GTR-200 Generator Controller Manual
Contents
1. if the Parameter 10 setting value Pressure build deactivate Starter is enabled This setting has nothing to do with low oil pressure delay The Low oil pressure delay is 1 second which is a fixed value and stated on the 7 4 system parameter File version MG200VO5E 12 eN S on GTR 200 Generator Controller Manual E 6 12 PRA 12 Coolant temperature sender brand selection viy Range 0 2 Default 1 Description Select the brand for coolant temperature sensor 0 SUSUKI 1 SCD 2 VDO 6 13 PAA 13 Oil pressure sender brand selection gz Range 0 3 Default 1 Description Select the brand for oil pressure sensor User selects the brand for oil pressure sensor 0 SUSUKI 1 SCD 2 VDO 10 BAR 3 VDO 5 BAR 6 14 DHL DH IH Current Transformer Ratio selection Range 50 5 6000 5 Default 500 5 Description Selects current transformer ratio 50 5 75 5 100 5 2 150 5 200 5 250 5 300 5 400 5 500 5 600 5 800 5 1000 5 1200 5 1500 5 1600 5 2000 5 2500 5 3000 5 3200 5 4000 5 5000 5 6000 5 6 15 PALA 15 Low voltage setting E Range 186 440 Default 346 Description When output AC voltage is lower than this setting the GTR 200 shows low voltage error and shuts down the engine if protection function is enabled 6 16 PALA 15 High voltage setting gt Range 220 484 Volts Default 414 Volts Description When output AC voltage is higher than this setting the GTR 200 shows high voltage error and shuts2. 10 sec Description Engine stopping time this affects the duration of the stop output period 6 2 PRA De Pre heat duration 00 Range 0 10 sec Default O sec Description The pre heat duration means the time before the engine starts 6 3 PALA 03 Crank attempts L Range 1 9 attempts Default 3 attempts Description When cranking attempt is equal or greater than this setting the GTR 200 stops cranking the engine and display over crank failure 6 4 PAFA EY Cooling duration Range 0 625 sec Setting value 0 250 Cooling time Setting X 2 5sec Default 0 sec Description After receiving normal stop command engine goes into cooling mode and engine runs until the time of this setting is reached 6 5 PALA ES Idle duration te Range 0 1250 sec Setting value 0 250 Idle running time Setting X 5secs Default O sec Description After engine starts successfully engine goes into idle mode if the Idle duration is not zero 6 6 PALA 05 Low battery Range 9 32 V Default 20 V Description When the battery voltage is lower than this setting the GTR 205 shows low battery fault 6 7 PALA 87 High frequency setting lt gt Range 48 70 Hz Default 66 Hz Description When frequency is greater than this setting the GTR 205 shows high frequency fault and shuts down the engine File version MG200VO5E 11 eN S on GTR 200 Generator Controller Manual E 6 8 PRA CB Protection function 1 Range 0 255 Default
3. Output 3 Com 14 E M S Input 9 gt Emergency Stop 46 Output 3 N O 13 L W L Input 45 Output 2 Aux Input 2 C B Indicate C B Indicate For Contactor 44 nt EG indicator 43 8 Output 1 42 C B Close 7 Output 0 41 C B Close 6 Stop 5 Alarm ham Rre peter EE as Pave stares A Magnet 2 Battery 1 Battery i sl LOAD Battery 8 36V A The controller is designed for Star connection 22 File version MG200V05E
4. delay monicon GTR 200 Generator Controller Manual 0 4 sec action stop 2 sec action stop 1 sec action stop 1 sec action stop 4 sec action stop 6 sec action trip or stop see 6 25 parameter 25 4 sec action trip or stop see 6 25 parameter 25 2 sec action trip or stop see 6 25 parameter 25 15 sec action trip or stop See 6 25 parameter 25 0 5 sec action trip or stop See 6 25 parameter 25 2 5 sec action trip or stop see 6 25 parameter 25 2 5 sec action trip or stop see 6 25 parameter 25 5 sec action alarm 7 5 sec After Gen set normally runs about 7 5second the terminal T41 and terminal T42 forms a dry contact output circuit for about 1 second e Frequency release motor e Cranking time e Protection pending time 16 Hz 10 sec 10 sec After Gen set starts successfully for about 10 seconds in this time period the controller bypasses the faulty signal except the emergency stop and the over speed File version MG200V05E eN Y GTR 200 Generator Controller Manual 8 Back view Description 8 1 Back view 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 oo L VRIO VR20 VR3O VRIO VR5O VR6O _Q _ _ _ _ _ n L oooooooo bssssssess 31 32 33 34 35 36 37 38 3940 41 42 43 44 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Fig 13 8 2 Pin definition Pin Description Pin Description 6 Taan output a G
5. down the engine if protection function is enabled 6 17 PA A 17 AC short setting 1 Range 100 500 Default 450 Description When output AC current is higher than this setting the GTR 200 shows AC short error and shuts down the engine if protection function is enabled 6 18 PA A 18 AC overload setting 7 Range 40 500 depends on Parameter 14 Default 400 Description When output AC current is higher than this setting the GTR 200 shows AC overload error and shuts down the engine if protection function is enabled File version MG200V05E 13 eN S on GTR 200 Generator Controller Manual E 6 19 PAFA 19 High water temperature setting viy Range 75 120 C Default 100 Description When coolant temperature is higher than this setting the GTR 200 shows high water temperature error and triggers the alarm 6 20 PAFA OU Low oil pressure setting 7 Range 5 65 Psi Default 15 Description When oil pressure is lower than this setting the GTR 200 shows low oil pressure fault and triggers the alarm 6 21 HHH g Protection function 2 Range 0 255 Default 143 Description Enable or disable protection function 2 Shut down Notin op alarm MMT Over Short Low after trip Auto alarm current Circuit voltage voltage Result 143 Default Y Table 3 B gt In table 3 M means Enable lx means Disable b gt The setting can be calculated by adding all related bits multiply its weighted value K
6. instruction 5 1 Please refer to Figure 17 for wiring connection 5 2 When the GTR 200 connects to the DC power the LCD panel lights up all icons LTN EI D MY BAE ere mn mE EE 0000 k Ho oo EEE REECE 5 3 After one second the GTR 200 is in OFF mode and information page displays L2 L3 voltage L2 current and battery voltage 5 4 Operating keypads y O 4 w Q Manual Auto Off Clear Pre heat Idle Rated 5 4 1 Manual Press the keypad M for 2 seconds under the mode of AUTO or OFF to start the engine Then LCD shows the icon representing it is in the state of pre heat After pre heat engine starts immediately If engine failed to start the GTR 200 returns to the OFF mode The pre heat state may not perform if the parameter setting of pre heat is O second 5 4 2 AUTO Press the keypad to switch the GTR 200 into AUTO mode In the Auto mode the GTR 200 starts the engine if T18 and T19 are wire shorted and then the LCD shows the ico 00 only if pre heat state is enabled After pre heat is finished the engine starts to crank If the engine failed to start the system returns to the pre heat state and then start to crank the engine again For example if the conditions and parameter settings are given as follow All crank criteria are deactivated and Parameter 1 Stop duration is 10 seconds Parameter 3 Crank attempts are 3 times as well as the Parameter2 Pre heat duration is 0 second In the Auto mode the engin
7. per second also generate 30 x 118 3540 electronic signals Then 1500 3540 0 423 75 177 0 423 set the numerator to 75 and the denominator to 177 6 29 PALA 29 Safety on timer Range 5 40 Second Default 0 Description All faulty inputs are ignored until safety timer expired Except the Emergency stop over speed over frequency and low water level 6 30 PALA 35 Shut down after trip timer has expired Range 30 7200 Second Setting Range 1 240 Setting value 1 Note Delay time Setting x 30 Sec Default 30 1 x 30 30 Description When trip occurred the running icon f is flashing and the designated relay output is activated The GTR 205 shuts down the engine if the fault is not cleared before this timer expires 6 31 PA A J Output 0 Relay Output List Range 0 27 Default O All errors Description Please see Relay Output List 6 32 PALA 32 Output 1 Range 0 27 Default 3 Pre heat output Description Please See Relay Output List File version MG200VO5E 16 gt on 6 33 PARA 33 Output 2 Range 0 27 Default 12 System in Auto Mode Description Please See Relay Output List 6 34 PAHA 34 Output 3 Range 0 27 Default 1 System trip Description Please see Relay Output List 6 35 PAFA 35 Output 4 Range 0 27 Default 2 Genset power ready trigger Description Please see Relay Output List 6 36 PAFA J6 Relay 5 GTR 205 only Range 0 27 Default 27 Gen
8. the CODE mode 2 a Press the keypad under the code of 0000 the GTR 200 shows the information about the total Start attempt record and failed to start as well as error record b Press the button under the code display 0528 the GTR 205 goes into the PARAMETER setting mode See Figure 6 4 7 1 Total start attempts Fail to start record amp Error record Total start attempts are 24 times Continuous start failed 5 times 000 naa TE nn Kai UUU LU UU U EET Re me enero Figure 3 Figure 4 record Press the keypad under code display 0000 the GTR 200 shows the information of total start attempts and failed to start as well as error record recorded As the figure 4 LCD shows start failed are 5 times and total start attempts are 24 times as well as the eighth errors record is Low frequency Press keypad to see the previous error recorded and press or to see the previous or next error record File version MG200V05E 7 gt S GTR 200 Generator Controller Manual on E 4 7 2 CODE mode entry Code 0528 Setting value 10 seconds Parameter icon Sege 7 Figure 5 Figure 6 Parameter 1 Under the OFF mode Press the keypad to enter the CODE mode Press the keypad 5 times and press the keypad 2 times and press the keypad 8 times to get the code 0528 As shown on figure 6 To enter the PARAMETER setting mode by pressing u
9. 255 Description Enable or disable protection function 1 SH LOP HWT LWL Gi Feen Speed el SEINE EES RW REE 1 Y 259 In table 1 M means Enable lx means Disable The setting can be calculated by adding all related bits multiply its weighted value gt For example The setting is 128 64 32 16 8 4 2 1 255 6 9 PALA 09 Low frequency setting lt gt Range 42 61 Hz Default 54 Hz Description When AC frequency is lower than this setting The GTR 200 shows low frequency error and shuts down the engine if protection function is enable 6 10 PAA iO Input switch type Range 0 63 Default 29 Description Designate switch type as normal open or normal close Pressure build L F L L W L H W T deactivate switch switch switch ee Table 2 In table 2 Vv means input switch as normal open type and x type The setting can be calculated by adding all related bits multiply its weighted value For example If the setting of Pressure build deactivates Starter is disabled and EMS switch type is normal close the setting is 16 8 4 2 1 29 x means input switch is normal close Bo Bo 6 11 PAA 11 Oil pressure switch deactivates starter delay 7 Range 0 4 6 sec Setting value 2 30 Delay time Setting X 0 2sec Default 1 2 sec 6 X 0 2 1 2 Description When oil pressure switch is activated and its active period is longer than this setting the GTR 200 deactivates the starter motor
10. Description This setting designates the fuel output before cranking if the setting value is not zero 6 27 PALA 27 Revolution numerator lt Range 0 200 Default 10 Description This Parameter is related to Parameter 28 6 28 PALA 28 R P M denominator ei Range 0 200 Default 10 Description The revolution numerator and denominator are the ratio of engine revolution versus total number of fly wheel teeth or the RPM of fly wheel versus the RPM of alternator charger For example Set up the revolution numerator and the denominator to 1 to find input pulse from the LCD File version MG200V05E 15 eN S on GTR 200 Generator Controller Manual E A If the engine revolution is 1800 and alternator revolution is 460 input pulse the numerator could be set to 90 and denominator could be set to 23 Solution 1800 460 3 913 The R P M calculation formula is as below R P M Input pulse revolution numerator revolution denominator 1800 460 90 23 B If the engine revolution is 1500 and total count of fly wheel teeth in one second is 4437 input pulse the numerator should be set to 45 and denominator should be set to 133 Solution 1500 4437 0 338 The R P M calculation formula is as below R P M Input pulse revolution numerator revolution denominator 1500 4437 45 133 C If the teeth count of engine flywheel is 118 Assume the rated rpm of Gen set is 1500 rpm Then the 1500 rpm 50hz gt 30 rps
11. GTR 200 Generator Controller Manual monicon Web Site http www monicon com tw E mail sales monicon com tw gt 1 on GTR 200 Generator Controller Manual INTRODUCTION The GTR 200 is a full digital Gen set controller equipped with all basic functions and LCD panel that includes error message display faulty input detection analog signal measurement and generator status When the error occurred GTR 200 shuts down the engine and real time diagnosis can be done easily by reading LCD panel information Furthermore parameters can be adjusted from front panel in accordance with user s requirement by six setup keypad Operating DC power range is from 8 to 38 volts and low power consumption in standby mode which is suitable for small battery charger 2 FEATURE Analog Display includes Coolant temperature Oil pressure Running hour AC frequency Engine speed DC voltage 3 phases AC voltage 3 phases AC current and 3 phases to neutral AC voltage Protection information includes Over speed RPM Low Frequency High Frequency High Coolant Temperature Low Oil pressure Over Crank Low Fuel Level Low Coolant Level Low Battery Sensor Open and Short 24 error recorders Fail to start recorder and Total start attempts recorder System Operation Buttons Off Auto Manual Pre Heat Stop Rated Idle Parameters are Programmable by six setup keypads on the front panel Super wide operating DC power range fr
12. Manual 4 4 LCD Icon Explanations gt enone R jam ke Hoh cooattemperate MAMUAL Manual mode OS joss om mae OB maes M Unt Cote eae Vasen A reen mem Vase File version MG200V05E 4 GTR 200 Generator Controller Manual Ges t dome ee Joten natgerg ao Pretest mi mann O o ring anes e a te sm momcon Sensor alarm Error occurred ran PLL Contgwraton upperimt l2 IN2Acton bE_L Configuration lower limit Fig 2 4 5 LCD Information e Battery DC voltage readout e Running hours e Coolant temperature readout e Oil pressure readout e AC frequency readout e RPM readout e Gen set L1 L2 phase voltage readout e Gen set L2 L3 phase voltage readout e Gen set L3 L1 phase voltage readout e Gen set Li phase ampere readout e Gen set L2 phase ampere readout e Gen set L3 phase ampere readout e Gen set L1 N phase Voltage readout e Gen set L2 N phase voltage readout e Gen set L3 N phase voltage readout e Error records e Failed to start record e Total start attempts record File version MG200V05E 5 GTR 200 Generator Controller Manual 4 6 Operating Keypads ett OO Gi EG her H HH H SRL Setup Keypads y la EJ 4 6 1 Setup Keypads Under the CODE entry mode this keypad represents the fourth digit Under the PARAMETER setting mode this keypad switches to next parameter sa Under the CODE entry mode this keypad represents the third digit b U
13. e cranks 10 seconds while detecting T18 and T19 wire shorted and then stop for 10 seconds After 3 attempts of cracking the LCD shows the over crank icon Lt and the alarm is triggered 5 4 3 OFF Press the keypad to stop the running engine and then Gi icon shows on the LCD After 10 seconds File version MG200V05E 9 Fu S on GTR 200 Generator Controller Manual E depends on Parameter 1 the engine stop completely and icon Gi disappears The icon sle appears on the LCD if the idle function is enabled 5 4 4 Clear Press the keypad eS to clear error and deactivate alarm The LCD back light turns red when errors detecting by GTR 200 Then GTR 200 stops the engine and shows the error messages on the LCD The button K clears error and switches the GTR 200 into OFF mode 5 4 5 Pre heat Press the keypad vs to manually activate the pre heat output under OFF or AUTO mode If the generator is running the pre heat function is prohibited 5 4 6 Rated Idle Press the keypad D to switch the engine to rated or idle speed The icon sels displays when the engine is running at idle speed Press the keypad a again to switch the engine to rated speed and vice versa The idle function performs by a relay which outputs a signal dry contact to speed governor controller File version MG200V05E 10 eN S on GTR 200 Generator Controller Manual E 6 Parameter setting 6 1 PA A UI Stop duration Gi Range 5 40 sec Default
14. ensetontoadIndeationinput 8 A 45 aout L Phase Current Input K Table 6 File version MG200V05E 19 eN GTR 200 Generator Controller Manual 8 3 V R Function V R is adjustment for matching tolerance between external and internal measuring meter readout All values can be shown on LCD panel 8 3 1 VR1 AC Voltage adjust fine tuning 8 3 2 VR2 AC Current adjust fine tuning 8 3 3 VR3 Water temperature value fine tuning 8 3 4 VR4 Oil pressure value fine tuning File version MG200V05E 20 GTR 200 Generator Controller Manual 9 Dimensions 209 mm 144 mm Fig 15 Side view 209 mm 156 mm mm Fig 16 Top view File version MG200V05E 21 E L D S O im 2 O d C O S N LC LK O Example iring 10 W X Please make sure to connect all 6 wires to the CT input pins GENERATOR X Generator N wire must be connected to the controller GTR 200 Controller GTR 200 Controller NFB No dan Breaker 30 Aux Input 1 29 Speed ST Meaning Bisan s Ol 60 Generator L1 29 Speed Sie Ol 59 Generator L2 27 O P Sen ay Ol Pressure Sensor Ol 58 Generator L3 26 W T Sen 57 Generator N PEO 25 Spare O 8 Ol 24 Freq D 2 Ol aa Ol 29 Freq D EAS 17 H W T Input o QAR enp Sw 16 L O P Input o oQilPressure SW 48 Output 3 N C 15 L F L Input S o Fuel Level SW 47
15. gt Forexample 128 8 4 2 1 143 6 22 PA A dd Display option Range 0 31 Default 28 Description Select an option for display the desired parameter source or unit Minimum Minimum RPM Reserve Reserve Reserve voltage frequency eal conven PSI BAR C F detect detect 2 Result Ve am DE BO In table 4 M means Enable lx means Disable b gt The setting can be calculated by adding all related bits multiply its weighted value BO For example 28 Display Frequency convert to RPM PSI C File version MG200V05E 14 eN S on GTR 200 Generator Controller Manual E 6 23 PAFA 23 The revolution of deactivating starter Range 150 900 Default 480 Description When engine speed is higher than this setting the GTR 200 deactivates starter while cranking 6 24 PA A OH Over speed Range 980 2100 RPM Default 1980 RPM Description When engine speed is higher than this setting value the GTR 200 shows over speed error and shuts down the engine if protection function is enabled 6 25 PAFA 25 Stop Trip Option Range 0 255 Default 0 Description Select the protection level for each faulty input ie Low High Low Fuel Low Result D faut Table gt In table 5 M means Trip K means Stop gt All protection functions listed above are for shunting down the engine 6 26 PALA db Pre activate fuel timer Range 0 30 Second Default 0
16. nder correct code input the GTR 200 switches into parameter setting mode and parameters switch alternately by pressing the keypad OS 4 7 3 Parameter setting mode TT U i Figure 8 Figure 9 Figure 10 Figure 8 shows the Parameter 1 and the setting is 10 seconds By pressing or to decrese or increase the setting For example To decrese the setting from 10 to 8 seconds by pressing the keypad twice As Figure 9 and then press the confirmation button the LCD shows SAVE on the place of PARA for half second The SAVE shows up that means the parameter setting has been changed successfully In the meantime the LCD screen changes form Figure 9 to Figure 10 for one second and then back to figure 9 again To increse the setting value from 10 to 12 seconds by pressing the keypad twice and then save the the setting To discard the parameter setting by pressing the keypad to return to the previus page or pressing the keypad or to go to next or previous parameter 4 7 4 Parameter setting value range Figure 11 Figure 12 By pressing or may reach the upper or lower limit of parameter setting For example The Stop duration ranges from 5 to 40 seconds lf the LCD shows b _ L that means the setting has reached to bottom limit and uP_L means that the File version MG200V05E 8 eN on GTR 200 Generator Controller Manual setting has reached to upper limit 5 Operation
17. nder the PARAMETER setting mode this keypad switches to previous parameter a Under the CODE entry mode this keypad represents the second digit b Under the PARAMETER setting mode this keypad increases the setting value Under the CODE entry mode this keypad represents the first digit b Under the PARAMETER setting mode this keypad reduces the setting value Enter or exit the parameter setting mode Confirm and save the settings 9660600 File version MG200VO5E 6 x S on GTR 200 Generator Controller Manual E 4 6 2 Information swapping keypad These two keypads are used for display gen set information alternately lt gt L1 N gen set voltage gt L2 N gen set voltage lt gt L3 N gen set voltage L1 L2 LCD line 1 L1 L2 gen set voltage L2 L3 gen set voltage L3 L1 gen set voltage a utility voltage lt gt L2 L3 utility voltage lt gt L3 L1 utility voltage lt gt L1 L2 gen set voltage LCD line 2 L1 gen set current L2 gen set current L3 gen set current Engine RPM L1 Gen set current lt gt LCD line 3 Coolant temperature Run hours Oil pressure lt gt Coolant temperature gt Battery voltage Oil pressure Coolant temperature Run hours Oil pressure Coolant temperature Battery voltage Oil pressure 4 7 Enter Code mode The GTR205 enters the PARAMETER setting mode via the OFF mode by following steps 1 Under the OFF mode Press the keypad to enter
18. om 8 to 38 volts Two colors back light makes it easier to distinct system status 9 output Power Relays not only provide several functions but also endure heavy power capacity Equipped with high security terminal connector that provides easy plug in and removal 3 Specification DC power input range 8 38 VDC Power consumption Max 250 mA O 12 V 150 mA O 24 V Measured Frequency Range 0 80 Hz Minimum detecting volts 10 V AC Accuracy 99 8 DC volt meter Range 10 31 V Accuracy 99 5 AC volt meter Range 15 512 V Accuracy 99 5 AC current meter Range Convert via CT ratio File version MG200V05E 2 onicon Accuracy 99 5 Output capacity 8A 30 V Operating temperature 30 C 70C Storage temperature 40 C 100 C Dimensions 216 mm x 144 mm x 89mm Panel cutout 210 mm x 138 mm Weight 925 g GTR 200 Generator Controller Manual 4 Panel descriptions 4 1 Front view File version MG200V05E x RADA E lan LY NL Sa Lan cet monicon Generator Controller Fig 1 x on GTR 200 Generator Controller Manual 4 2 Circuit Breaker status indication 4 2 1 Circuit Breaker status LED This LED light up when terminal 43 and terminal 44 are wire shorted Indication of circuit The Circuit Breaker status LED is independent from GTR 200 breaker status 4 3 LCD display figures com Etage 588481585 es a Mansel TIL LJ LAL Bar
19. set in Normal Description Please see Relay Output List 6 37 PA A 31 User code 1 Range 01 99 Default 28 Description Change the user code 1 0528 Note By pressing V to save the changed value 6 38 PHHA 38 User code 2 Range 00 99 Default 05 Description Change the user code 2 0528 Note By pressing amp to save the changed value File version MG200V05E GTR 200 Generator Controller Manual All errors System Trip Genset Power Ready 3 4 5 6 7 8 9 Trigger Pre heat Output Pre activated fuel Idle Output Over Speed RPM Over Frequency Low Frequency Low Oil Pressure 10 High Water Temperature 11 12 13 System not in Auto Mode System in Auto Mode Genset Running by Manual operation Over Crank Over AC Voltage Under AC Voltage AC Over Current AC Short Circuit Low Battery Auxiliary Input 1 Auxiliary Input 2 Low Fuel Level Low Water Level Emergency Stop Sensors Alarm Genset Power Ready Geneset in Normal List 5 gt 7 System parameters Emergency stop delay Over frequency delay High coolant temperature delay Low oil pressure delay e Low coolant level delay e Low frequency delay e Low fuel level delay e Input 1 Input 2 delay e Overload delay e AC short delay e Low voltage delay e High voltage delay e Low Battery Voltage e Circuit breaker closed
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