User Manual
Contents
1. Generator sensing Input Connect to Alternator Output Generator sensing Input Connect to Alternator Output Oil Pressure switch Input Connect to Oil Pressure Switch Pre heat Signal Output Accessory ON Output 6 DC Plant Supply input V System DC positive input Battery Positive Eight pins din rail terminal J2 PIN No DESCRIPTION NOTES EN Spare User Define Warning Signal Signal need to be a negative switch Input Input Remote Start Input Connect to A T S device Signal needs to be a p negative switch input ee Connect to Fuel Solenoid or Fuel Valve Control EN Fuel Solenoid Signal Output Supply V 5 Amp 11 Start Signal Output Connect to Starter Motor Supply V 5 Amp ESC gt 13 Coolant Temperature switch Input FAN ined o switch Signal needs ICC 57 ICCCECN ala Rear Panel layout J2 15 se 123 45 6 7 AN zi GCU 10 Automatic Engine Control 4 6 Standard Wiring Diagram GCU 10 Without GCU 10R LP AC 5 V 300 V JOJeUJaU y ole OIL SW e r Temp SW el ef Emergency Stop AUX Alarm er clar Remote Start 6 cf EL Pre Heat e Stop LINA TOULNOO YOLVYSANADS OL NOD Accessory ON Idle control Idle Contr2. REMOTE START signal Should a REMOTE START signal be detected a start sequence similar to previous manual start sequence is initiated When removes the Remote Start signal the Cool Down delay timer will count down After the Cool Down ends the Fuel Solenoid is de energized or energized as the case may be bringing the generator to a stop and the POWER SOURCE LED will start flashing indicating the genset is on standby and ready to start Should the Remote start signal be re activated during the cooling down period the set will immediately return to load NOTE Even if the generator is executing Engine Cool down Timer The Module protection system remain in operation and if any failure occurs the module bypasses the Engine Cooling Timer shutting down the generator immediately 2 3 OFF Operation The OFF position places the module into its Stop or Reset mode This will clear any alarm conditions for which the triggering criteria have been removed If the engine is running and this position is selected the module will automatically shut down the generator The fuel supply will be removed and engine will be brought to a standstill Should a remote start signal be present while operating in this mode a remote start will not occur GCU 10 Automatic Engine Control 3 PROTECTION SETTING AND SYSTEM WARINNG FAILURE DESCRIPTION 3 1 Protection Functions Engine fail to start reattempt Engi
3. on cranking Not below 6V e Check oil pressure switch type e Check GCU 10 Start signal output e Check Starting motor e Check wiring to see if it is open circuit Check fuel e Check wiring of fuel solenoid e Check Governor and wiring e Check Battery Volts on cranking Not below 6V e Check Starting circuit and wiring e Check oil pressure Switch e Check AC Input Voltage 5 300VAC e Check wiring to see if it is open circuit e Check oil pressure switch e Check Starter motor e Check emergency stop terminal and wiring e Check wiring to see if it is short circuit e Check engine oil pressure e Check oil pressure switch e Check wiring to see if it is open circuit e Check engine temperature e Check water temperature switch e Check wiring for short circuit REMEDY e Change Battery e Check and confirm voltage and wiring e Change fuse e Change Control Unit e Change Battery e Correct Oil pressure Switch type to correct setting e Change Control Unit e Change Starting motor e Correct the fault point Add fuel e Correct Engine Stop Mode setting e Change Governor e Change Battery e Change Wiring e Change appropriate oil pressure switch or cancel the Oil Pressure Detection Engine Start option e Change Automatic Voltage Regulator AVR e Correct the fault point e Change appropriate oil pressure switch e Change Starting Motor e Select emergency stop to normal open input e Correct the wirin
4. CCU 0 Automatic Engine Control Unit Operators Manual Ej E USA NS KUTAI ELECTRONICS INDUSTRY CO LTD 90 Headquarters No 3 Lane 201 Chien Fu St Chyan Jenn Dist Kaohsiung TAIWAN Tel 886 7 8121771 Fax 886 7 8121775 URL http www kutai com tw GCU 10 Automatic Engine Control TABLE OF CONTENTS Section Page INTRODUCTION uote ade ando 3 1 PANEL LAYOUT niaan aeaa aeaa e ea daa 3 1 1 Front Fanel Layos NENE A EN A NEA ERES 3 Te Reat Panel Layos 3 2 OPERATION ooa aa aaa a 4 2 1 Man al Operation a aaa aaa a a a aa sodas is a Aa AEE a A aE IE aN 4 2 2 AUTO Remote Start Operati n steini ndai aae ara aaan a ahaa rar aiani atadai a aaan Naaa 4 2 0 OPE Opero A a a a aaa aE RSS 4 3 PROTECTION SETTING AND SYSTEM WARINNG FAILURE DESCRIPTION cceeeeeereees 5 3 1 Protection SO A eee en A ee 5 3 2 lconReterance Table cis nari hae Se OR SE i Ge Se ie 5 4 SYSTEM INSTALLATION conti ia eid eto ee Ge ei ati ed 6 4 1 Specification wick teh an as eel uae Ed ee eee 6 4 2 Working Environment ias Aita 6 4 3 P anel Cut Out A ee eA a ee eel 6 AAN DIMENSIONS 4 532th eis Gh iS SE i ee Ls eee 6 4 5 Connection Details riist kee a elit deh tel ad eed eee aadi N ina 7 4 6 Standard Wiring Diagram GCU 10 Without GCU 10R cc ceeceeeeee eens eeeaeeeeeee teense taeeeeaaeeeeeeeees 8 4 7 Standard Wiring Diagram GCU 10 With GCU 10R ococccccnccconocinonoccnancccnoncnnnonananoccnncncn nn ana
5. at Adjustable from 2 to 30sec o B Engine Start Adjustable from 1 to 15sec C Engine Stop Adjustable from 1 to 30sec a D Engine Idle da Adjustable from 0 to 300sec Set to 0 for no Idle gx E Engine Cool down ee hai Adjustable from 0 to 300sec Set to 0 for no Cool down SW 1 Generator Frequency ON 50Hz OFF 60Hz SW 2 Battery Voltage ON 12 Volt operation OFF 24 Volt operation SW 3 Stop Solenoid ON Energize to Start OFF Energize to Stop SW 4 Oil Pressure Switch ON Normal Open NO OFF Normal Close NC SW 5 Oil Pressure Switch Crank Disconnect ON Not used for crank disconnect OFF Used for crank disconnect 8 9 10 11 12 13 14 O s G rai D ella ON y D S AS GCU 10 Automatic Engine Control 2 OPERATION 2 1 Manual Operation To initiate a start sequence moves the front control to MANUAL The LED above the knob eo illuminates indicating the generator is in MANUAL First the pre heat timer begins by energizing terminal 4 Don t care the terminal 4 output if the pre heat function is no used After pre heat ends the module de energizes terminal 4 and begin engine starting The module Fuel Solenoid energizes terminal 10 together with Engine Idle terminals 14 amp 15 After a 1 s
6. ec delay the starter motor engages and the engine cranks for the duration of the crank timer When the engine fires the starter motor is disengaged and locked out with an 18 Hertz signal from the generator output Alternatively the oil pressure switch can serve as an additional back up crank release When the engine fires and the Engine Idle option is used the ENGINE RUNNING LED will continuous flashing in Idle period indicating the status is IDLE Should the engine not fire on the first attempt and the crank timer expires the module will once again attempt to start the engine until the engine fires or after the third attempt is completed Should the generator fail to start place the front knob in the OFF Reset mode Establish why the engine failed to fire before making any more start attempts After the generator starts the module allows Oil Pressure High Engine Temperature Under speed and the Auxiliary fault input to stabilize without triggering any faults in 20 seconds Once the engine is running full fault protection is available By moving the knob to the OFF position the genset will STOP immediately 2 2 Automatic Remote Mode Operation By moving the knob to the AUTO mode the POWER SOURCE LED will start flashing indicating the module is in AUTO and the genset can start at any time In the AUTO position the module monitors input terminal 9 for a
7. g Add engine oil lubricant e Change oil pressure switch e Correct the fault point e Change water temperature switch e Correct the fault point 10 GCU 10 Automatic Engine Control SYMPTOM PLEASE CHECK n E e Check Engine Pre heat countdown In Auto Mode the Setting to see if preset time 2 30 generator does not start sec has been reached with a remote start e Check remote start signal input signal e Check GCU 10 start signal output e Check wiring to see if it is open circuit e Check Engine Pre heat Countdown Setting e Check GCU 10 Pre heat signal output Pre heat does not work Check Engine Cooling Countdown time setting excessive time delayed e Check Engine Stop Countdown time setting inadequate time delayed Engine does Ob DE Check Engine Stop Mode setting stopped in off mode Check GCU 10 Engine Shutdown output signal Check Fuel Solenoid REMEDY e Correct the fault point e Change Control Unit e Correct the fault point e Reset settings e Change Control Unit e Reset Engine Countdown time Cooling e Reset Engine Stop Countdown time e Reset Engine Stop Mode Change Control Unit e Change Fuel Solenoid
8. ltage Warning EXECUTION Generator standby in Auto LED Flashing Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Warning Only GCU 10 Generator Control Unit Auto Yi Manu GCU 10 Automatic Engine Control 4 SYSTEM INSTALLATION Install the Model GCU 10 Module on the front panel by using the two installation clips provided When installed in a panel with too much vibration use appropriate anti vibration isolators 4 1 Specification DESCRIPTION SPECIFICATION DC Supply 9 0 to 36 VDC Alternator Input Range 5 300VAC Alternator Input 50 60 Hz Frequency Fuel Solenoid Signal 5 Amp 12 24VDC Output Start Signal Output 5 Amp 12 24VDC Warm up Signal Output 5Amp 12 24VDC Accessory ON Output 5Amp 12 24VDC Idle Control Conductor Capacity 5 Amp 12 24VDC 4 4 Unit Dimensions Measurement mm GCU 10 Generator Control Unit ga Auto Manu KUTAI 2 4 2 Working Environment The module works over a wide temperature range 20 to 70 C however make allowances for temperature rise within the control panel enclosure Do not mount close to any heat sources without adequately ventilated also the humidity inside the control panel should not exceed 90 4 3 Panel CUT OUT in mm GCU 10 Automatic Engine Control 4 5 Connection Details Seven pins din rail terminal J1 PIN No DESCRIPTION NOTES
9. ne tries 3 times to start Engine High Water temperature Protection Shutdown activated after 3 seconds Temperature Switch Type Normally Open Engine Low Oil Pressure Protection Shutdown activated after 3 seconds Oil Pressure Switch Type Normal Open or Normal Close Engine Over speed Protection Shutdown activated after 3 seconds If set for 50Hz operation Over speed is activated at 55 Hz If set for 60Hz operation Over speed is activated at 66 Hz Engine Under Speed Protection Shutdown activated after 5 seconds If set for 50Hz operation Under speed is activated at 45 Hz If set for 60Hz operation Under speed is activated at 54 Hz Emergency Shutdown Shutdown activated by Normal Open Contacts Spare User define Shutdown Activated after 5 seconds delay Using Normal Open Contacts Low Battery Voltage Warning Activated after 5 seconds delay For 12VDC operation set at 10 V For 24VDC operation set at 20 V Start Up Grace Period There is 20 seconds after engine idle ends all alarms are ignored untile start up grace period expired except the emergency stop and over speed Once the engine is running full fault protection is available 3 2 Icon Reference Table DESCRIPTION Power Source Indication Generator Operating Normally Engine Start Failure High Water Temperature Low Engine Oil Pressure Over speed Under speed Emergency Shutdown Activated Spare Shutdown Low Battery Vo
10. ol JOUJSAOLH 91401109 3 GCU 10 Automatic Engine Control 4 7 Standard Wiring Diagram GCU 10 With GCU 10R GCU 10 GENERATOR CONTROL UNIT gt GCU 10R TN Alternator 5 300 VAC Battery Pre Heat J3 8 Y 35A ON To Genset Accessory J2 13 XL J2 12 J2 8 L Emergency Stop AUX Alarm J2 9 U Remote Start Idle control Idle Control Electronic Governor GCU 10 Automatic Engine Control 5 TROUBLE SHOOTING SYMPTOM In MANUAL MODE Power Source LED does not illuminate and generator can not start In MANU MODE Power Source Indication illuminates and Starter Motor fails to operate In MANUAL MODE Power Source LED illuminates and Starter Motor ails to crank In MANUAL MODE Starter Motor cranks but engine fails to fired Starting motor does not disengage after generator starts Emergency stop always Engine not operating And does not start Low oil pressure always while engine is running High water Temp always while engine is running PLEASE CHECK e Check Battery Volts on cranking Not below 6V e Check DC supply Voltage e Check DC supply fuse e None of the above e Check Battery Volts
11. r nn nancccns 9 5 TROUBLE SHOOTING Sreo aai ia i ia ce an ee en nein 10 GCU 10 Automatic Engine Control INTRODUCTION The Model GCU 10 is an Automatic Engine Control Module designed to meet the demand of the generator industry The module starts and stops the generator and fault conditions If it senses a fault it will automatically shuts down the engine and indicates the engine failure by means of eight LED s The technician is able to adjust the settings to enable it to work with any type of generating set and comply with different engine conditions and protections 1 PANEL LAYOUT 1 1 Front Panel Layout Operation of the GCU 10 is by a three position waterproof switch indicating AUTO OFF and MANUAL Two LED s indicate POWER ON and ENGINE RUNNING and the other eight LED s indicate the operational status and fault conditions of the genset Each LED indicates engine start failure high water temperature low oil pressure over speed under speed emergency stop and low battery voltage An extra LED and corresponding input can be defined by the technician as a failure each LED has a picture graph that are universally recognized GCU 10 Generator Control Unit Auto Manu KUTAI 20 1 2 Rear Panel Layout In the back the GCU 10 has two terminal blocks J1 8 J2 five adjustment pots that change the time delay functions and five pins dip switch that set the specification of the genset a A Engine Pre He
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