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index automatic microprocessor control panel for stand

1. E 33 2114 STARTING MOTOR 28 re re en d E E arm 33 2 11 5 GAS SOLENOID VALVES for gas motors out 28 nnn 33 2 11 06 RESET Ut 28 core at tte eri rette ede ag em equ deep am amer meet 34 2 11 7 DOUBLE STARTING 28 9490 NFS61 940 34 Note for the adjustment to the rules of safety fireproof the FORCED RUNNING can be required to see 2 10 5 34 2 11 8 ANTI THEFT P ROTECTIQN tct eb set tre ee P ente ple eb ta teo m ente 34 2 11 9 ALARM HISTORY RECORDS iint eem ect e aatem di cb t dete pente 35 2 12 PROGRAMMING a rui Tav irr ra rara d o rn t i Far a cr E a a v c 36 242 SETTINGS aot cte rte tette oh eal qutt ed e rta m erac eb era mo RR er d 36 2 12 PARAMETERS Doe t t edem dens be eaae pen ddl o entem de 37 2 123 TIMESETTING rettet vetet tanta aa tute TE E E fes 37 2 12 o Stn o ts thes n sut ette thls hitters 38 212 5 VARIOUS SETTINGS sator et mete dta ted temi qon ed timed e meds 39 2 12 06 REMOTE CONTROL SETTINGS ich ee cn tr e t c ved e e i ote 40 2 13 S ELF PROGRAMMING aeri kde ria nn lr d Rr a E 41 2 14 CONNECTIONS AND RELATIVE DESCRIPTIONS rennen nnne nre nen rese rese rene reae ei rena 42 2 14 1 VIEW OF THE GCMO2MP CONNECTION UNIT 42 2 14 CONNEC
2. VER VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 2 Anomaly due to low oil pressure high motor temperature low water or oil level fuel reserve Check the relative levels water oil fuel and top up if necessary then reset Anomaly of the battery dynamo In this case request technical assistance 4 Alarm due to local or remote emergency stop status Set the programming switch on LOCKED mode and turn and pull the emergency push button enabled then reset Alarm due to failed starting Try starting with manual control and inform the supplier 6 The generator overload protection switch has tripped Itis to be reset manually by a qualified engineer see simple maintenance jobs section c2 1 6 PROGRAMMING If the electronic module should be disconnected from the power supply the established weekly timer programming is deleted consequently all the functions foreseen for the internal timer would fail to work at the time and on the day programmed therefore the weekly timer is to be re programmed Access the page below to re program it Press ENTER the day flashes Using the keys modify the day and press ENTER to confirm The time flashes Using the keys modify the time and confirm with ENTER The same goes for the minutes and seconds You cannot change page until programming is complete 1 7 VARIOUS CONTROLS LED TEST Hold the push buttons down together br 2 seconds Al
3. nennt tener erret tee ertet t rnt 17 243 POWER SUPPLY FROM GENERATOR iicet dete ec Rt dr 17 24 4 MANUAL STOPPAGE iie ne fete fo heben t etn 17 25 VARIOUS FUNCTIONS AND UTILITIES errem e i e 18 2 5 1 CC12 AND 24V POWER SUPPLY CIRCUITS enne 18 225 2 COMMAND REUAYS sicci treni mere rire re rre rere rr erre tii rne irme reete eri S 18 2 5 3 MOTOR STARTED READING eene teet teinte t rns 18 254 MOTOR PREHEATING sentent mter trente mirer Deren ertet i ere eere 18 25 5 AUTOMATIC BATTERY CHARGER n c e edite Pte eere 19 2 6 MOTOR AND ALARM PARAMETER READING nnne i i f 20 2 6 1 POSITIVE MOTOR PROTECTION INPUTS eene tenente tenera 20 2 6 2 ANALOGUE MOTOR PARAMETER READING INPUTS PRESSURE TEMPERATURE AND FUEL LEVEL 20 263 0L PRESSURE cette ree e pb rec de eri a Pct e rtp v ERR 21 2 6 4 MOTOR TEMPERATUR E entente erento terere meret eee Pee nre eere arl 21 2 65 PUELLEEVEL L citate edere but ten ar ceca t ere e er t m ver con de bt rc eer 22 PROGRAMMING EE 22 2 6 6 FUEL PUMP 22 FEE VER VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 Page 2 of 57 2 7 MEASURING THE GENERATOR S AND MAINS PARAMETERS rennen e i a 23 COMED ie NE ER oed Me MH Morti
4. 2 AUTOMATIC MICROPROCESSOR CONTROL PANEL FOR STAND BY GENERATOR AUTOMATIC MICROPROCESSOR CONTROL PANEL FOR STAND BY GENERATOR read through this manual you will realise the outstanding performance and variety of applications offered by his supremely technological unit pre arranged for the direct serial communication with a PC or using a GSM unit your generator can be completely remote controlled from miles away he GC M02 unit is equipped with a complete set of digital testers that are required to monitor all mains generator and motor parameters 1 1 PURPOSE 5 12 OPERATIONAL PRINCIPLE eren nnnm rrr nr rr ri ni i i i 6 VIEW OF THE 2 UNIT nnne nnn rr rr i i ri i i i i f n 7 14 FUNCTIONAL DESCRIPTION OF THE CONTROL PANEL rn n 7 14 FUNCTIONAL DESCRIPTION OF THE CONTROL PANEL 8 1 5 COMMANDS AND OPERATIONAL MODES ersnene rne nn i i i i i 11 1 6 PROGRAMMING sssini 1 7 VARIOUS CONTROLS 21 CONSTRUCTIONAL DESCRIPTION OF THE CONTROL PANEL nennen ea 14 2 2 OPERATION incer i rc i E E T E RR E D a 15 2 3 DETAILED DESCRIPTION OF HOW THE CONTROL UNIT WORKS rnm e 15 2 4 MANUALLY CONTROLLED FUNCTIONS rrr erre er i i f f anann 17 2 4 1 POWER SUPPLY FROM MAINS manual command enne 17 24 2 MANUAL STARTING
5. 37 OA Vac 38 NO 10ACR command contact 10A29Va 0 39 NC 10A CR command contact 1 1 S 10A259Va O 40 NO NC configurable contact to command GE switch opening 10A25Vac 41 configurable contact to command GE switch opening 10A250Vac 4 5 5 OA OAc OT 43 NO 10A CG command contact 1 S 10A259Va 0 44 INC 10ACG commandcontact O 10A258Va POWER SUPPLIES ooo 45 46 Primary220Vacbatterychargertransormr 10050Vac 0 47 Mains neutral O OO OVA 48 49 50 MainsR S Tphases S E 1 Generator neutral 04 52 53 54 GeneratorX Y Zphases A LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 15 TECHNIC AL CHARACTERISTICS PROTECTION RATING OF FRONT PANEL Ps O 507 60H2 mao oOo MAX INPUT CURRENT PROTECTION AGAINST INVERTED POLARITY Butin POLLUTION RATING 10 250V ca BUILT N AUTOMATIC BATTERY CHARGER PROTECTION AGAINST OVERLOAD AND SHORTCRCUT 80 51 MAINS LINE PROTECTION AGAINST MIN AND MAX VOLTAGE AND FREQUENCY lt V 2
6. N 1 2 Regulation transducer oil pressure 9 Ed Ed Regulation TM transducer Regulation zero oil pressure To bring the oil pressure to zero and to press reset to confirm the operation Regulation zero TM Not to change Regulation reading oil pressure Regulation reading TM o O VDO VEGLIA MANUAL 500 700 1000 1 Regulation transducer fuel level Regulation zero LC To bring the fuel level to zero and to press reset to confirm the operation Regulation reading LC To bring the fuel level at the most and to press reset to confirm the operation Regulation zero VB Regulation reading VB 18 Regulation current 19 Regulation differentials 2 12 3 TIME SETTINGS Number of starting attempts This establishes after how many starting attempts the failed starting function is to be enabled Starting time and pause This establishes the starting time and the pause between one starting attempt and another Generator enabling delay The load output is enabled following a set time that is triggered by the motor started signal minimum 5 secs Starting delay This makes the GE insensitive to micro disconnections due to a pre VER LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Mains enabling delay When the mains retums within the established limits bllowing the set time the output is switched from generator to mains alarm prior to start
7. 8 9 2 1 VER LAST ISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 Page 29 of 57 2 9 FUNCTIONS OF BUILT INWEEKLY CLOCK 2 9 1 WEEKLY CLOCK The M02 generator contactor has a builtin weekly clock that allows the input to be programmed to suit the unit or the cutout to be programmed to prevent the unit from starting even during a power failure Where the electronic module loses its mains power supply the settings for the weekly clock are cancelled which means that all the functions that depend on the built in clock will not work on the day and time set and so the clock must be reset When a function such as automatic test automatic stop or automatic start is active should the battery be disconnected the display will read OPERATION CLOCK TO BE SET set is go to the next page Press ENTER the day will flash use the keys to change the day press ENTER to confirm The hour will begin to flash use to change confirm using ENTER and repeat the procedure for the minutes and seconds The page cannot be changed until setting the clock has been completed 2 9 2 CLOCK FOR AUTOMATIC TESTING This allows the unit s operation to be tested automatically It can be set weekly or every two weeks While the test is in progress the operation display reads Automatic Test Should the power fail during such a test the unit immediately Switches over to the generator supply and back again when the
8. Pus It indicates the temperature which determines the pre heating It indicates the temperature which deactivates the pre heating Low engine temperature 20 60 less than 60 C OFF lll cocco TN When exceeded the switch or contactor is opened hi Maximum mains power supply current Current setting for tripping of 12040 A the Mains Contactor Determines the maximum current permitted on the mains power supply side when exceeded an alarm is raised protects the Mains Contactor Working hours between services 0 excluded When the hours set have expired an alarm is raised or the unit cuts out Restore energy 0 kW excluded Determines power supply and stoppage after motor cooling 2 12 5 VARIOUS SETTINGS Each alarm can be programmed as follows DESCRIPTION VALUE FIELD CHANGE CT on load or on gen set Load Gen set ON Special functions Cut out Test Selects one of the special functions provided on connections EJP 18 and 20 SCR 2 GEN on standby Pre heating out CONNECTION 28 Pre h motor Pre h Mot Selects the function pre heat motor pre heat glow plug starter Pre h G PI reset gas or double starting Starter Reset Gas Double Start 6 Sequence phases mains It activates the control of the sequence phases on the mains the failure determines the opening of the relative contactor CR the failure determines the opening of the relative contactor CG RPM Engine VER LAST I SSUE LANG P
9. _ LASTISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 Page 30 of 57 2 10 REMOTE COMMAND AND CONTROLS The following remote commands and controls are available in the terminal board that can be configured on inputs 18 20 1 Remote locking command to assure that the unit is not started when there is no mains power supply overnight locking and week end shutdown for offices etc Remote automatic test command TEST to remotely start the generator function command Programmable Remote starting command with forced output even in the presence of the mains power supply SCR Stand by generator operation command used to program the two units that run alternately for a set amount of time M 02 Cops po EJ P FRANCE SPECIAL TIMES EJP 2 SCR forced start with supply SPECIAL cem _ SCR FORCED START RES two generators SPECIAL BLOCK one on standby SETTING 2 GEN CHANGE BES Bab Forced stop BATTERY X SCR TST test MISC SETTINGS TEST The TEST BLC AND SCR functions are active simultaneously standard configuration When the EJ P or RES functions are activated all the other functions are deactivated 2 10 1 EJP FUNCTION The special EJP function is fitted only in French systems When JP1 is activated after the set time times menu the unit starts up The EJ P2 command causes an immediate switch over from the mains power supply to the generator As soon as this input is disabled if
10. NOTE Even when the generator is stopped some safety devices relating to the fuel and water level are enabled and if an anomaly is detected an alarm status is triggered The switching of the mains generator is also constantly controlled and if there should be an overload on the mains contact maker an alarm buzzer is triggered To ensure the perfect efficiency of the generator a battery charger automatically holds the battery perfectly efficient An automatic fuel filling system constantly keeps the correct level in the daily tank A pre heating system maintains the motor the ideal temp erature so that it is ready to start whenever necessary PLE VER VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 1 3 VIEW OF THE GC M02 UNIT Functional description of the block diagrams 2 Commutator of programming 1 Automatic test T 1 Alphanumeric display of visualization of all the 3 Block Locked excluded logic measures and the literal description of the type of alarm 4 Feeding forced from mains CR es Reserve Fuel 5 Manual starting 6 Feeding forced from generating CG 3 Button of selection measures and button of reset for restoration functions or unlock alarm BATTERY CHARGER 10 The flash indicates that the microprocessor is elaborating a function 5 Manual command fuel 9 Buttons for the manual command pump of work or stop 6 Intervention of the 7 Fed battery charg
11. BATTERY REPLACEMENT PROCEDURE gt Set the programming switch on Manual Mains mode Disconnect the BATTERY and BATTERY CHARGER fuses gt Replace the battery and re connect fuses and reset program PEE MH LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 WARNING considering that the battery charger generators output a voltage of between 50 and 150 Volts when disconnected from the battery while the generator is running which is very destructive for the electronics the connections must strictly not be touched while the generator is running or the loose cables 2 19 4 GC M02 BOARD REPLACEMENT PROCEDURE Disconnect the BATTERY CHARGER and BATTERY fuses Set the programming switch on LOCK mode and replace the board Copy the programming of the SW1 and of the J UMPERS situated on the replaced M02 Re connectfuse F1 to the battery Program the operational voltage and the frequency if different to the standard 400V 50Hz e Rationofthe TA 5 e Overload current enter the rated current that may be output by the generator plus 5 e Shortcircuit current ener the overload current multiplied by 3 e Compare the remaining values with the test board gt The settings ofthe type of test TA the overload and shortcircuit current are crucial gt Re connect all fuses and check the efficiency VVVVV WARNING the wiring to the terminal contactors may introduce residual voltages into the M02 which may generate a value
12. GCM02 MT ING4 NEW doc 04 03 2003 Page 55 of 57 3 MAINTENANCE The control panel has been designed to operate without the need for maintenance The following is to be kept under control nevertheless every 30 60 days check the electrolytic level of the battery every 30 days check the water oil and fuel levels every 30 days check the motor pre heating temperature if installed every 30 days run the unit automatic test every 6 months check the battery efficiency 3 1 ELECTRICAL MAINTENANCE See the relative manual for the maintenance of the GENERATOR The inbrmation provided herewith simply relates to the electrical command and control parts of the generator WARNING The control panel is powered by the mains and by the generator Before accessing it for maintenance purposes disconnect the mains and stop the generator by setting the programming switch on LOCKED 3 2 EFFICIENCY TEST Efficiency tests of the various automatic functions to be executed with the AUTOMATIC or TEST programs The safety devices against min voltage min frequency low oil pressure and dynamo are enabled when the generator is running at a steady state and following the programmed tripping of the generator delay that enable the load output Therefore all simulations are to be performed following this timing 3 3 MOTOR SAFETY DEVICES Disconnect the wire on the motor from the relative reading probe and connect itto earth for roughly 3 seconds An buzz
13. When output 28 is set to RESET each time the RESET command is given via the button or remote control output 28 is active 2 11 7 DOUBLE STARTING out 28 UNI9490 NFS61 940 saa _ LJ LJ LJ This allows an automatic switch over to a second starter battery The number of starts set under time settings is spread over the two batteries alternately If OUT 28 at the end of the cycles the motor has not started an alarm is raised for no start having occurred 1 BATT 2 RB1 2 contactors for CC current from 150 to 300 A Coil 12 or 24V for continuous service Note for the adjustment to the rules of safety fireproof the FORCED RUNNING can be required to see 2 10 5 2 11 8 ANTI THEFT PROTECTION Only on M02 with a serial 5 232 output This is only active on plants that are fitted with remote controls If the generator is disconnected an alarm is raised and transmitted via modem or GSM Each alarm is stored in the alarm history file Operation When the generator circuits relating to the 30A R1 relay that isolates the battery cables are interrupted and wire 12 that activates the burglary alarm status is disconnected the power supply to the M02 is maintained by battery 2 that powers the remote control System and sends the burglary alarm message Programming Under Misc Settings set High Oil Temperature alarm 12 to Anti Burglary 1 O HLE VER LASTISSUE LANG GCM02 MT ING4 NEW
14. alarm is triggered and the generator is stopped the following occurs The alarm triggered appears on the display The generator contact maker is immediately opened Activation of the immediate stop SI or delayed SR after the phase of cooling motor if enabled stop Activation of the acoustic alarm and lighting of the flashing red led on the drawing of the engine The alarm cause is saved e The LOCKED status is triggered until the alarm is reset the first impulse to SILENT RESET ACK button it silents the acoustic alarm it recognizes the alarm with function ACK function ISA M and the alarm led from flashing it becomes fixed to restore the functions excluding the block for alarm to press a second time the RESET button and alarm red led will be turned off 2 When the voltage returns within the rated parameters the switch back to mains delay timer is triggered that enabled the mains to settle before switching back the load 2 K Once the load is switched the motor cooling phase of roughly 1 minute begins At the end of this phase the immediate or delayed stoppage phase is enabled 2 L Pre arrangement for a new cycle 2 M With the mains connected the overload safety device 51 of the mains contact maker is enabled EXCLUSIVE which when tripped triggers the buzzer without interfering with the mains output warning the operator that the rated current of the CR contact maker has been exceeded 2 N To the command of the contactors CR a
15. for a current that does not exist To eliminate this go into the measurements menu zero the current and press Reset The M02 starts selfprogramming This operation must be carried out without current in the power circuits Where this charge cannot be eliminated short circuit the wires to the Terminal Contactors 2 19 5 2 POWER BOARD REPLACEMENT PROCEDURE WARNING It is absolutely prohibited to touch any parts while they are powered Disconnect the mains and stop the generator if this is running Disconnect the BATTERY CHARGER and BATTERY fuses Replace the board paying utmost attention to terminals 3 and 4 of the 12 and 24V voltage If the motor is pre arranged for positive inputs program the relative UMPERS and SWITCHES under the guard of the MP02 board see the positive motor protection inputs and motor parameter analogue reading inputs sections Re connect the battery and battery charger fuses Check the efficiency of the unit VVVV WARNING the wiring to the terminal contactors may introduce residual voltages into the M02 which may generate a value for a current that does not exist To eliminate this go into the measurements menu zero the current and press Reset The M02 starts self programming This operation must be carried out without current in the power circuits Where this charge cannot be eliminated short circuit the wires to the Terminal Contactors Ft VER LAST ISSUE LANG PAGE
16. modes that can be selected with the programming switch are six namely 15 1 Automatic test This starts to test the generator without disconnecting the mains power supply from the utility When the Switch is turned back to automatic mode the generator stops following a delay of roughly one minute it is used for periodic tests or to check the running efficiency following maintenance 152 Automatic mode if there should be a failure in the mains the circuit board responds by opening the mains contact maker If the generator fails to start another 4 starting attempts are made 10 seconds after it has started the generator powers the utility While running the generator and motor are constantly controlled and a possible anomaly is immediately displayed examples fuel reserve water level overload min voltage etc and the relative stopping cycle is triggered Once he mains is re connected following the set time the utility is switched back to the mains and the generator is stopped following a delay of roughly one minute to allow it to cool down this is the normal operational situation 153 Lock this sets the generator a locked status It completely disables every possibility of starting while the mains power the utility This mode is used to work on the system in complete safety being certain that the generator will not start even if the mains should be disconnected itis used during maintenance 1 5 4 Manual mains this enables the forces t
17. not only controls the control software of the circuit board but is also equipped with an electro mechanical circuit that totally ensures the stoppage of the unit and the opening of the generator contact maker WARNING The command is double the NO contact of the emergency push button is required to ensure the immediate opening of the generator contact maker even in the case of an anomaly in the electronics In fact to ensure the emergency power supply even in extreme cases the contact that commands the mains and generator contact makers CG CR is normally closed NC therefore if the contact maker is to be opened the command relay must be powered The motor stoppage on the other hand is ensured by the NC contact positive safety which disconnects the power supply from the motor even if the circuit is disconnected or in the case of an anomaly in the electronics as per standard BATT AC PAE BATT Other operating solutions can be applied to suit the overall design REMOTE SWITCHING OF THE MAINS GENERATOR Switching with tetrapolar contact makers of adequate capacity for the power of the unit mechanically and electrically interlocked and scaled in AC1 in compliance with standard ISO DIS 8528 4 Switching is controlled directly by the RG 42 43 44 and RR 37 38 39 relays built in the MP02 power module which by means of contacts free from voltages and protected by fuses directly control switching that can be carried out using
18. of the situation plant PIRE Gruppo Elettrogeno N 1 CAPPUPAHTE uo 2 130 CR ico KY A GENERATORE em PWR 50 440 2 m Hz COS PH en 50 L Differ i 140 RX es Dev GRUPPO NUM MOTORE 10 ITO TEMPERAT MOTORE 100 0 BS PRESSIONE OLIO BAR 23 mer 11 42 48 aru VEO NUMERD GIRI 1524 to NItINALLO rore TENSIONE BATERA v a ea CORRENTE CARICA AF i PROGRAMMAZONE GRUPPO MANCANTI ALLA MANUT ORE 1 d RIAT AUTOMATICO ANYAMENT FALLITI Bia OT ASR O SSES Se MAIER RIUSCITI FORZATURA LOCA INTERVALLO ORE 2 asd EX nis JRZATURA LOCALE een t BE CONTA ORE ALLARNI AVVIAMENTO FORZATO L mY 5 ALL ARN CETENSENERATORE DURATA CONNESSIONE 0000153 f EU UVS ESCI TARATURE STORICO Service 2 17 3 REMOTE CONTROL AND MODEM Concerning the GCM02 unit with the release 6 0 the remote control user connector is on left side of the unit view in frontal way near to dip switch which enables settings and languages and to the trimmer which regulates the intensity of the display LCD The 15 03 serial interface unit for the serial communication has to be set to work in two different way of serial connection RS232 and RS485 On this unit
19. the GC M02 control panel for handling your generator unit As you read through this manual you will realise the outstanding performance and variety of applications offered by this supremely technological unit This electronic microprocessor module not only completely controls the generator and its switching but is also pre arranged for the direct serial communication with a PC or using a GSM unit your generator can be completely remote controlled from miles away The GC M02 unit is equipped with a complete set of digital testers that are required to monitor all mains generator and motor parameters To make the control of the unit absolutely comprehensible the manual 15 split up into two parts namely The first USER MANUAL part has been prepared to provide a clear and simple guide to help you use the generator rapidly completely and safely 11 PURPOSE The manual has been prepared specifically for the user of the generator unit Information required for the following is provided 1 to learn the operational principle of the unit 2 to interpret the indications given on the electronic control panel 3 to control it for the various operational requirements 4 to perform the basic checks required to ensure the efficiency of the generator itself Technical or adjustment matters are not dealt with as these involve the installation engineer when setting up the system PE VER DATAULT VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 0
20. the installation to connect the modem with the prolongs PIN TO PIN usually supplied with the modem to our serial IMPORTANT if it has a modem also trained to the operation GSM it is of fundamental importance to remember also to insert before the start the SIM card opportunely trained to the traffic data a standard SIM not trained to the data communication it allows only the communication by SMS As first operation to feed the modem inside the GCM 02 unit In the case of modem GSM needs immediately to insert the number of the PIN of the telephone SIM and subsequently to set in the field of the serial regulations they cab be activated elevating the switch 4 the telephone numbers of reference two normal and two trained for the sms to which it has to correspond a computer with our software In case of signallings of alarms before they are contacted the numbers corresponding to the sms and subsequently those with the normal numbers It is important for a correct control to insert gen set identification number to make possible the controls and the modifications by the remote control use The address modbus in standard conditions has to be set to 1 after set the modem that you want use and opportunely connected to the unit The U S Robotics modem works as a normal modem of telephone line and it is not trained to the function GSM So the communication speed is usually set to 9600 Kb s also if U S Robotics could work up to 57600 Kb s Whe
21. while the test is running the mains should be disconnected the utility is immediately powered by the generator By disabling the TEST command the generator is automatically stopped after a few minutes When the Test function is active the generator status display reads AUTOMATIC TEST The RES functions are excluded PEE LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 10 5 FORCED RUNNING OR SAFETY FIREPROOF 18 UNI9490 NFPA NFS61 940 It forces the feeding and it avoids the stop with any type of alarm the stop can be effected only manually Connecting the 18 to B the gen set intervenes for the foreseen commands mains failure remote start test ets and during the working the feeding is forced this is showed on the display and the acoustic alarm is activated The gen set is in feeding up to manual stop command When the command is active 18 to on the display it is displayed FORCED RUNNING If during the running the command to the 18 is removed the normal functions are activated automatic stop in this condition the time of delay stop cooling engine is programmed to a fixed time of 60 Programming There are two options 1 bringing to 1 one the stop time the command FORCED RUNNING is activated only giving a B to the 18 2 bringing to O zero the stop time the command of forced running is permanent namely to every start the gen set has the deactivates protections and th
22. 4 03 2003 12 OPERATIONAL PRINCIPLE HOW A STAND BY GENERATOR UNIT WORKS Fig 1 illustrates the system components that consist of a public mains R a generator unit G M a QGE command and control panel with a builtin mains contact maker CR a generator unit contact maker G and the M02 module that controls the system UTILITY Supposing that the mains R is within the normal limits the CR mains contact maker is closed therefore the utility is powered from the mains The M02 module controls the R mains and if there should be a drop in voltage a phase should be missing or the phases should be dissymmetrical the control panel l opens the CR mains contact maker 2 Starts the G M generator unit which when the established operating conditions are reached the M02 module closes the CG contact maker that then powers the utility from the generator unit G NOTE When running the M motor and G generator are safeguarded against possible anomalies which if encountered cause the generator to stop immediately and the cause for the alarm is saved and displayed i e low oil pressure overload and so on 3 When R mains is restored within the normal limits the M02 after an adjustable delay opens the contact maker of the CG generator and one second later closes the CR contact maker thus powering the utility from the mains again 4 The generator continues to run for at least another minute to cool down after which it stops automatically
23. 7 and gt V59 81 FUNCTIONS WEIGHT OF GCHODUNT ig WEIGHT OF GC MP02 UNIT 1000g COMPLIANCE WITH STANDARDS EN 60255 1 5081 2 EN 6100 4 2 EN V50140 1000 4 3 8 ISAM Note The technical characteristics are subject to modifications without notice following technical improvements Ht VER LASTISSU LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG Page44 of 57 2 16 DIMENSIONS 2 16 1 DRILLING TEMPLATE OF THE GC M02 UNIT 4HOLES 4mm 2 16 2 DIMENSIONS OF THE MP 02 POWER UNIT 4 HOLES 5 VER LAST ISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 Page 45 of 57 ADJUSTMENT TO THE LANGUAGES To allow an immediate interpretation of the commutator of switching a pocket has been foreseen in which a nameplate is inserted with the writings in the wanted language VER LASTISSU LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG 46 of 57 2 17 OPTIONAL EXPANSIONS 2 17 1 REMOTE SIGNALS INTERNET INTRANET ETHERNET The serial output has an interface board attached to it which has an independent microprocessor that allows special functions to be installed to suit the client s specifications The following is provided for 1 The control of three eightrelay modules providing a total of 24 remote signals with free contacts This also allows a single module to be connected for the remote signals required 2 The same interface board has outlets that can configur
24. AGE GCMO02 MT ING4 NEW doc 04 03 2003 Page 39 of 57 NM T NE Sequence phases gen set On Off It activates the control of the sequence phases on the gen set 1500 1500 3000 Time of automatic test 0 From 0 to 24 Hrs Block TOT BLOCK To press reset To select the day of the week To press again PAR BLOCK reset and to select the kind of block for that day To press START reset and to select an other day or to press more times down PAR or up to exit BLOCK START Block Sets the times at which the unit cannot start up automatically only manual control can be used 7 Automatic test the clock must be set Active or inactive Sets the day weeks time and duration of the test Weeks 1 or 2 Days 1 7 Duration of automatic test select an other position or to press more times down or up to exit Antitheft Temp Oil It changes the alarm entry for high oil temperature 12 in Antitheft usable only with the remote control Opening CR By start It is effected the opening of the CR or by mains failure or by By mains failure start 2 12 6 REMOTE CONTROL SETTINGS Baud mains 9600K It indicates the speed of execution of the operation effected through the serial Modbus Address It allows to select the address modbus of the equipment Gen num Advertising page To press reset To move the cursor To press again reset and to select the character for the position To press reset and to It allows to pla
25. AL FROM EARTH IT ti EEC VER LASTISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 ENG 24 0 57 CURRENT MEASUREMENTS The three current measurements for CT 5A are 0 5 class up to 1000 A and 1 class from 1000 to 2000 A The ammeter circuits are made up of three 0 10 5W resistances with a dissipation of 2 5W at maximum current 5 A They can work at a constant overload of 2096 6 A and have a shortcircuit protection of 15 A for 3 or 20 A for 2 To ensure protection against overloading and shortcircuits the CTs used must have a minimum power of gt 4VA Where the CTs also power other equipment this power is increased to suit the power these require plus losses in the wires Consumption table in VA per metre of wire SECTIONmm2 15 25 CONSUMPTION 0 685 VA 0 41 VA 0 254 VA 0 169 VA VA CONNECTIONS CT CT PHASE R L1 33 36 CTPHASES L2 34 36 CTPHASET L3 35 36 CT 100 2000 5A The M02 is provided for managing generator units that operate automatically or manually with or without mains power supply generator switching over The circuit in which the CTs are installed and the readings shown on the display vary depending on their application For example Isolated generator without mains power supply generator Emergency generator backing up the mains power switching or with separate switching supply with mains power supply generator switching The CTs only read the generator current The
26. AT __ controlled by the software and if programmed to pre heat the Sparkplugs each time it is triggered the pre heating cycle is enabled STARTING 5 0688 before each starting cycle In manual to press OK to activate the sparkplugs pre heating for the desired time T06 2 11 4 STARTING MOTOR out 28 STARTER Output 28 can be configured also with the starter function In this case upon each starting cycle the output is enabled for the set timing STARTER In manual to press OK to activate the starter for the desired time COMAND STOP 2 11 5 GAS SOLENOID VALVES rent for gas motors out 28 EM When the start command is given the actuator is powered OUT 15 54 and it CRANK opens the butterfly valve after the ignitions are fed OUT 27 with the gas solenoid Out27 7 1 i valve is opened after the delay set OUT Ignitions 28 This allows unburned mixtures to be MOTOR CRANK MOTOR RUN STOP removed before each start up LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 33 of 57 When stopping first the power supply to the gas solenoid valve is interrupted and then the supply to the ignition and rev regulator is interrupted In manual activate first the start and then the fuel pump button to supply EV GAS and Ignitions 2 11 6 RESET out 28 Plants managed by remote control require a control that can reset circuits or close switches
27. CM02 MT ING4 NEW doc 04 03 2003 ENG 14 0 57 2 2 OPERATION READINGS All readings are shown on the display on two lines of 16 alphanumerical characters All the reading pages are controlled using the push buttons which run in both directions The reading pages available are the following e mains status volts hertz and amperes of phase 1 S T line mains voltage LED RN SN TN mains star voltage TEST Current on the three phases mains KVA KW KWAr mains powers Power factor cosfi HZ mains Generator status volts hertz and amperes of phase 1 X Y Z line generator voltage XN YN ZN generator star voltage Current on the three phases gen set KVA KW KWAr gen set powers Kilowatthour gen set Power factor cosfi HZ Differential trip switch programmed current dispersion current and programmed time Battery voltage and charging current Status of the inputs Status of the output Start counter Weekly timer for programming the automatic test Operation active automatic test forced start pilot GE cutout etc Supplier s name and telephone number Maintenance with programmed hours and working hours remaining before service If an alarm is triggered it will be shown on the display For example a low oil pressure fuel reserve high battery voltage alarm etc 2 3 DETAILED DESCRIPTION OF HOW THE CONTROL UNIT WORKS All operational modes are controlled by the GC M02 contro
28. CTs read the mains power supply and generator currents 3xCT 100 2000 A 5 3xCT 100 2000 A 5 The ty pe of operation is selected on the basis of the positioning of the current transformers CT via misc settings by selecting l for units without switching CT ON GENERATOR 2 for units with switching CT ON SWITCHING VER LAST I SSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 Page 25 of 57 A WARNING the wiring for the CTs may introduce residual voltages into the M02 which will generate a value for a non existent current To eliminate this go to the measurements menu zero the current and press Reset The M02 starts a self programming procedure This should be done without any current on the power circuits Where the load cannot be eliminated short circuit the wires on the CTs ELECTRONIC PROTECTION AGAINST OVERLOADS 51 AND SHORT CIRCUITS 50 OF THE GENERATOR The generators are supplied with their power expressed in KVA because the effective capacity limitation on the generator is given by the Amps on the coils Thus in order to effectively protect a generator the amps must be controlled Overloads 51 If the rated current of the generator is exceeded following a set timing the generator contact maker is opened at the same time the TRIP 40 and 41 contact is activated the overload alarm is triggered and the generator is stopped following the motor cooling phase DEFAULT IT CAN BE EXCLUDED REGU
29. E LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 0 Following the STARTING DELAY phase 4 starting cycles of 5 seconds each start split up by pauses of 5 seconds these may be programmed 2E Atthe end of the start cycles if the gen set has not started there is the FAILED START signalling if the gen set starts but it doesn t reach the speed values after 120 there will be the min voltage or frequency alarm 2 F With the motor running at a steady state the voltage output by the generator is read When this is within the established parameters the generator delay timer is triggered this may be adjusted from 1 sec to 30 min approx At the end of this timing the generator CG contact maker is closed on 2 0 means of a normal VDO probe or reading motor temperature the minimum temperature beyond which the load output is enabled can be programmed This is to prevent operating at a low temperature in the case of the failure or failed pre heating of the motor 2 While the generator is running two pre alarm safety devices are enabled oil pressure and motor temperature When these trip a buzzer sounds The following safety devices and indications when tripped are displayed and trigger the programmable functions described DESCRIPTION ON DISPLAY LED COLOUR STOP DELAYED MEN a 3 lowollvl A 4 Hin rescue peaini o 6 Highoiltempera
30. Excessive speed upon starting Calibrate the electronic revs regulator device aia NN voltage jLowolprssue Replace pressure switch High motor temperature Replace thermostat CG fuse blown Replace 10x38 fuse with identical fuse Remote switch coil bumt Replace L Ne votage outputby generator Requestassstance CRfuebown Replace fuse with identical fuse Remote switch coil bumt Replace Not earth reference on mains sensor Check earthing of generator control panel and accessories e Defectin stopping system Clean from dirt lubricate or replace e Emerg stop p button pressed Turn and pull up to release p button Motor too cold Repair or replace pre heating system r 0 5 ES a a m Nu UE EHE ane _ ETT HHELLLLE L LE iL eee LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003
31. G SCALING TEST If the utility system is modified check the scaling of the mains generator line switching The maximum load current must not exceed the Switching limit values indicated on the internal nameplate 3 8 TROUBLE SHOOTING All control panels are marked with a work order number written on the test nameplate inside the panel All the technical and constructional data of the control panel are associated with the work order number therefore you must refer to this when requesting technical assistance or Spare parts The following details must be indicated in any event 1 of electronic board indicate on front panel 2 battery voltage 12 or 24V 3 mains voltage 230 or 400V 4 generator capacity KVA 5 frequency 50 60 Hz 6 indications displayed on GCM02 module when the problem occurs 7 operational mode AUT or MAN TROUBLE SHOOTING output PROBABLE CAUSE SOLUTION Battery flat 6A Fuse of battery charger Battery flat Battery charger Battery with inverted polarity Check and invert cables Loose or oxidised battery connections Clean tighten and lubricate battery terminals u E 25 battery fuse blown Replace 25Afuse __ _ T Failed starting alarm Eailed mains The pinion fails to engage in the crown Replace pinion or whole starting motor wheel No connection with oil pressure switch Connect and check the connection to earth of the pressure switch
32. ISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 2 6 MOTOR AND ALARM PARAMETER READING 2 6 1 POSITIVE MOTOR PROTECTION INPUTS Some modern motors are equipped with positive outputs to indicate the Low Oil Pressure and High Motor Temperature anomalies The M02 is pre arranged to communicate with these motors by modifying the UMPERS on the MP02 unit NEG INPUTS POS INPUTS CoC UU 9 11 9 11 Modifying the jumpers placet on the electronic unit of the power module the M02 can to work with posive inputs IT 15 NOT REQUIRED ANY PROGRAMMING SOFTWARE 2 Batt OP WT 1 Batt OP WT 2 6 2 ANALOGUE MOTOR PARAMETER READING INPUTS PRESSURE TEMPERATURE AND FUEL LEVEL The three inputs 15 16 17 used to read the pressure temperature and fuel level can be configured using the SW2 switch on the MP02 unit for motors type MTU that output 0 10V for the above mentioned readings SW2 ANALOGUE INPUTS DESCRIPTION OFF ON FUELLEVEL 0 10V MOTOR TEMP 0 10V NEGATIVE OIL PRESSURE 0 10V NEGATIVE qe ve vt e me JUMPER INPUT When SW2 is configured to ON normal motor probes transducers of a VDO or VEGLIA type can be used which can be configured from the Misc Settings Menu Since they are not linear the working fields available are restricted by the limits of the transducers Where the probe is not installed no indication will appear on the display automatically When individually c
33. LATING THE THRESHOLD TO ZERO Short circuit 50 It trips immediately when the load current exceeds of 2 sec the parameter set The generator is stopped in the same way as in the case of overloads IT CAN BE EXCLUDED REGULATING THE THRESHOLD TO ZERO These are active when the Generator Current contact is closed at 25 Set under threshold and time settings WARNING measuring TAs are provided for the 50 function to protect against shortcircuits that are able to provide three times the nominal current 5x3 15 A in linear mode without reaching saturation ELECTRONIC PROTECTION AGAINST OVERLOADS OF THE MAINS CONTACT MAKER CR With M02 shaped with TA CT on use Fig B itis possible to control the mains parameters KW cosfi and the current that circulates on the mains contactor While the unit is running with the mains connected an overload safety device is active on the mains contact maker set at the rated current of the contact maker which when exceeded triggers the mains overload buzzer alarm 51 This is active when the Mains power supply contactor is closed at 24 IT CAN BE EXCLUDED REGULATING THE THRESHOLD TO ZERO Set under the threshold settings for the current corresponding to the 1st Mains power supply Current setting 1 O HLE VER LASTISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG Page 26 of 57 EARTH DIFFERENTIAL PROTECTION TRIP This checks any leakage of current towards earth
34. OSE CG BY MANUAL COMMAND ON 12 CLOSE CG BY MICRO OFF LED BRIGHTNES 1 STOP ALWAYS ENABLED HE ON 1 5 ENABLED ON IN MANIIAI SW PROGRAMMING SWITCH Six languages can be selected and programming can be activated using four switches or Or or Y ON OFF OFF ENGLISH SPANISH FRENCH on PORTUGUESE ON OF ON GRMN Pd PROGRAMMING EXCLUDED OT PROGRAMMING 2 12 1 SETTINGS To gain access to the tunction programming page turn switch no 4 of the SW1 switch ON situated at the side of the M02 unit All the parameters indicated on the display can be modified both the value indicated i e 380V can be changed to 395 or 378 or any other value and the ZERO of the same parameter Once access has been gained to the programming function the messages that appear on the display will guide you through the possibilities offered by the program that is in continuous development surely you will find on the module more options of programming in comparison to those brought on the manual All conditions can be worked on even while the unit is running To gain access to the programming function after having set the switch ON use the push buttons to select the block required TEST To help you find the block the fields that may be programmed hav
35. PLY FROM MAINS manual command This enables the mains power supply permanently and disables all the electronic functions with the exception of the battery charger and the EMERGENCY stop function 2 4 2 MANUAL STARTING Enable the start button and the 15 54 relay that provides power to all the unit s services solenoid valves actuator etc will be activated simultaneously 2 4 8 POWER SUPPLY FROM GENERATOR Once the unit is running in normal mode switching the commutator to GENERATOR POWER SUPPLY causes the contactor for the Generator unit to close and the unit then draws power from the generator While the unit is supplying power all the trip switches are active However since these are entirely controlled electronically any fault in this system could render it inactive 2 4 4 MANUAL STOPPAGE The stop push button is enabled at all times Press it until the motor stops completely By moving the jumper 1 on the MO2 module the stop push button is enabled only when the programming switch is in MANUAL START mode VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 5 VARIOUS FUNCTIONS AND UTILITIES 2 5 1 CC12 AND 24V POWER SUPPLY CIRCUITS The M02 module is arranged to operate at 12 and 24V By bridging connections 3 and 4 all the functions are adapted including the control threshold of the battery charger for the 12V voltage and the same without bridge for the 24V power supply voltage The first level
36. SITION The control panel consists of the following 1 GCMO02 electronic circuit board that houses the control logic control and reading of the operational parameters of the generator 2 Emergency stop mushroom push button optional 3 Nameplate with operational standards 4 Nameplate with safety instructions INTERNAL COMPOSITION numbered cables placed within PVC sheathing 10 x 38 fuses with disconnectable fuse boxes battery charger transformer of adequate capacity automatic generator protection switch if provided switch with tetrapolar contact makers of adequate capacity for the power of the unit interlocked mechanically and electrically and scaled in AC1 in compliance with standard ISO DIS 8528 4 three amperometric transformers for measuring the generator and mains current terminal for the mains and generator inputs the utility output and any auxiliary connections 8 safety fuse gauges and connection terminals nameplate 0 Switching is controlled directly by CG and CR relays built in the MP M02 module which directly command switching via unpowered contacts IMPORTANT The CG and CR command contacts are normally closed to allow the command circuits in the case of certain anomalies to force the mains contact maker to close For example by disconnecting the battery and also the power supply to the battery charger transformer the mains contact maker is forced to close Ht VER LASTISSU LANG G
37. SSURE ATTENTION NOT CHANGE THE VALUE OF ZERO WHEN THE MOTOR IS RUNNING To align eventually the zero reading to go to page REG ZERO PO and with the stopped engine 0 pressure to push ENTER The transducer reading in that instant will be as zero 2 6 4 MOTOR TEMPERATURE i MOTOR TEMPERATURE This measurement is provided by Veglia or VDO water temperature transducers up to 120 C Different values be set from the Measurements Menu The following are activated and can be set using the transducers fitted 150 PREALARM 1 pre alarm high temperature normally set on a 150 C scale base 1 2 pre heating control activate out 28 pre heating in misc settings two levels are set one for activation ON and one for stopping OFF 3 minimum temperature can be activated from misc settings when the motor temperature is below the set value the generator command 42 43 44 is deactivated to allow the motor to warm up without any load until the minimum ON PRHEAT temperature is exceeded MIN TEMP OFF PRHEAT 1 If you wish to set the high temperature pre alarm bear in mind that the value indicated is affected by the wiring and a tolerance in the transducers that may be as much as 7 C The temperature must therefore be set using the measurements menu and checked using a thermometer The setting entered must take the level at which the maximum temperature thermostat intervenes into account as this cause
38. TIONS ON THE MP02 POWER 43 2 15 TECHNICAL CHARACTERISTICS eren nennen nennen nen rennen rer 44 44 2 16 0 Ond a ur Rr T a TR Rr E 45 2 16 1 DRILLING TEMPLATE OF THE 2 UNIT 45 2 16 2 DIMENSIONS OF THE 02 POWER 45 eate ede quaedam cad qa tet dme ene 46 ADJUSTMENT TO THE LANGUAGES 5 tette tenete ei E hen tite tege eee 46 2 17 OPTIONAL EXPANSIONS eren nenne nennen ressent e IE H AE HR EE RI I E E AE 47 2 17 1 REMOTE SIGNALS INTERNET INTRANET ETHERNET seen 47 ATE REMOTE CONTRO eR teme toi dee est tetti etu 41 COMMUNICATION PROTOCOL x erectio Oe haere rere aree qtue bap tan 49 248 INSTALLATION P rv i v va i aa rv ER 51 2 18 POSITIONING etr teeth tenir te aeter etr tege N peut etd 51 2 18 2 EARTH CONNECTIONS BEY DUE RE ea ots ates 51 2 19 33 POWER CONNEGTIO tentent detenti cen ntti o dient doa M AS pr 52 2 84 CONNECTIONS TO THE BATTERY rior mete tranne teinte ertet tete 52 2 18 5 STARTING AND STOPPING cesscssscsssessessssssessrsssssssssssssvssssesessrssnsesessssussarsrseesesansssseessaresaessssesesesearssseesssaressse 52 248 6 STOPPAGE WITH SOELENOID VALVE itti ben te eedem eti e
39. When it trips the contact maker between connection 40 41 is opened the contact can be configured NO NC If while the unit is running the set current is exceeded by 50 the TRIP LED will flash rapidly The display shows the dispersion current the programmed current and the programmed delay The differential switch is equipped with a test coil that is triggered with the DIFFERENTIAL TEST Using the command key combination test led and while these are pressed press the RESET key that will trigger the devices The TRIP LED remains lit steady and the relay on 40 41 are triggered which remain saved until the RESET command is given Technical characteristics e Sensitive to wave forms type sinusoidal choked sinusoidal pulse and pulse with continuous component up to 6mA e Operating frequency 47 63 Hz e Tripping current An programmable from 0 1 to 5 A or OFF excluded e Tripping time programmable from 0 5 to 5 seconds e Instantaneous tripping within 60 milliseconds e Negative safety NA modifying the output contact 40 41 e Adjustable to torus with 500 750 1000 1 shading coils and with test wrapping e Reset using the RESET push button enabled with current leakage less than 50 An OPERATING PRINCIPLE The M02 uses a toroidal transformer on the load power supply line fig B to constantly monitor the sum of the supply and return currents When the difference exceeds the set value this indicates that part of the current i
40. ads GENERATOR STATUS STANDBY The TEST SCR EJP functions are excluded 2 11 SPECIAL FUNCTIONS The M02 has a transistorised output 28 for controlling a dc contactor A number of functions can be programmed individually for output 28 MOTOR PRE HEATING GLOW PLUG PRE HEATING STARTER RESET GAS MOTOR CONTROLS AND DOUBLE STARTING N WARNING to protect transistor from overloading 1A diode must be fitted in parallel with the contactor s coil as shown in the layout 2 11 1 PROGRAMMING MISC SETTINGS OUTPUT 28 TIME SETTINGS MOTOR PRE HEATING a THRESHOLD SETTING 200mA GLOW PLUG PREHEATING aM GLOW PLUG 10 120 STARTER STARTER 0 10 28 EV GAS a EV GAS 0 10 RESET RESET 2 10 DOUBLE STARTING 2 11 2 MOTOR PRE HEATING out 28 Default The Motor P re heating function can be controlled in two ways 1 When the unitis running or the programming switch is set to Cutout itis deactivated otherwise itis always active 2 If the motor temperature transducer is connected 16 it can be used to programme the activation 40 C and deactivation 50 C settings when the motor temperature has reached the set value See analogue inputs Programming under misc Settings and threshold settings 2 11 3 SPARKPLUGS PRE HEATING out 28 START CMND i A transistorised output is provided that may be programmed to command a pre heating system of the sparkplugs This output is SPARKPLUG PRE HE
41. ating system check if the motor is warm each time a check is made otherwise request technical assistance WARNING a cold motor at low temperatures could have difficulty in starting or outputting once started 3 Ifthe generator is rarely triggered due to the lack of mains power supply execute an automatic test for at least 2 minutes 4 if new electrical machines are installed in the system powered by the generator request technical assistance to check the suitability of the CG CG mains generator switching to the new load SUMMARY On a periodic basis check the electrolytic level of the clear batteries Touch the motor to feel if itis warm if equipped with pre heating system and execute an automatic test FEE VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 TECHNICAL MANUAL 21 CONSTRUCTIONAL DESCRIPTION OF THE CONTROL PANEL The contol panel is entirely manufactured in compliance with the following European standards ANS low voltage electrical control panels EN 60439 1 EMC electromagnetic compatibility directive 89 336 EEC Each control panel or device is completely tested and supplied with test certificate declaration of conformity and EC marking in compliance with 626 safety standards The control panel is manufactured in a steel sheet cabinet 15 20 10 that is skilfully treated and painted with standard grey silicon epoxy powder Ral 7032 and has a standard protection rating of IP 42 EXTERNAL COMPO
42. ben ent e 53 2 187 MOTOR CONTROLLING PROBES retired p HER eene ete be a a 53 2 18 8 ELECTRICAL 5 5 tiit teinte iieri inii 53 2 19 SERVICE PROCEDURES ree nre rer rete reni RI HE EE IE HA AE HR EE EI E 2A E Maiana 54 2 19 1 SERVICING PROCEDURE deem ht edet bana d ratones ere 54 2 19 2 SERVICING PROCEDURE WITH THROUGH MAINS GENERATOR DISABLED 54 PLE VER VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 2 19 3 BATTERY REPLACEMENT PROCEDURE utensil 54 2 19 4 GC M02 BOARD REPLACEMENT PROCEDURE eene nnne teneret 55 2 19 5 MP02 POWER BOARD REPLACEMENT PROCEDURE viii 55 3 1 ELECTRICAL nennen n i i i i a i f fn 56 3 2 EFFICIENCY TEST nnn nne nr i i i i 56 3 3 MOTOR SAFETY DEVICES sssrinin 56 3 4 GENERATOR SAFETY DEVICES serene rn nn ir i ii i i f i fn 56 3 5 OVERLOAD SAFETY DEVICE 51 eren nr nn nr i i i i a n 56 3 6 BATTERY EFFICIENCY enne nere nnn i i i i a a f n a 56 3 7 SWITCHING SCALING TEST nere rrr nn ri ri i a a n 57 3 8 TROUBLE SHOOTING rennen ner rin ri i i i f a a f a fj 57 N B THE INFORMATION CONTAINED IN THIS DOCUMENT MAY BE CHANGED DUE TO TECHNICAL IMPROVEMENTS WITHOUT NOTICE FEE VER DATAULT VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 1 USER MANUAL INTRODUCTION We congratulate you for having purchased
43. controls the fuel pump so that the daily tank requirements are constantly ensured A push button enables the direct control of the pump with only a maximum Safety level safety function WAIT PROG A newly conceived and remarkably useful LED has been fitted on the GCM02 module to assist the operator namely the WAIT PROG LED This LED flashes each time the timer is triggered informing the operator what is happening even over a lengthy timer period All LEDs are provided with a general description that make the control panel easily comprehensible SUMMARY The unit is normally programmed in AUTOMATIC mode When any jobs to be performed on the generator it is to be set the LOCKED status If the generator is not to start even if the mains is disconnected it is to be set in the MANUAL MAINS status The reason for this is that if while the generator is not working there should be a failure in the electronics the power supply from the mains would be ensured in any case HOW TO PROCEED IF THE GENERATOR SHOULD FAIL TO WORK A possible alarm status will be shown on the display Whatever the anomaly the cause is to be found first and foremost then press the RESET push button The causes and the solutions differ depending on the type of anomaly involved 1 Electrical anomalies due to min max voltage and frequency Ifthe anomaly should persist after the RESET push button has been pressed then request technical assistance _ O FRLtE
44. ction 7 is defined 15 54 it emits the B with a maximum current of 16A as the GE starting is commanded to stop when the stoppage command is received 15 54 OTHER MOTOR UTILITIES 16A max ELECTRONIC RPM REGULATOR 2 18 7 MOTOR CONTROLLING PROBES These detect the operational status of the motor The integrity of the actual motor relies on their efficiency They are of two types Contact type to command alarm status such as low oil pressure high motor temperature low fuel level etc Variable resistance type depending on the parameter to command reading instruments such as thermometers gauges levels etc The parameters read by the M02 are performed with VDO probes or compatible types OILPRESSURESWITCH NCCONTACT ZERO OHM WATER THERMOSTAT NO CONTACT OHM INFINITE WATER OIL THERMOSTAT NO CONTACT OHM INFINITE 120 C OIL PRESS VARIABLE VDO 0 180 OHM pm dg O RESISTANCE threshold pre alarm pump control thresholds Fig 5 CONTACT PROBES VARIABLE RESISTANCE PROBES PRESSURE THERMOSTAT SWITCH TRANSDUCER P PRESSURE T TEMPERATURE L LEVEL NO MOTOR MASS 2 18 8 ELECTRICAL STRENGTH TEST The control panels that are subject to the electrical strength test are to be prepared baring in mind that the only connection point with the electronic logic is established by the MAINS sensor inputs 50 49 48 to which a divider is connected that is made up of 3 500 K ohm re
45. d selectivity and a differential switch on the utility line EN 60439 1 TABLE Al VALUES FOR ONE SINGLE WIRE SWITCHING IN NUMBER OF THE MIN CROSS SECTION MAX CROSS SECTION AMPERE Ith WIRES IN sqm IN sq m LE 8 10 66 25 035 9 a 70 70 For further information contact a reliable installation engineer or our engineering department 2 18 4 CONNECTIONS TO THE BATTERY To supply power to the GC M02MP power module we advise connecting directly to the battery cables that are connected to the starter motor The use of motor earths to connect up the B has often given rise to operating problems 2 18 5 STARTING AND STOPPING These may directly command devices with currents up to 30 A Use terminal no 6 to command electromagnetic switches energised during stoppage START STOP 30A max T IN ECTION PUMP STARTING MOTOR Operation with the stopping command the electromagnet is energised and stops motor To establish the stoppage of the motor the closure of the oil pressure switch is controlled which after 20 seconds from when it closed automatically disables the electromagnet thus avoiding settings and adjustments Fig 3 LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 52 of 57 2 18 6 STOPPAGE WITH SOLENOID VALVE Stoppage with SOLENOID VALVE normally energised while the generator is running and while the utilities of the unit are powered Conne
46. doc 04 03 2003 ENG Page 34 of 57 2 11 9 ALARM HISTORY RECORDS This records all the parameters measurements and alarms at the time of an alarm being raised and allows the last 15 to be displayed consecutively This is only active when the programming commutator is set to block This can be displayed by pressing the buttons and ENTER together for 8 seconds The operation page will display HISTORY 1 and histories 1 to 15 can be selected using the buttons and by confirming the selection using enter LED TEST TO PRESS FOR 8 EVENTI latest history EVENT2 penultimate Etc The conditions atthe time the alarm was raised are displayed It is possible flow the pages of the recorded measurements at the time of the event as in the normal functioning The Output page is changed with the alarm page which caused the event recording This page can be alternated every 4 seconds from the possible state page present during the recording Every 8 seconds a writing HISTORIAN EVENT N x remembers what event we are viewing To display another event to press ENTER for to exit select it with the buttons and to press again ENTER To exit from the pages of HISTORIAN turn back the switch in AUTOMATIC or MANUAL or to press together the buttons ENTER and A page CLOSING HISTORIAN informs of the happened exit 2 11 10 PROTECTION BY INVERSE POWER 32 In the use of the M02 with groups predisposed to the working
47. e been split up into four blocks 1 Parameters LED lt 2 time settings PN 3 thresholds 4 various settings 5 remote control Once the block concerned has been selected press ENTER to display all the fields that may be modified Use the push buttons to find the field to be modified and once found press ENTER again and using the keys modify the value and confirm with ENTER Access is E to the iS gai iS gai Access is gained to the The type of remote time settings to be j various alarms and the control can be modified ified j j i ications programmed on a PC Start delay in max volt hz MODEM orGSM as Stop delay well as the necessary Etc parameters LASTISSUE LANG 04 03 2003 ENG Page 36 of 57 2 12 2 PARAMETERS The electrical parameters V Hz A KVA etc are set in the factory combining the two modules The Pressure Temperature and Fuel Level indications depend on the tolerances allowed by the various probes The temperature reading is particularly closely checked and calibrated When the MP02 module is changed the electrical measurements may also need to be adjusted Changeable measurements VALUE i Regulation zero current mE confirm the operation 10 15 20 25 40 50 Regulation of the CT 5 60 80 100 150 200 250 300 400 500 600 800 1000 1200 1500 2000 3000 5A VDO MTU VEGLIA Pp P P P p ee VDO MTU VEGLIA Oooo Regulation power factor cos f
48. e stop is only manual with out any command to the 18 which is available for others running modes In setting times to adjust the time of stop to 0 or 1 Note for the adjustment to the rules of safety fireproof the double system of start can be required to see 2 11 7 2 10 6 FUNCTION FOR TWO UNITS WORKING ALTERNATELY Connections 18 and 20 are provided for the RES standby function Itis used in plants that have a standby unit Two applications are provided for 1 Two units one in standby and to provide an emergency supply in case of a power failure 2 Two units one is standby to act as a power source without a mains power supply 2 10 7 MAINS POWER SUPPLY EMERGENCY BACKUP When a power failure occurs the pilot generator starts up Should it fail to start or should any fault occur during its operation the standby generator starts up to provide sufficient power for the user Programming in SPECIAL SETTINGS to select 2 GEN CHANGE with the connection to the mains the M02 is programmed selfit for the function of two gen set of reserve in emergency to the mains 2 10 8 POWER SUPPLY PLANT WITH TWO GENERATORS ONE ON STANDBY The pilot generator starts up when the START command is given via connection 18 The operating time is set on the Times Menu At the end of this time the standby generator is started and once it is at ful production the signal to the pilot generator is switched off and the power is supplied by the standby generat
49. ed for connecting to the internet local intranet or Ethernet networks as well as other connections upon request THREE MODULES WI SIGNALS 2 17 2 REMOTE CONTROL Upon request an IS 03 serial board can be provided This is to be fitted to the module and has two serial RS232C and RS485 ports The 5485 port communicates using a standard MODBUS protocol that can communicate via networks and with PLCs The RS232C serial port is used to interface with PCs GSMs and Modems for remote control It allows the switching status to be monitored as well as all the parameters voltage frequency current etc and all the alarms It is also possible to control the following functions Automatic Automatic Test Stop Start Forced start with generator supply and Reset Each message is recorded in a history document and up to 60 000 units can be handled each unit having an individual board Each unit can address the alarm status to a PC Server and another two numbers for local service centres The server is able to transmit SMS or fax messages to local service technicians The control software is only supplied with boards fitted with serial ports RS 485 100 1000 a RS 232C lt gt CONVERTER RS 485 RS 232C RS 232C MODEM OR GSM VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Through the serial communication all the parameters and commands of the group are under control General monitor
50. en A Ma LC Ee Ear i led 23 HJ 23 COntTOL steterat tenete eher nudos Ei NAM Rb Ls LUAM ML CM 23 Network s tem peo eto rmt s 23 Connections x sa m Eo etu ON m ette tonc ORT ta Ce D TE e i 27 2 8 INPUT OUTPUT aaa aa 29 2 9 FUNCTIONS OF BUILT IN WEEKLY CLOCK 30 2 91 WEEKLY C EO CK 5e tete o pede ptit Pe Lake ttn Hh endete e echar dn 30 2 9 2 CLOCK FOR AUTOMATIC TESTING scat i ertt t om m ema es 30 2 93 AUTOMATIC STOPPING OR STARTING itte mete eterne eter 30 2 10 REMOTE COMMAND AND CONTROLS rernm nen rennen reste rei eiii Hi Roo e E 31 ATOL EJ P FUNCTION ether tee titer tete hant rn ete 31 2 10 2 SCR FUNCTION OR FORCED STARTING WITH OUTPUT default eennnn 31 2 103 LOCK FUNCTION eee mien e re e a e 31 2 104 TEST FUNCTION Ie eed emn dd e t dom dete d 31 2 10 6 FUNCTION FOR TWO UNITS WORKING ALTERNATELY eene 32 2 10 7 MAINS POWER SUPPLY EMERGENCY BACKUP sese nnne nnne nnn 32 2 10 8 POWER SUPPLY PLANT WITH TWO GENERATORS ONE ON STANDBY sessies 32 2 11 SPECIAL FUNCTIONS nennen ree nre terere rates rerit e E HIE H EAE HR E RI HE E E A a 33 2 ETSPROGRAMMING tite aod A Nite bit Rata tk nain bie hat ss 33 2 11 2 MOTOR PRE HEATING out 28 Default nnne 33 2 113 SPARKPLUGS P RE HEATING 0UE 28
51. ention Generator overload delay PRC glow plug pre heating time EJ P delay Alternating generator changeover delay Three phase or single phase Maximum mains power supply voltage Minimum mains power supply voltage Maximum mains power supply frequenc Minimum mains power supply frequency Maximum generator voltage Minimum generator voltage Maximum generator frequency Minimum generator frequency Maximum generator current lg Generator short circuit Motor start Hz Maximum battery charge voltage Maximum battery charge current Pump level ON Pump level OFF Fuel reserve level Minimum oil pressure Maximum motor temperature Differential activation current Maximum mains power supply current Working hours before service request Energy return Pre heating out CONNECTION 28 Automatic test the clock must be set Time of automatic test Duration of automatic test Automatic cut out Phase sequence Special functions 100 130 C Three phase 17 3072A 17 Hz 135 27 V 2 7 gt 30 lt 80 gt 10 130 1000 0 excluded 0 KW excluded Pre h motor 37 Cut out Oil temp Not changed On generator Name and telephone number Current transformers gt zm 5 Ka gt eo 47 VER LAST ISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 2 14 CONNECTIONS AND RELATIVE DESCRIPTIONS The GCM02MP unit is connected by means of FASTON 6 3 mm type terminal b
52. ept efficient by the automatic battery charger which controls its charge avoiding oxidation and sulphating It controls possible rising in voltage caused by the disconnection of internal components and also voltage sagging causes by anomalies in the battery charger The storage capacity or rather the capacity of facing up to the number of starting times sufficient to ensure the running efficiency of the generator is to be checked once a year in the following manner Check with the battery fully charged with a voltage greater than 13 5V for generators with 12V batteries and a voltage greater than 27V for generators with 24V batteries With the generator in locked mode disconnect the electromagnet the safety solenoid valve or the actuator or anything else necessary to prevent the generator from starting The power supply to the injection pump must be prevented so that upon starting the motor turns without starting Setthe programming switch on TEST count 4 starting attempts at a rotation speed that is more or less the same from the first to the fourth command The same procedure can be performed by setting the programming switch on ENABLE START mode and manually commanding the starting attempts for 5 seconds with pauses of 10 seconds for atleast 5 times one after the other VER LAST I SSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 Page 56 of 57 If starting fails after these 5 attempts minimum 4 the batteries are to be replaced 3 7 SWITCHIN
53. er 8 Signalings gen set running and differential protection and battery alarm motor 4 Mains and switching mains gen set situation FEE VER DATAULT VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 1 4 FUNCTIONAL DESCRIPTION OF THE CONTROL PANEL COMPONENT Description of the components Programming switch Type of operational mode selection 1 Automatic test T 2 Standard automatic run mode 3 Locked status electronics disabled used for maintenance 4 Utility power supply forced from mains CR 5 Enable start push button to start in manual mode 6 Utility power supply forced from generator CG Display reading selection push buttons These are used to select the reading page required and to program the weekly timer DIFFERENTIAL TEST with the switch in BLOCK to operate for 2 the buttons TEST LED and while the led are turned on to press RESET to have the differential protection Reset Enter push button used to reset the functions and to eliminate an alarm status RESET and also to confirm parameters entered in the programming phase ENTER To push one time to exclude the acoustic alarm SILENT and to fix the signalling of alarm two times to reset DESCRIPTION OF THE VARIOUS READING PAGES When the mains are connected these readings are automatically displayed that indicate the mains voltage and frequency The current on the phase 1 is displayed if the CT are connected and rese
54. er alarm will be triggered the motor will stop and the relative will be displayed The functions of each alarm are indicated in the AUTOMATIC RUN MODE section 34 GENERATOR SAFETY DEVICES Manually operate the lever of the accelerator or actuator to modify the revs or Consequently the variation of the Hz frequency will be displayed Continue until the safety threshold is triggered with consequent alarm status and locking Minimum and maximum voltage Manually turn the VOLT trimmer on the electronic voltage regulator inside the generator First turn or then vice versa altering the voltage output until the safety devices are tripped Upon completion set the voltage back to the normal value 3 5 OVERLOAD SAFETY DEVICE 51 Supposing that a load sufficient to exceed the maximum current that may be output is not available it is advisable to modify the calibration of the overload to a value lower than the load current available see setting section With the generator in automatic mode disconnect the MAINS and when the CG generator contact maker has closed enable the load When the set current is exceeded following the delay timing the CG contact maker is opened and the relative LED flashes the alarm is triggered and the generator stops following the motor delay timing Resetthe current calibration maximum current of generator in ALARM THRESHOLDS section after the test has been completed 3 6 BATTERY EFFICIENCY The battery is k
55. ervention of the differential protection if flashing protection it means that there is a superior dispersion to 50 than the foreseen value The led on the generator indicates that the group is running The led on the motor indicates state of alarm of the gen set Battery charter and battery The led indicates feeded battery charger and feeding of M02 module from the battery end of the flashing the result of the elaboration it will be had Es when the led is turned on on the pylon of the mains it means that the mains has reentered in the normal values the switching gen setmains CG CR is had only after a certain delay during which the led WAIT PROG flashes mm The led WAIT PROG indicates an elaboration in progress from the microcontroller to the The GCM02 is provided with automatic command of the pomp of restocking gas oil when the led is turned and the button serves to the manual command The button of starting motor START is trained only when the switch is in pos MANUAL START The command is directed and to motor in running itis necessary to leave the button The led indicates that the command of starting is in progress The button of arrest Stop always trained ithas to be pressed up to the suit arrest of the motor The led indicates thatthe command of arrest is in progress VER LASTISSU LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 10 of 57 15 COMMANDS AND OPERATIONAL MODES The operational
56. f the level probe or the circuit breakage automatically excludes the operation of the pump and display indication When the level probe is being installed the real upward and downward excursion ofthe level rod must be taken into account 1 O HLE VER LASTISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG Page 22 of 57 2 7 MEASURING THE GENERATOR S AND MAINS PARAMETERS The voltmeter measurements indicate the actual real value RMS and are at a precision of 1 The unit has a deviation of V to measure temperatures between 20 and 70 SINGLE THREE PHASE MAINS SENSOR The three phase mains sensor is made with three 500 K OHM resistance dividers with high insulation voltage capable of withstanding any excessive voltages of up to 8Kv for 1 second Itis sensitive to the minimum and maximum voltage on the single phase and to the phase displacement angle of the three phases All parameters can be modified the sensibility to the sequence of the phases can be activated Main characteristics Three phase 27 59 60 81 47 100 600 V ac OFF 60 400V 27 110 600V OFF 59 30V on MIN 15V on MAX gt 8 KV for 1s 50 60 Hz Minimum and maximum programmable frequency Min 35 55 Hz Max 51 75 Hz 81 OFF L1 L2 L3 can be activated When the software is used to configure the sensor in biphase the control is activated only on connections L1 L2 OFF 60 400V 27 When the softwa
57. he power supply from the mains even if the command and control electronics are faulty itis used when the generator is left inoperative 15 5 Manual starting this enables the generator to be started manually using the start push button The control is direct without the involvement of electronic components It ensures the operation of the generator even when the electronics are faulty itis used for the manual emergency controls or for maintenance purposes A WARNING When the programming switch is in this position all the utility circuits of the generator are powered such as the solenoid valves electronic rpm regulators etc If the switch is forgotten in this position with the generator stopped the starting battery would run flat very quickly 15 6 Manual generator this enables the forced power supply from the generator itis available for manual procedures or in the case of problems with the automatic functions STOP This is enabled whatever the situation It is to be held down until the motor stops completely EMERGENCY STOP If pressed the red mushroom push button in the middle of the door stops the generator immediately instantaneously opening the contact maker of the generator CG thus locking it To release the emergency status set the programming switch in Lock position and then turn the emergency push button and pull up FUEL PUMP CONTROL if foreseen The M02 module electronically controls the fuel level It automatically
58. hing the lever down to the OFF position and then returning it to the ON position Where switches have been installed inside the electrical board follow the ELECTRICAL MAINTENANCE procedure before opening the board 1 9 2 MECHANICAL MAINTENANCE If the generator should fail to start due to an anomaly in the fuel circuit and also in an emergency status the following tips may prove useful How to restore the fuel circuit 1 the programming switch on Manual Start mode without starting the generator In this way the 15 54 that powers the fuel interception solenoid valve is activated 2 Once you have filled up with fuel operate the hand pump situated on the motor until the circuit is restored which can be seen by the pump becoming harder to move 3 Startin manual mode It is advisable to restrict the starting attempts to 10 seconds each with a pause of 15 seconds in between to allow the battery to recover efficiently Once the unit has started and is running regularly reset the automatic functions 1 9 3 PERIODIC CHECKS To keep the unit efficient some periodic checks must be made together with those scheduled by the manufacturer of the motor and by the installation engineer l check the electrolytic level of the battery every 15 days following installation and request the assistance of an engineer if an excessive consumption is noticed Following the initial period check every 30 60 days 2 In generators complete with motor pre he
59. i serea _ ___ The generator is started Determines start up of the unit Minimum mains power supply frequency 20 Hzn emn Jo mem o m Alarm triggered stoppage Alarm triggered stoppage following cooling delay Actus uale we Alarm triggered stoppage after 3 secs Alarm triggered stoppage following cooling delay Max generator current Value of max current 1 2040A This establishes the max current admitted on generator beyond on generator which an alarm is triggered and generator is stopped following Gener nameplate appropriate delay Generator short circuit Igx3 1 8160A Motor started Hz value 17 HZ B Interrupts automatic starting when this frequency is exceeded sd Max battery charger current 13 5 27 V 5 4 14 4 V VER LASTISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG Page380f57 The buzzer alarm is triggered Po 10 8 28 8 V Maximum current battery charge 2 0 8 0A Limits the maximum current allowed on the battery charging transformer Pump level ON gt 30 5 80 omememtenm Et emm m mm This stops the fuel pump 17 Fuelreserve level gt 10 4 30 Fuel lack 5 1 30 This triggers the pre alarm min oil pressure read by the transducer Max motor temperature Temperature of 100 160 This triggers the pre alarm temperature read by thermostat thermostat 3 over 160 C OFF oem
60. in parallel itis activable the Inverse Power protection function relay 32 this begins working if the generator absorbs current rather than to supply it The survey of the inverse power is effected with a mathematical calculation on the cosfi in fact only when the cosfi is L or C we have power inverse in the generator COSFiPOSITIVE L4 ACTIVE POWER NEGATIVE L J C INVERSE POWER Setting to go in the menu thresholds and to set inverse power to the 10 of the nominal power the intervention is delayed of 5 with the intervention the load is not connected and the GE is stopped after the phase of cooling motor 2 11 11 SETTABLE INPUTS The inputs 12 HIGH OIL TEMPERATURE and the input 23 OVERLOAD can be renamed the change can be effected only by connection to PC The alarm intervention is that foreseen for the respective input VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 35 of 57 2 12 PROGRAMMING The MO2 module has Jumpers and Switches that provide various functions 2 in the ON position overrides the units contactor command to the programming commutator in the MANUAL GENSET position When it is in the OFF position the generator contactor unit is in automatic mode e 1 inthe ON position permanently enables the STOP button When it is in the OFF position it is only active in MANUAL START e A trimmer is provided to vary the brightness of the display 2 2CL
61. ing Stopping delay This establishes the timing required between GE MAINS switching and stopping to enable the motor to cool down 7 Differential tripping When the differential current exceeds the value established for a longer amount of time than this the generator switch or contact maker is opened Generator overload delay If the set current is exceeded the time set at the end of which the overload alarm is triggered is overridden only by a possible shortcircuit current pe Sparkplug pre heating time PRC This is the time setting of the sparkplug pre heating prior to starting EJ P Delay This is the starting delay following the 30 mins command Delay failure CG If it doesnt close at the end of time it is required signalled failure CG Delay failure CR If it doesn t close at the end of time it is required signalled failure CR Delay change 2 GE in stand by At the end of the programmed time it is required the intervention of the other group _ Pressing reset we have the reset of the hour meter resna resete have the resetofthe stants counter 18 Pressing reset we have the estate klonatu 2 12 4 THRESHOLDS Ne DESCRIPTION Three phase or single phase Three phase Three phase This establishes the type of control over the mains power supply Single phase input and generator input Max mains voltage 10 Vn 210 600V 440 V _______ remm Tregern
62. is excluded CUSTOMISATION This page can only be seen if programmed It has two lines the first can be used to enter a name of up to 16 characters and the second for a telephone number of up to 16 digits VER LASTISSU GCM02 MT ING4 NEW doc 04 03 2003 Page 28 of 57 2 8 INPUT OUTPUT During the starting up phase a number of outputs may be in an abnormal condition To identify these the status of all the inputs and outputs are indicated on the display When a number of alarms are raised at the same time these are shown on the display Even after pushing RESET repeatedly is difficult to define all the alarms raised The correspondence table is used to identify all alarms raised and reset INPUT Correspondence table when the input or output is on 1 this means that itis active ON 1 LOWOLPRESURE SARS 3 HIGH MOTOR TEMPERATURE 0 4 5 FULREENE A 6 ALAR SSS 7 OVERLOAD TR SWIICHTRPPED STAR 8 EP AUIMTEST SCR CONDTONALSTARR 9 EMERGENY AMNM o moco C MANSCONTACTWAKERON POWER SUPPLY CONTACTOR STATUS D GENERATORCONTACTMAKERON GENERATOR CONTACTOR STATUS OUTPUT 7 Ol 2 3 E NEM 6 EUM
63. l panel equipped with a programming switch to select the following functions 1 2 AUTOMATIC MODE AUTOMATIC 3 LOCK MODE 4 POWER SUPPLY FROM MAINS RUNNING 9 MANUAL START 6 POWER SUPPLY FROM GENERATOR 1TEST it performs all the automatic functions with the exception of the switching function 1B it tests the efficiency of the whole system without disconnecting the mains power supply to the utility LC all safety devices are enabled while the test is running 1 if the mains should be disconnected while the test is running generator starts immediately LE the test ends automatically when the mains power supply is restored or following a programmed external command 2 AUTOMATIC MODE 2 4 A special three phase voltage relay is capable of working at a voltage of 8Kv to safeguard the mains against sagging of over 20 of the rated voltage this can be modified excessive rise in the rated voltage of over 15 this can be modified missing phase incorrect angle between the phases phase displacement 2 B If one of the above mentioned anomalies should occur the CR mains contact maker is immediately opened to safeguard its integrity also in the case of excessive voltage sagging 2 When the mains is disconnected starting delay timer is triggered programmable time It makes the system insensitive to brief mains disconnections A buzzer will sound in this case LAST I SSU
64. l the LEDs barring the start stop and battery charger LED will light up ALARM SILENCING With the state of alarm the red led of alarm on the motor flashes and the sonorous is active alarm Pressing once the SILENT button the acoustic alarm is interrupted the red led on the motor remains turned on to fixed light FUNCTIONS RESET Pressing the RESET button two times the conditions of alarm are annulled all the functions are restored and the red led on the motor is turned off PROTECTION DIFFERENTIAL TEST if active To activate the TEST LED and with the turned on led to press RESET the TRIP has to intervene with the detached load 1 8 SPECIAL FUNCTIONS The GCM02 is set up for special operating functions such as automatic testing or cutout routine maintenance remote control etc When these are active a page comes up on the display when they are activated indicating which function is active There are functions that affect how the unit operates and that require direct intervention to allow the unit to be used GE CUT OUT The cutout function is mainly used when the unit is run in a builEup area and emergency standby is not required outside of working hours During the cutout hours if the mains power supply fails the unit does not react and should it be necessary to start up the unit during this time this can only be done manually SERVICE REQUEST This does not change the operating status but raises an acoustic alarm to mark the
65. mains power supply is restored once the test time set has expired SETTING under Misc Settings AUTOMATIC TEST EXCLUDED ACTIVE Where active the following are set test every 1 or 2 weeks at time 00 00 duration 00 minutes 2 9 3 AUTOMATIC STOPPING OR STARTING It is possible to activate the unit s automatic cutout so that it does not intervene automatically as a result of a power failure as well While in Cutout mode the operation page on the display reads GENERATOR CUT OUT In this mode the unit can only be controlled manually PROGRAMMING in Various Settings To select BLOCK enter To select the day Monday enter To selectthe kind of function 0 excluded Total block Partial block Forced start Partial block forced start Activate or deactivate this function and enter the cutout time CUT OUT ON OFF 00 00 If ON is active select the days of the week MTWTFSS and the time the cutoutis to end OFF 00 00 When the unit is working without the mains power supply the cutout function determines the times at which the generator is stopped Outside of these hours the unit is placed in automatic mode Example it needs to program that a gen set works every working days from 7 to 21 and the remaining hours it has to be stopped PAR BLOCK PAR BLOCK ee O AVAILABLE GENERATOR SU TOT BLOCK ON TUE THU RI l N M U W F SA BLOCK OFF 7 00 21 00 VER
66. n an identifier number of the group Num Tel 1 Num Tel 2 Num Tel 3 SMS Num Tel 4 SMS Telephone number It allows to effect the choice among different telephone numbers previously introduced Modem selection i It allows to effect the choice among four different kind of Falcom A2D GSM modem Falcom TWIST GSM U S Robotics 56K PIN number Use mode as advertising page VER LASTISSUE LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG 40 0 57 2 13 SELF PROGRAMMING The GCM02 module is capable of programming itself This function is very useful where wrong configuration of a board could give rise to conflicts in operational terms The selfprogramming function allows all the setting fields to be reset to comply with a table of sandard preset values These must then be adapted to suit the plant s working parameters but they do provide a specific starting point for configuring the board In order to allow selfprogramming shut down the programming commutator by pressing the and Enter keys together for 8 seconds After this time the display will read SELF PROGRAMMING and the board will configure itself using the parameters shown in the table below DESCRIPTION DEFAULT VALUE VARIATION TA ratio 5A uel level 100 full otor temperature Number of starts tarting and pause times Mains power supply activation delay Generator activation delay Starting delay top delay ifferential interv
67. n it operates with modem trained also to the use of the function GSM in the case in which the PIN of the SIM inserted resulted wrong the signaling it would appear on the display Alarm SIM PIN In this case to come into the range of the serial regulations and to check the correct insertion of the code and eventually to modify it In the case the code for PUK is asked due to the wrong digitation for three consecutive times of the code PIN to remove from the modem the card SIM and to handle the insertion of the code PUK through a normal cellular GSM When a modem is used also for to the functions GSM if you are in the functionings screening that usually active where the hour and tha day are visualized you can also verify the field signal radio present When the field results to be of smaller value than 91 dBs the communication could result not perfect POSSIBLE ERROR MESSAGES 1 anybody answered from the modem to verify the correct installation of the modem and his opportune lighting 2 alarm lack SIM to check to have inserted inside the modem GSM the telephone SIM 3 alarm damaged SIM it can appear in the case the code PUK has been wrong for 10 times to replace it 4 alarm SIM PUK it can appear in the case the code has been wrong for three times to extract it from the modem FEE VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 and to insert the code PUK through the use of a normal telephone GSM 5 alarm e
68. nal is received If due to an anomaly the generator is not powered at least 7V the starting phase is stopped once and for all by the second safety control established when the oil is pressurised which triggers a delay of 3 seconds that stops the starting phase 2N Start ON Reached the programmed frequency 51 Krank 9Hz for 3000 rpms i 52 Hz 18Hz for 1500 rpms Off The start command is cut off 0 10 20 Hz N B For the safety engine if the oil pressure switch is not connected gen set can not to start 2 5 4 MOTOR PRE HEATING A feeding is foreseen for the engine preheating system the M02 has a transistorised command which controls a contactor in direct Current to deactivate automatically the preheating when the gen set is running or above the max programmed temperature OFF and to activate it automatically when the engine temperature is inferior than least value ON this function is enabled only when the temperature transducers is connected to terminal 16 28 VER LASTISSU LANG GCM02 MT ING4 NEW doc 04 03 2003 ENG Page 18 of 57 2 5 5 AUTOMATIC BATTERY CHARGER The automatic battery charger is the double semi wave type with phase choker totally controlled by the micro controller It keeps the starting battery charged with a max load of 8A and the charge is selfadjusted to compensate for consumption and for when the battery automatically runs flat The voltage of the battery and the chargi
69. nd CG itis done the control of the real closing contrarily there is the alarm it is activated inserting the ADJ USTABLE DELAY 2 0 If there is a stop nottrained DELAY STOP TO ZERO the Ge supplies with any alarm the gen set can be stopped only manually 2 P The change of the switching from CG to CR or from CR to CG it is alternated by a break of 1 to avoid a malfunction of the mechanical interlock 3 LOCKED STATUS It immediately stops the generator if this is running 3 B It disconnects the power supply from all starting circuits 3C it ensures safety throughout maintenance It deactivates the fuel pump and the preheating in order to there is not any components in voltage during the maintenance 2 4 MANUALLY CONTROLLED FUNCTIONS The manual operational mode is considered as an emergency back up mode for the automatic functions It also ensures the operating efficiency with the micro controller in an abnormal condition The programming switch ensures the direct commands that are not backed up by electronic logics This means that when the START push button is pressed for example the starting motor will be operated for as long as the push button is held down The following functions are possible 1 Forced power supply from the mains CR 2 Manual starting the generator CG contact maker is opened 3 The mains CR contact maker is opened and the power supply is forced from the generator 4 Manual stoppage 2 4 4 POWER SUP
70. ng current can be displayed on the GCM02 unit The electronics are built in the MP 02 unit whereas the battery charger transformer is fitted externally It is equipped with e Automatic cutout of the charge during the starting phase e Electronic restriction of the current to prevent excessive loads e Electronic restriction of the voltage to limit the maximum load levels 2 3 V E 13 5 27V e Protection against shortcircuits e Protection against inverted polarity Protection against excessive input voltage Auto programming of the voltmeter thresholds on the battery voltage Protection with low battery voltage for excessive discharge e Programmable values also for batteries Nichel Cadmio Technical features 50 and 60 Hz From 1to 8A 29V 21 6 V Min 20 Vac 150VA 8 A 32 Vac 250VA 8 A Do PROGRAMMING To setthe value of max currentof charge on the power ofthe installed transformer CHARGE DIAGRAM FOR PLUMB BATTERIES Max charge voltage limit Discharged battery Alarm min voltage for discharged battery Charge max of programmed current Current auto regulated to compensate the electric consumptions and the auto drain of the battery Ve for component 12 Battery 26 components 24V Battery 12 components FUNCTIONAL BLOCK DIAGRAM I Feed 100 440 50 60Hz MPO ip pP CONTROL Shunt Fuse i Battery 17 29V 11201241 VER LAST
71. oard 2 14 4 VIEW OF THE GCMO2MP CONNECTION UNIT TAA eau toy BASIC INDICATIVE WIRING DIAGRAM Vac Vac EMERGENCY CT3 PAE s E zoom ze lt c ts E E E EBORE B s si EATEN Ed ES Es xc COMAND 16 odie ety 12 Vc ax om m tor xc oP M er CCD MES EE PD 3 A d S c MOTOR GROUND CONNECTION DIAGRAM FILE VER J LASTISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 ENG 42 of 57 2 14 2 CONNECTIONS ON THE MP02 POWER UNIT This entails 6 3 mm 54 terminals and a 25 poles connector for connections between the GC M02 module and the MP 02 The faston connections used for isolated terminals can take conductors of up to 6 mm The wiring of the terminal board that is also illustrated on the safety guard respects the numbering indicated in the table below DESCRIPTION USAGE LIMITS INPUT OUTPUT no 30 1 0 32V 16A board power supply 2 10 32 16 board powersupply o 30 3 4 Bridge for 12V power supply CTC 5 48 30Amaxstartingcommandoutput o 304 0 6 148 30A maxstpcommandouput Oo 30A O0 11554 8 0 8 1100 alarm output 1 S oac 0 JV 9 L
72. of possible splashing of water or for control panels exposed to rain A WARNING It is advisable not to install the control panel further away than 20 meters from the generator CONTROL PANEL GENERATOR i MAX 20m This requirement is due to the excessive currents caused by lightening that hits the public mains causing the voltage inside the control panel to rise excessively if the connection line exceeds 20 meters If there is no other choice than installing the control panel further away than 20 meters our engineerin department can provide you with various technical solutions 2 18 2 EARTH CONNECTIONS PE A WARNING To ensure the reliability of the system all of its components must be connected to earth _ OSOS CONTROL PANEL DAILY FUEL TANK FUEL TANK GENERATOR EARTH OTHER COMPONENTS VRO LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 18 3 POWER CONNECTIONS To facilitate installation wiring diagrams and indicative tables for scaling the line and utility wires are supplied Bare in mind that all devices and lines must be protected against shortcircuits and overloads by law and that for reasons of safety all prevention measures against accidental direct contacts must be taken see IEC 64 8 4 standard therefore an automatic switch of adequate capacity is to be installed at the beginning of the mains inlet cable an
73. of the reserve gen sets HL VER LASTISSU LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 9 of 57 Differential protection the intervention is suitable from the signaling TRIP and it intervenes when the current of dispersion to earth it overcomes the programmed values Signed among parenthesis This page is displayed only if the differential is active DIFFERENTIAL TEST with the switch in BLOCK to operate for 2 the buttons TEST LED and while the leds are turned on to press RESET it will have the differential protection Itindicates how much hours miss to the request of maintenance 1 Among parenthesis the interval of maintenance This page is only visualized if the application of maintenance is activated Itindicates how much hours miss to the request of maintenance 2 Among parenthesis the interval of maintenance This page is only visualized if the application of maintenance 15 activated Advertising page brings name and telephone number of the producer or the technician This page is only visualized if it is compiled in the settings The block indicates that the plant feeds the use e The pylon represents the public mains and the turned on led indicates that the three phases are in the established parameters while when it ge S turned off it indicates the contrary one The leds CG and CR rep indicate what contactor is closed to feed the use The led TRIP Fw indicates the int
74. oltage under 15V differential threshold d it has the same condition of voltage within the limits 440 15 425V and associated cycles V over limit starl MOV c cuc XLI ue Max limit 10 Vn OAL di PNEU eere E Return limit differential or hysteresis 15V 400V Voltage range Vn nominal voltage Within limits 350V L X BA O A Return limit differential or hysteresis 30V ax ete M a cease ede 20 Vn min limit V over limit start OV T Network connections MP M02 MP M02 MP M02 R L1 A Rel A Rel A B A 48 Bott 48 Sele 48 c 59 59 N Taa 59 N L 4 50 50 EOIN TERMS CONN BIPHASE CONN SINGLE PHASE CONN WITH NEUTRAL THREE PHASE SINGLE PHASE GENERATOR SENSOR The generator sensor is sensitive to the maximum and minimum voltage in single phase and to the sequence in three phases It can work within a range of 60 to 600 V with the same characteristics as the network sensor Generator connections GEN MP M02 MP M02 GEN MP M02 Xx L1 52 52 X L1 52 53 53 53 54 54 54 51 51 51 THREE PHASE WITH INSULATED NEUTRAL FROM EARTH THREE PHASE CONN WITH THREE PHASE WITH NEUTRAL NEUTRAL AND IT INSULATED TO EARTH TNC OR TNS GEN MP M02 GEN MP M02 GEN MP M02 XL 52 X L1 52 X L1 52 53 53 c 53 o 54 c 54 54 51 51 BIPHASE CONNECTION WITH BIPHASE WITH INSULATED SINGLE PHASE CONNECTION NEUTRAL TO EARTH TNC OR TNS NEUTR
75. onfgured as OFF the three inputs operate at between 0 and 10V and are connected directly to the MTU motors and others of the same concept for taking motor measurements The reading scale can be changed from the Measurements Menu oC C FUEL LEVEL WATER TEMP OIL PRESS ANALOGIC SETTABLE INPUTS VEGLIA OR VDO ANALOGIC SET INPUTS 0 10V HE VER LASTISSU LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 20 of 57 COMPARISON AMONG THE DIFFERENT TRANSDUCERS VDO TEMPERATURE TRANSDUCER TRANSDUCERS VALUE VEGLIA VDO OHM OHM OIL PRESSURE 0 10BAR 300 0 0 200 WATER TEMP 20 120 2200 200 660 20 OIL TEMP 20 150 2200 100 660 10 FUEL LEVEL 0 100 200 0 0 200 20 30 40 50 60 70 80 90100 110 VDO pressure transmitter more Thermistor varying resistance thermostat 0 8 bar alarm contact contact NO VDO fr instrument and pilot lamp 9 17 11 16 2 Batt OP OM WT ET 2 6 3 OIL PRESSURE This measurement is provided by 8 bar transducers Different values can be set from the OIL PRESSURE ENGINE Measurements Menu An acoustic alarm can be activated to indicate minimum oil BAR pressure and this is set at 0 5 bar above the pressure at which the oil pressure switch intervenes PROGRAMMING From the Menu various settings to select for 17 analogic input the kind of transducer Veglia VDO or MTU If the transducer is 10 bar to correct the reading value from the Menu measures PREALARM MIN PRE
76. or with power to the user being interrupted for 1 second When the set time for the standby generator expires the pilot generator is activated using the same procedure When the unit is running any fault automatically causes the other generator to be activated Programming in SPECIAL SETTINGS to select 2 GEN CHANGE To determine which is the PILOT unit select on the display the page 2 GEN CHANGE The display will read Pilot Standby When the Reset button is pressed the Pilot Standby selection is reversed Bear in mind that if for example GE1 is the pilot unit GE2 must be the Standby unit and vice versa The built in clock can be used to programme automatic interventions by the two generator power plant When the cut out function is programmed using the built in clock the individual generator is excluded for the hours programmed Obviously the times set for the two generators must be compatible Since a break in the power supply to the generator M02 module results in the clock losing its setting itis advisable to use two 40A diodes D1 and D2 to provide power If the built in clock is not used these diodes are not necessary This circuit with diodes on the battery can only be used for plants without battery charges powered by the mains power supply Connection layout ON STOP OFF START LASTISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 ENG Page 32 of 57 When the RES command is active the status re
77. otor has started 10 Wait 20 30 seconds and switch to POWER SUPPLY FROM GENERATOR 11 Check the rotation direction of the motors in use invert two phases if incorrect 12 Setthe programming switch back to Enable Starting the CG contact maker will open and the load will be disconnected 13 Command manual stoppage 14 Setthe programming switch on POWER SUPPLY FROM MAINS 15 After atleast 15 20 seconds power the control panel with the mains and check the rotation direction of the motors in use again invert two phases if incorrect 16 Setthe programming switch in AUTOMATIC mode check if by disconnecting the mains all the starting functions are enabled power output and generator protection When the mains is restored there will be a delay before the lines are switched then a further delay to allow the motor to cool down ATTENTION If in start phase the oil pressure switch 9 is not connected and the gen set doesn t start 2 19 2 SERVICING PROCEDURE WITH THROUGH MAINS GENERATOR DISABLED In cases in which the electrical system is started but not the generator therefore its circuits and battery are practically not powered the powering of the electronics by the mains is to be avoided as this does not offer the control and safety devices provided by the battery Therefore the BATTERY and BATTERY CHARGER fuses are to be disconnected When the generator is enabled again follow the Servicing procedure 2 19 3
78. oweroil pressure alarm input Negative positive 1 SOSAN batery charger generatorn f 1 EMEN ION 1 POiltmpertuealamingt Negative Ld REESE Em Water level alarm input S Negative 35 Fuel evel wensducer int 1 16 Wotor temperature vansdueerinpat 17 transducer input 10 3000 101001 I 18 RES TEST function input programmable 1 Negative 11 Emergencyinput l O an Loci Reg Wires 1 UTILITIES CONNECTIONS E UIT car c C 23 jOveoadalermcontact o Generator contact maker ON indication input Negative 1 2627 12 or 24V fuel pump contact maker command 200 O O 2930 Toroidfor differential protection reading coil CTC Y 3132 for differential protection test coil CTC Y lAMPEROMETRICTRASFORMERS S 33 MnptTA 5SApasX 34 MnptTA SAphseY Oo 35 hputTA 5AphseZ o 305A 36 MnptTA 5Amtal SWITCHING COMMAND y
79. re is used to configure the sensor in single phase the controls on connections L1 L4 are activated Network control Single phase Voltages used 10 340 V ac Adjustable minimum voltage 10 280V 27 Adjustable maximum voltage 110 300V 59 20V on MIN 10V on MAX Bringing the MIN V GEN MIN HZ MAX V and MAX HZ values over the programmed maximum the OFF function can be activated to deactivate the control FUNCTIONS 27 Min voltage 59 Max voltage 60 Dissymmetry 81 Protection for min max frequency 47 Sequence phases 50 Instant current or short circuit 51 Max current with programmable delay 87G Protection differential of breakdown to earth 32 Protection by energy s inverse or directional power protection VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 23 of 57 FUNCTIONING When there is a lowering of the voltage a lower than the programmed value es Min V 320V the CR mains contactor is open If setting OPEN CR BY FAILURE MAINS and after possible delays it will have the cycle of start of gen set and the open CR if setting OPEN CR BY START When the voltage increases after overcome the differential threshold b we have the normal condition of value within the limits 320 302 350V which activates all the cycle of return mains If there is an increasing over the programmed value c es Max V 440V itis had equally the cycle of start GE and with the lowering of the v
80. remote control switches motorised commutators or motorised switches The CG and CR command contacts are normally closed to allow the command circuits in the case of particular anomalies to force the closing of the mains contact maker by simply removing fuse F1 from the MP02 unit and disconnecting the fuse on the battery charger OPERATING STATUS A page on the display has been set aside to show the unit s status to facilitate use of the EIN generator This page shows all status indications such as automatic test cutout forced starting remote controlled pilot generator standby generator clockto be set etc These status indications allow the operator to know the status of the unit and whatto do For example a clock to be set the battery has been disconnected and the clock must be reset as some operations need to use the clock b cutout Stop command the generator cannot react automatically and can only be controlled manually c forced start the generator is controlled by forced power supply and can only be operated manually SERVICE REQUIRED STOP DUE TO TIME EXPIRED When the working hours before the next service are entered the alarm state is activated without affecting the operation of the unit and the display will read SERVICE REQUIRED The hours run are zeroed during servicing by going into the COMPLETED section of the Misc Settings Menu and pressing RESET If the SERVICE hours field is set at 0000 this function
81. rred PIN to check the correct insertion of the code PIN in the sector of the serial regulations It is obviously possible to check the gen set through a personal computer with the projected software adequately to the functions of the GCM 02 It is possible in fact once connected to the interested group to command to distance the STOP the START or the AUTOMATIC TEST of the same group In this case on the display of the GCM 02 following information are visualized respectively e START FROM SERIAL COMMAND e STOP FROM SERIAL COMMAND e AUTOMATIC TEST FROM SERIAL COMMAND After 250 of absence of serial communication every command sent from PC is annulled and the 2 ittakes back the normal operation REMOTE COMMAND AND CONTROL BY CABLE With an easy and cheap CCD of modular structure suitable for the normal civil installations it is possible to command and control the GE through 6 telephone threads foreseen functions and commands AUTOMATIC RUNNING FORCED START WITH SUPPLIED POWER LOCKED GEN SET SIGNALING OF MAINS OR INSERTED GEN SET ALARM SITUATION WITH ACOUSTIC ALARM BY BUZZER Oe 09 NE ES 6 WIRES TYPE TELEPHONE MAX 200m Ht MH LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 50 of 57 2 18 INSTALLATION 2 18 1 POSITIONING The control panel must have a protection rating IP suitable for the area in which it will be installed IP 42 normal supply for closed areas IP 55 in the case
82. s dispersed to earth and after the relevant delay the load is deactivated via commands 41 and 42 This function is available from GCMO2MP modules rel 6 0 or superiors Connections Fig A shows the 67G earthed fault protection commonly used in generators since in addition to protect the unit against direct contacts it also detects leakage to earth from the generator s coils The insulation between the neutral N and the earth PE must be checked on setting the unit up as any link between the two would by pass the differential trip switch AL MP02 FIG A GEN FIG B MP02 29 32 ror TORUS TORUS WITH TEST WRAPPING 29 m TORUS WITHOUT TEST WRAPPING 29 30 MEASURE i 32 31 USTABLE TO TORUS WITH SHADING COILS REPORT 500 1 750 1 1000 PROGRAMMING 1 In the menu measurements to program the shading coils report REG DIFFERENTIAL 500 1 it is fundamental for the correspondence of the reading with the value of foreseen intervention 2 In the menu thresholds to program the intervention current VER LAST I SSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 p 0 5W 3 In the menu times to program the intervention delay EMERGENCY DEVICE Pre arrangement for the external emergency command enabled in all operational modes with immediate stoppage of the motor opening of the generator contact maker and triggering of the alarm The emergency device
83. s the unit to stop WT11 The pre alarm temperature must be set at least 3 C lower than the thermostat LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 2 6 5 FUEL LEVEL 15 The measure is foreseen for the level transducers Veglia or VDO from 0 to 200 Ohm for different values it needs the manual setting the scale is in from 0 to 110 max FUEL LEVEL PROGRAMMING From the menu various setting to select for the analogic input 15 the kind of transducer Veglia or VDO 80 OFF FUEL PUMP ADJUSTMENT PROGRAMMING TO ANY TYPE OF FLOAT The programming of the measure of the fuel level is effected with the float outside of the tank ON FUEL PUMP To activate the switch 4 to enter in the programming menu go to page REG ZERO LC in the pages REGOLAT MEASURES FUEL RESERV To put the measuring stick in the position of void Press ENTER FUEL FAULT To go to page REG LETT LC To put the measuring stick in the position of full Press ENTER The unit will calculate automatically the run of the float aligning the reading Tum back the switch 4 on OFF 2 6 6 FUEL PUMP COMMAND The GC M02 control panel is pre arranged to command the fuel pump that fills the daily tank The fuel level probe VDO that commands the digital tester that indicates the percentage of fuel inside the tank electronically establishes the following levels The tripping thresholds can be programmed The failed installation o
84. safety device against excessive power supply voltages are fitted in the MP02 module it is capable of operating constantly up to 40V it can also withstand transitory voltages above 250V A second level safety device is also fitted against inverted polarity of the power supply which prevents the circuits in which itis encountered from being powered Any anomalies cause the 1 fuse to trip 25A that cuts out all the electronic circuits WARNING if after having powered the control panel the battery LED should fail to light up check the POLARITY OF THE BATTERY before operating any commands Possible connection errors could cause electronic anomalies in the MP02 module if commands are operated with the poles inverted 3 4 3 4 1 12 Volt 24 Volt 2 5 2 COMMAND RELAYS Two 30A relays command the starting and stopping and one 16A relay the utilities 15 54 Two 10A relays with free contacts command the contact makers of the mains and generator CG CR switching An additional relay with contact that can be configured in NA NC is pre arranged to command the opening of the generator switch It is designed to trip the differential or for overloads 30A 30A 16A lj 1 5Start 6Stop 7 15 54 2 5 3 MOTOR STARTED READING This requires no external signal The control is achieved on the frequency of the generator During the motor starting phase once 540 rpms are reached which correspond to 18Hz programmable the 1st motor started sig
85. set time and a message reading SERVICE appears on the display ALARM MAINTENACE 1 or ALARM MAINTENANCE 2 pressing RESET the function is restored REMOTE CONTROL The unit can run under remote control by using remote communication PC or modem or GSM and this can be activated automatically Ht VER LASTISSU LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 ENG 19 SIMPLE MAINTENANCE WORK USER SAFETY PROCEDURE A WARNING It is strictly prohibited for anyone to touch powered parts 1 9 1 ELECTRICAL MAINTENANCE All jobs must be performed by skilled personnel The control unit is equipped externally with all the possible command control and reset functions Proceed as follows to access the equipment within the control panel 1 the programming switch on LOCKED mode 2 Check if the unit has stopped completely 3 Disconnect the mains line that powers the control panel and switch the main ON OFF switch of the mains off 4 Check if the mains has been effectively disconnected which can be seen by the mains OK LED switched off and by the display switched to the mains that must indicate zero 5 Open the control panel and check for any anomalies in the e fuses e automatic switches e thermal relays Once maintenance has been completed repeat the procedure in reverse order to reset the unit Overload fault This may cause the unit s trip switch to open lever in central TRIPPED position This must be reset by pus
86. sistors for high voltage for phase and connected to earth Therefore R 5 T N inputs are to be disconnected FEE LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 Page 53 of 57 THE INFORMATION INDICATED IS NOT BINDING AND IS SUBJ ECT TO CHANGE DUE TO TECHNICAL IMPROVEMENTS WITHOUT WARNING 2 19 SERVICE PROCEDURES 2 19 1 SERVICING PROCEDURE Before proceeding with the functional test 1 Disconnectthe BATTERY and BATTERY CHARGER fuses 2 Check the connection of the oil pressure switch If the connection to earth is not present B by means of the oil pressure Switch the motor will not start Once installation is complete check its correctness by performing the procedures advised below 1 Switch the programming commutator to stop 2 Close the fuses 3 Check that the Battery LED comes on If not the polarity on the battery may be incorrect and need inverting or the power supply may not be on WARNING Do not give commands Erroneous connections could cause damage to the power module 4 Programme the M02 on the basis of the working data and characteristics of the generator Move switch N 4 to programming ON and complete the procedure shown on page 30 If different from the standard 400V 50Hz setthe working voltage and frequency TA ratio 5 Overload current enter the nominal current the generator can supply increased by 596 S hort circuit current enter the overload c
87. ted on the load The three line voltages between one phase and another are displayed for the detailed control of the mains It indicates the three star voltages between phase and neutral The three currents of phase enable to verify the situation about the load on the single phase of the mains This page is displayed if the CT are connected and reseted on the load The powers indicate the state and the load type on the mains KVA kilovoltampere apparent power KW kilowatt real power KVAr kilovar reactive power This page is displayed if the CT are connected and reseted on the load Cosfi power factor phase displacement angle between voltage and current with the normal load it indicates 0 if with capacitive load it indicates C 0 xx This page is displayed if the CT are connected and reseted on the load When the gen set is running gen set voltage the frequency and the current on the phase 1 are displayed FEE VER DATAULT VERSIONE LINGUA PAGINA GCM02 MT ING4 NEW doc 04 03 2003 Page 8 of 57 For a control more detailed of the gen set the three linked voltages are visualized between phase and phase It indicates the three starry voltages between phase and neutral of the gen set The three current of phase allow to verify the state of the load on the single phase of the gen set The powers indicate the state and the type of load on the gen set kilovoltampere apparent power KW kilo
88. the mains is connected and is within the normal operational limits the output is switched to the mains and the motor is stopped following a cooling delay FUNCTIONS EJ P1 Command the unit starts without switching over after the delay set EJ P2 Command switching over takes place immediately When the EJ P command is active the generator operating status display reads EJ P The TEST SCR RES functions are excluded 2 10 2 SCR FUNCTION OR FORCED STARTING WITH OUTPUT default By configuring input 18 for the SCR function when this is enabled it starts the motor with the consequent forced output from the generator As soon as this input is disabled if the mains is connected and is within normal operational limits the output is switched over to the mains and the motor is stopped following a cooling delay When the SCR command is active the generator status display reads FORCED START The RES functions are excluded 2 10 3 LOCK FUNCTION default This forces the board to a locked status by means of an external command This function proves particularly useful for locking the board overnight or at the week end When the cutout command is active the generator status display reads CUT OUT In this mode only direct manual commands can be used The RES function is excluded 2 10 4 TEST FUNCTION default This sets the unit in automatic mode by means of an external command without disconnecting the power supply from the mains If
89. there are also a green led and another red the green is the transmission function TX and the red is the receipt flashing during the operation In the following figure is brought the external view of the 1503 unit RS 485 END LINE RESISTOR FOR RS 485 PIN CONNECTION TO THE PANEL 2 RX CONNECTORS PIN The jumper opportunely connected enables the closing of the line of the RS485 serial inserting the resistance R which closes the line For the connection from 1503 to PC by RS 232 interface it needs a wire null modem standard for PC his configuration is the following LAST ISSUE LANG PAGE GCM02 MT ING4 NEW doc 04 03 2003 The connection of the 15 03 to PC by RS485 interface allows the control of more GCM02 units using a bight for a correct functioning the units should be set to the same speed but with different and consecutive address modbus his configuration is the following COMMUNICATION PROTOCOL The standard MODBUS is particular type of protocol suitable to communicate on a RS485 serial up to max speed of 256 Kb s The speed used as standard is however that of 9600 Kb s At the end of the manual in the appendixes section there are the modbus mapper they cab be used on serial mains controlled from PLC etc If after the lighting the TX green led is again turned press reset for to repeat the handshake with the IS03 COMMUNICATION BY MODEM OR GSM During
90. ture 8 Veryhighwatertemperature YES 9 Highwatertemperature pre alarm ts 11 13 Starting 15 Fulpumpmmig N f v TCS 16 Minimumtemperaure A Po BATTERY y 17 Battery connected ET 18 Exessvebateyvolage EA 19 A 20 Batterycharging Po poo PR ff _ E O D E B 23 Lowvoltage 27 CTC SR a LEES 25 Shortcircuit G0 st SR AE Dem eee YS 29 Inverted power CC seen E 30 Generator contact maker closed ON G 3 J J 32 Differential trip switch earthing faut J J SR 33 0 0 y PMA 34 Mainsconnected V 35 Exessivevotage9 Jo VOFF _ 36 Low voltage 27 displacement vor o 37 Ovradol CTC A SR 38 Phasesequence A 39 Mains contactmaker closed do 6 1 y 40 Emergency push button pressed A GCM02 MT ING4 NEW doc 04 03 2003 ENG 41 CR mains contact maker anomaly L6 42 CG generator contact maker anomaly _ AT 2 1 When an
91. urrent multiplied by three If required activate the special functions pages 26 30 The Terminal Contact wires may introduce residual voltages into the M02 which generate a value for current that does not exist To eliminate this use the Measurements Menu to zero the Current and press Reset The M02 carries outself programming h Return switch N 4 to OFF 5 Switch the programming commutator to ENABLE STARTING 6 Since the protective devices are also active in Manual mode check the probes for fuel reserve motor temperature etc against the respective indications by disconnecting the conductors on these and connecting it to the earth temporarily and checking that the message displayed is correct 7 Oncethe alarm check has been completed in case of faults see the input output paragraph press the START and STOP button quickly and check the motor for the correct reaction and the power supply to the solenoid valve and actuator itis not necessary to start the unit 8 Visually check the power connections between the generator and the panel making sure that he board detects the motor started status via the generator voltage If this voltage cannot be detected due to the power connection not being formed properly or a switch open along the power supply line the starter motor must remain active for three seconds after the motor has started 9 With the commutator switched to ENABLE STARTING press the start button until the m
92. watt real power KVAr kilovar reactive power Cosfi power factor phase displacement angle between voltage and current with the normal load it indicates L 0 xx if with capacitive load it indicates C 0 xx ATTENTION In this last case it means that the automatic rephasing is inserted ofthe plant that during the operation of the gen set Has absolutely to be disconnected DANGEROUS CONDITION The kilowatthour indicates the supplied power from the gen set The voltage of the battery and the current of load are brought in case of present mains firm group and of inferior tide to 2 A La tension doesn t have to overcome the 13 5 Vs in case of 12Vdc batteries and the 27V forthe 24Vdc batteries when the group is running the voltage are superior since conditioned by the generator battery charger RPM motor revolutions LC percentage of the fuel in the tank PO oil pressure TM motor temperature Attention LC PO TM are displayed only if the the respective probes are connected Hour counter totalizator the value remains memorized even if the battery is not connected State of the inputs it is displayed by the technicians in phase of test of the plant State of the outputs it is displayed by the technicians in phase of test of the plant Counter succeeded and failed starts Weekly clock every time is reseted that the battery is interrupted and itserves forthe operation ofthe automatic test of the automatic block and

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