (B) Phase voltage has fallen Warning/
19 B Phase Under Voltage
below pre-set under voltage threshold Shutdown
None/
Warning/
20 DG Phase Reversed Alternator phase sequence (R-Y-B) is not correct Electric trip/
Shutdown/
Notification
None/
21 Mains Phase Reversed Mains is in unhealthy condition
Notification
Indicates that genset output frequency has Warning/
22 Over Frequency
exceeded the pre-set threshold Shutdown
Indicates that genset output frequency has fallen Warning/
23 Under Frequency
below the pre-set threshold Shutdown
None/
Shutdown/
Indicates that genset current has exceeded the
24 Over Current Warning/
pre-set shutdown threshold
Electrical Trip/
Notification
None/
Shutdown/
Indicates that the measured kW load rating has
25 Over Load Warning//
exceeded the pre-set threshold
Electrical Trip
Notification
None/
Shutdown/
Load on any phase is greater or less than other
26 Unbalanced Load Warning/
phases by a threshold value
Electrical Trip/
Notification
Indicates that genset speed has exceeded the
27 Over Speed pre-set over speed threshold. Genset will shut Shutdown
down after Over Speed Delay.
28 Gross Over Speed pre-set Gross Over Speed Threshold. Genset will Shutdown
shut down immediately without any delay.
The engine speed has fallen below the pre-set
RPM
None/
The charge alternator voltage has dropped below Shutdown/
30 Charge Fail
the pre-set threshold Warning/
Electrical Trip/
Page | 55
GC2599 SEDEMAC
Sr.
No.
Notification
31 Over Speed pre-set over speed threshold. Genset will shut Shutdown
down after Over Speed Delay.
32 Gross Over Speed pre-set Gross Over Speed Threshold. Genset will Shutdown
shut down immediately without any delay.
The engine speed has fallen below the pre-set
RPM
Warning/
The charge alternator voltage has dropped below
34 Charge Fail Electrical Trip/
the pre-set threshold
Shutdown
None/
Shutdown/
The battery voltage has fallen below the pre-set
35 Battery Under Voltage Warning/
threshold
Electrical Trip/
Notification
None/
Shutdown/
The battery voltage has exceeded the pre-set
36 Battery Over Voltage Warning//
threshold
Electrical Trip
Notification
Lube oil pressure is detected above the crank
37 High Oil Press Detected Warning
disconnect threshold when the engine is off.
Indicates that engine running hours has exceeded Notification/
38 Maintenance Due the pre-set hours limit or maintenance due date
has occurred and filter servicing is required. Warning
None/
Shutdown/
Indicates the battery is not getting charged by the
39 Battery Charger Fail Warning/
charger
Electrical Trip/
Notification
None/
Shutdown/
Controller has detected smoke / fire through its
40 Smoke Fire Warning/
digital input
Electrical Trip/
Notification
None/
Aux S2 / user defined Warning/
41 Auxiliary sensor S2’s threshold being crossed
name Electrical Trip/
Shutdown
Page | 56
GC2599 SEDEMAC
Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Table 35: Troubleshooting
Sr.
Fault Possible Causes / Remedial Actions
No.
• Check the battery voltage.
• Check the fuse on the battery supply.
The controller does not • Check continuity between battery +ve and controller terminal
1
power ON. # 2.
• Check continuity between battery ground and controller
terminal # 1.
The controller screen
2 • Reset the controller power.
freezes or hangs up.
• Check the battery voltage.
• Enter the “configuration mode” in controller and verify the
configuration for the “START” output. Also, check that
“START” output is working correctly by measuring its voltage
The controller fails to crank- o/p.
3
start the engine. • Enter the “configuration mode” in controller and verify the
configuration of “CRANK DISCONNECT” method. Verify the
configuration of “LLOP SWITCH” polarity. Also, ensure that
the lube oil pressure switch & sensor are working OK. Check
their wiring.
The “Emergency Stop” • Check if the “Emergency Stop” switch is working OK. Check
alarm comes up even when its wiring also.
4
the “Emergency Stop” is not • Enter the “configuration mode” in controller and verify the
pressed. configuration of “EMERGENCY STOP” polarity.
The controller generates
• Check the respective switch/sensor and wiring.
unnecessary “Shutdown
5 • Enter the “configuration mode” in the controller and verify the
Alarms” or “Warning
Alarms” respective threshold configuration.
• To check if the controller's charging alternator terminal is

working or not: disconnect the charging alternator wiring to
the controller's terminal # 10. Short the terminal # 10 to the
ground through a DC ammeter. Crank-start the engine. The
The controller reports DC ammeter should indicate the current in the range 200 -
6 400 mA for ~30 seconds. If yes, the controller's chg
“Charging Alt Fail” alarm.
alternator terminal is working OK.
• Disconnect and re-connect the charging alternator ind
connection to the controller's terminal # 10.
• Check if the charging alternator is working OK or not.
A) The controller shows
• Enter the “configuration mode” in the controller and verify the
genset “ON” while
configuration for the LLOP and LOP. Check their wiring also.
7 genset is at rest.
B) “Fail To Stop” alarm • Ensure that the mains voltage wiring is not connected by
mistake to the controller's genset voltage terminals.
when genset is at rest.
Page | 57
GC2599 SEDEMAC
Sr.
No.
• Ensure that the controller's o/p terminal is not directly
connected to the starter relay. The controller's o/p should be
given to an intermediate relay which should in-turn power
the starter relay. The controller can get permanently
The controller issues damaged and will need to be replaced if this precaution is
unnecessary “crank-start” not taken.
8
command immediately after
• Check start-relay connection with the suitable controller
power on.
terminal.
• Enter the “configuration mode” in the controller and verify the
configuration for “START MODE” and the “START RELAY”
o/p polarity.
• Check for alternator voltage signal (R phase) is received by
The engine runs, but the the controller terminal.
9 controller shows genset to
be “OFF”. • Check if the LOP and LLOP are working OK. Also check
their wiring to the controller.
The controller displays • Check wiring of the respective alternator phase voltage and
10 incorrect PF value or kW or the CT to the controller.
load current. • Check the CT ratio (if kW or current reading is faulty).
The controller displays
incorrect mains voltage or
11
incorrect main alternator • Check the wiring of the respective phase to the controller.
voltage.
• Check respective sensor and its wiring.
Controller displays incorrect
• Check SCP wiring.
reading for any of LOP, Fuel
Level, Engine Temp
sensors. calibration for the respective
• sensor in configuration.
Possible Issues in AUTO Mode
The controller displays • Check wiring of the main alternator’s R-phase and neutral to
13
incorrect engine RPM. the controller.
The controller does not start • Check the wiring of the “Remote Start” signal to the
the engine even when a controller's respective digital i/p terminal.
“Remote Start” command is • Enter the “configuration mode” in the controller and verify the
14 configuration for the “Remote Start” digital i/p terminal.
sent from an external
device such as a telecom • Check that the controller is in “Auto” mode.
PIU. • check for mains monitoring disabled & Site mode disabled.
Controller does not stop • Check the wiring of the “Remote Stop” signal to the
engine even when a controller's respective digital i/p terminal.
“Remote Stop” command is
sent from an external
configuration for the “Remote Stop” digital i/p terminal.
device such as a telecom
PIU. • Check that the controller is in “Auto” mode.
While in Auto mode, • Check the wiring of the mains R, Y and B phase to the
controller issues “Start” controller's respective i/p terminal.
16
command even if the mains • Enter the “configuration mode” in the controller and verify the
present. configuration for the “MAINS MONITORING”.
Possible issues with Site monitoring
Page | 58
GC2599 SEDEMAC
Sr.
No.
• Check if earthing is proper for panel
Site voltage is observed and Site
17
continuously varying • Check if the connections are done properly for the
differential input (pin # 24 & 25)
Possible issues with MODBUS communication
• Check if the MODBUS communication is enabled in GCU
• Check if the MODBUS communication settings of slave
(GCU) match with the master
GCU is not sending data
• Check if the connections are done properly for the MODBUS
18 over MODBUS
input (pin # 31 & 32)
communication
• Check if the connections are interchanged
• Check the 120 Ω resistance between terminal A (pin # 31) &
terminal B (pin # 32)
Communication Protocol
The GC2599 genset controller supports a custom protocol based on MODBUS over a RS485
layer. The GC2599 genset controller implement a custom protocol based on the standard
MODBUS protocol. It operates in a slave mode and responds to commands received from an
external MODBUS master. The transmission mode used by GC2599 controller is MODBUS RTU
(not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits, no parity bits
and 1 stop bit, Cyclic Redundancy Check (CRC).
Connection Details
The following section describe the connection details of RS485 MODBUS to SMPS MODBUS module.
On the GCU Pin 31 is represented as A, Pin 32 is represented as B and Pin 30 is represented as
ground.
Figure 29: RS485 MODBUS connection with the help of two core shielded twisted pair cable
Precautions
• Keep the slave ID of the GCU controller and the SMPS controller same, take the slave ID from
the SMPS and configure the same ID in GCU.
• Enable the GCU in the configuration of the SMPS after hardware connections are made, so the
SMPS can communicate with the GCU.
• Connect the Pin # 31 & 32 (A & B) of the GCU to the pin # A & B of the SMPS respectively and
not with any other pin.
• Connect the ground of the RS485 MODBUS module of the controller to the ground of SMPS. If
ground of the SMPS is not present, leave the ground terminal (Pin 30) of the controller open.
Page | 59
GC2599 SEDEMAC
• Use two core shielded cable for connection.
• Use different colour wires for Pin # 31 & 32 (A & B) for easy detection and connection.
• Route the Pin # 31 & 32 (A & B) wires properly ensuring they do not get short with any other
wires.
• Do not use multi strand wires for the connection.
Supported Functions
This genset controller operates as a MODBUS slave that responds to certain commands (or
functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate
format. Supported functions and respective command-response structure is as shown below. If the
command received from the MODBUS master is other than the three functions mentioned below,
an exception message is generated.
Table 36: Details of function codes
Function Code MODBUS Name Description

Reads one or more 16-bit from the slave device of
03 Read holding register
read/write location
Reads one or more 16-bit from the slave device of
04 Read input register
read/write location
16 Write holding register Writes one or more 16-bit registers to the slave device
Page | 60
GC2599 SEDEMAC
Communication Settings
Table 37: RS485 MODBUS communication configuration setting
RS485 Communication
Slave ID 1-247
Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/115200
Parity None/Even/Odd
Stop Bit 1, 2
Recommended polling frequency: 50Hz
No response timeout: 250ms
Function 04 is used to read measurement parameters and status from the GC2599 controller.
Function code is a part of MODBUS message that defines the action to be taken by the Slave.
SEDEMAC GC2K supports following functions and the command-response format is as shown in the
following table.
Table 38: Command from MODBUS master for Function 4
Byte Field Remarks
0 Slave address As configured in GC2599
1 Function code (0x04)
2 First register address – high byte 16-bit register address, register address map is
3 First register address – low byte described in section 8
4 Number of registers to read – high byte Number of registers to read must be between 1
5 Number of registers to read – low byte to 255
6/7 Error check CRC
Query response format for Function 4 is as follows:
Table 39: Normal response from GC2599 slave for Function 4
Byte Field Remarks
0 Slave address As configured in GC2599
1 Function code (0x04)
Equals to number of registers to be read times
2 Byte count (n)
two. 8-bit even number between 2 to 250
3 First register – high byte
4 First register – low byte
...
1+n Last register – high byte
2+n Last register – low byte
3+n/4+n Error check CRC
Page | 61
GC2599 SEDEMAC
Table 40: Register map
Register Scale Unit /
Parameter Bits/ Sign
Address Factor Interpretation
Protocol revision 0 - - Unsigned
Generator L1-N voltage 1 0.1 V Unsigned
Generator L1-L2 voltage 4 0.1 V Unsigned
Generator R frequency 7 0.1 Hz Unsigned
Generator Y frequency 8 0.1 Hz Unsigned
Generator B frequency 9 0.1 Hz Unsigned
Generator power factor L1 10 0.01 -- Unsigned
Generator average power factor 13 0.01 -- Unsigned
Mains L1-N voltage 14 0.1 V Unsigned
Mains L1-L2 voltage 17 0.1 V Unsigned
Mains R frequency 20 0.1 Hz Unsigned
Mains Y frequency 21 0.1 Hz Unsigned
Mains B frequency 22 0.1 Hz Unsigned
Load L1 current 23 0.1 A Unsigned
Load L1 watts 26 0.1 kW Unsigned
Load total watts 29 0.1 kW Unsigned
Percentage Load 30 1 kW Unsigned
Load L1 VA 31 0.1 kVA Unsigned
Load total VA 34 0.1 kVA Unsigned
Load L1 VAR 35 0.1 kVAR Unsigned
Load total VAR 38 0.1 kVAR Unsigned
Generator cumulative energy 39-40 0.1 kW Unsigned
Page | 62
GC2599 SEDEMAC
Generator cumulative apparent
41-42 0.1 kVA Unsigned
energy
Generator cumulative reactive
43-44 0.1 kVAR Unsigned
energy
Mains cumulative energy 45-46 0.1 kW Unsigned
Mains cumulative apparent energy 47-48 0.1 kVA Unsigned
Mains cumulative reactive energy 49-50 0.1 kVAR Unsigned
Oil pressure 51 0.1 Bar Unsigned
Coolant temperature 52 0.1 Deg C Unsigned
Fuel level 53 1 % Unsigned
Fuel Level in lit 54 0.1 lit Unsigned
Charge alternator voltage 55 0.1 V Unsigned
Battery voltage 56 0.1 V Unsigned
Engine speed 57 1 RPM Unsigned
No of starts 58 1 -- Unsigned
No of trips 59 1 -- Unsigned
Eng run hrs 60 1 Hrs Unsigned
Eng run min 61 1 Min Unsigned
Mains run hrs 62 1 Hrs Unsigned
Mains run min 63 1 Min Unsigned
Auxiliary Input S1 value 64 0.01 Unsigned
Site Voltage 68 0.1 Unsigned
Site Run time hrs 69 1 Unsigned
Site Tun time mins 70 1 Unsigned
Alarm Status
Alarm 1 71
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Radiator water level / low fuel level -- -- 5/16-8/16
Reserved / Radiator water level
-- -- 1/16-4/16
switch
Alarm 2 72
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
Alarm 3 73
Generator low voltage/ reserved -- -- 13/16-16/16
Generator high voltage/ reserved -- -- 9/16-12/16
Page | 63
GC2599 SEDEMAC
Generator low frequency -- -- 5/16-8/16
Generator high frequency -- -- 1/16-4/16
Alarm 4 74
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
Alarm 5 75
Charge alternator failure -- -- 13/16-16/16
Oil filter maintenance / filter
-- -- 9/16-12/16
maintenance
Fuel filter maintenance / reserved -- -- 5/16-8/16
Air filter maintenance / reserved -- -- 1/16-4/16
Alarm 6 76
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- -- 9/16-12/16
Oil pressure circuit open engine
-- -- 5/16-8/16
Temperature Circuit open
Reserved -- -- 1/16-4/16
Alarm 7 77
Fuel theft -- -- 13/16-16/16
Magnetic pick up fault -- -- 9/16-12/16
Extended over load trip / oil pressure
-- -- 5/16-8/16
circuit
Reserved -- -- 1/16-4/16
Alarm 8 78
Digital input A -- -- 13/16-16/16
Digital input B -- -- 9/16-12/16
Digital input C -- -- 5/16-8/16
Digital input D -- -- 1/16-4/16
Alarm 9 79
Digital input E -- -- 13/16-16/16
Digital input F -- -- 9/16-12/16
Digital input G -- -- 5/16-8/16
Digital input H -- -- 1/16-4/16
Alarm 10 80
Digital input I -- -- 13/16-16/16
Analog input J -- -- 9/16-12/16
Analog input K -- -- 5/16-8/16
Analog input L -- -- 1/16-4/16
Alarm 11 81
Auxiliary input M -- -- 13/16-16/16
Page | 64
GC2599 SEDEMAC
Auxiliary input N -- -- 9/16-12/16
Auxiliary input O -- -- 5/16-8/16
Auxiliary input P -- -- 1/16-4/16
Alarm 12 82
Gen L1 phase low volt -- -- 13/16-16/16
Gen L1 phase high volt -- -- 9/16-12/16
Alarm 13 83
Dg phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
Alarm 14 84 --
Open fuel level -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Extended overload trip/Reserved -- -- 5/16-8/16
High oil pressure detected -- -- 1/16-4/16
Alarm 15 85 --
Auxiliary Input S4 13/16-16/16
Alarm 16 86
Auxiliary S4 open ckt alarm 13/16-16/16
Alarm 17 87
Auxiliary S4 overcurrent/overvoltage
13/16-16/16
alarm
Auxiliary S3 overcurrent/overvoltage
9/16-12/16
alarm
Auxiliary S4 short to ground alarm 5/16-8/16
Auxiliary S3 short to ground alarm 1/16-4/16
Input and output status
Input diagnostics 88
Digital input A -- -- 16/16
Digital input B -- -- 15/16
Digital input C -- -- 14/16
Digital input D -- -- 13/16
Digital input E -- -- 12/16
Page | 65
GC2599 SEDEMAC
Digital input F -- -- 11/16
Digital input G -- -- 10/16
Digital input H -- -- 9/16
Digital input I -- -- 8/16
Analog input J -- -- 7/16
Analog input K -- -- 6/16
Analog input L -- -- 5/16
Auxiliary input M -- -- 4/16
Auxiliary input N -- -- 3/16
Auxiliary input O -- -- 2/16
Auxiliary input P -- -- 1/16
Output Diagnostic 89
Digital output A -- -- 16/16
Digital output B -- -- 15/16
Digital output C -- -- 14/16
Digital output D -- -- 13/16
Digital output E -- -- 12/16
Digital output F -- -- 11/16
Digital output G -- -- 10/16
Unimplemented -- -- 9/16
Dg status 90
GCU Mode Config /Run 16/16
Mains Healthy / unhealthy -- True (1) / False (0) 15/16
Scheduler/cyclic/A
DG operation mode -- 14-12/16
uto / Manual
Load on DG True (1) / False (0) 11/16
Load on Mains -- True (1) / False (0) 10/16
Current DG status -- Running / stopped 9/16
DG stopped normally -- True (1) / False (0) 8/16
DG stopped with fault True (1) / False (0) 7/16
DG fail to start -- True (1) / False (0) 6/16
Gen available True (1) / False (0) 5/16
Common shut down -- True (1) / False (0) 4/16
Page | 66
GC2599 SEDEMAC
Common electric trip -- True (1) / False (0) 3/16
Common warning -- True (1) / False (0) 2/16
Common notification -- True (1) / False (0) 1/16
Current EPOCH
Current time stamp 91-92 --
time
Page | 67
GC2599 SEDEMAC
Notes
Page | 68
GC2599 SEDEMAC
Disclaimer: Due to continuous development, the details provided in this document are subject
to change without any prior notice.
SEDEMAC Mechatronics Pvt Ltd

Technical Centre
C 9-10, C Block, MIDC Bhosari
Pune 411026, India
Manufacturing Plant
G-1, MIDC, Phase-III Chakan
Industrial Area, Nighoje
Pune 410501, India
Manufacturing Plant
Survey No. 64/5, Off Sinhagad Road
Vadgaon Budruk, Narhe
Pune 411041, India
Page | 69

SED MAN GC2599 002 Manual For GC2599 Controller

Uploaded by

Copyright:

Available Formats

You might also like

SED MAN GC2599 002 Manual For GC2599 Controller

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SED MAN GC2599 002 Manual For GC2599 Controller

Uploaded by

Copyright:

Available Formats

ABSTRACT

This manual is intended as

SEDEMAC Mechatronics Pvt. Ltd.

• Highlights an essential element of a procedure to ensure correctness

• Indicates a procedure or practice, which could result in damage or

• Indicates a procedure or practice, which could result in injuring

Key Highlights of the Product

Figure 1: GC2599 genset controller's front fascia

Figure 2: Connectors of 5.08 mm pitch

Figure 3: Connectors of 10.16 mm pitch

Genset Voltages and Frequency Measurements

Genset Current Measurements

Mains Voltages and Frequency Measurements

Figure 4: SCP connection

Analog Current/Voltage Inputs

Site Battery Inputs

Magnetic Pick Up Inputs

1) Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID” directly to

• Recommended for genset contactor and mains contactor

Sensor Common Point

Deep Sleep Mode Feature

• Pin 30 should be connected to master’s isolated ground only

• Keep pin 30 connection open if shielded cable is not available

Figure 6: Dimensions of the GC2599 genset controller

Figure 7: Fixing clip and screw supplied along with controller

Figure 8: Controller mounting on the panel using the fixing clips

Over tightening of the screws may damage the controller casing.

Figure 9: Rear view of the controller for terminal detail

Typical Wiring Diagram

Product Info Manual mode

Auto mode Auto - SITE mode

Auto – Cyclic mode Auto - Exercise mode

Generator Voltage Genset Power Factor

(The “Y” and “B” phase will be visible only

Mains Voltage Mains Run Time

DG and Mains load status*

Load Apparent Power kVA Load Power KW

Load Current Load Reactive Power kVAr

Generator energy Mains energy

Engine lube oil pressure Engine fuel level

Engine temperature Shelter temperature

Engine Run Time SITE Run Time

Engine Battery & Site battery voltage Engine speed

Functions of Control Keys

Figure 12: Configuration mode screen

Figure 13: Configuration mode authentication page screen

Figure 14: Saving setting screen

Use Input As Not used/Dig In M/Auxiliary

Set Speed Selection Fixed Speed (0%

Table 23: Digital input source selection

Table 25: Fuel level sensor calibration

Table 26: Engine / shelter temperature sensor calibration

Table 27: Auxiliary (S1/S2) resistive sensor calibration

Table 28: Auxiliary (S3/S4) current sensor calibration

Table 29: LOP (4-20 mA) sensor calibration

Table 30: Auxiliary (S3/S4) voltage sensor calibration

Table 31: Load – RPM calibration

Table 32: Digital output source selection