7. Warning And Shutdown Alarm

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GU310A Controller Operation Manual Contents 1. Description ...........................................................................................2 2. The Outline Dimensional Drawings and wirings of Controller ............2 3. Operation Panel ..........................................................................................6 4. Installation Guide ........................................................................................7 5. Control and Operation Instruction ............................................................8 6. Measure and Display Data ......................................................................11 7. Warning and Shutdown Alarm ...................................................12 8. Parameters Setting ..........................................................................14 9. LCD display and Menu System....................................................17 10. C o m m u n i c a t i o n F u n c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 11. Preparation before Start the Controller..................................................27 12. Troubleshooting .......................................................................................29 13. Technical Parameters.................................................................................31 1 GU310A Controller Operation Manual 1. Description GU310A Genset intelligent controller can modify the control procedure and protection parameters of generator, completely meet requirements of Genset auto start, stop control and basic protection. Controller through LCD on panel display control status, running status and related measuring data for Genset. Controller has three operation modes: AUTO/MAN/OFF, they are selected by the key switch on panel. Controller measure and display output voltage (optional single phase and 3-phase), current (single phase), oil pressure, coolant temp, frequency and DC source voltage for generator, and the voltage is measured by true RMS to make sure data accuracy. Optional communication interface of TI485 or TI232, realizing long distance monitor, or communication with PC, fully realizing functions of remote signaling, telemetering and remote control, can read and set the running parameters of controller. The controller adopted DIN96 standard enclosure, all connections are connected by pin-like and locked up terminal, easier and more convenient to install, connect, move and displace the device. This manual only suitable for GU310A generator intelligent controller, user must carefully see this manual first. 2. The Outline Dimensional Drawings and wirings of Controller 2.1 Following Details: Operation Panel Install Hatch Thickness W96mm×H96mm W92mm ×H92mm D61.5mm（unconnected） 2 GU310A Controller Operation Manual 2.2 Connecting Terminals: Pin No. Function Description Signal Dim 1 2 3 4 5 6 7 8 oil pressure signal temperature signal E-stop signal remote {external control } signal reserve signal measure oil pressure detect temperature detect reserve ☆ 9 magnetic sensor signal {＋} 10 magnetic sensor signal {-} low potential is active low potential is active low potential is active low potential is active low potential is active P-sensor (<2KΩ) T-sensor (<2KΩ) 0~5VDC signal 1~70VAC internal connect to the cathode of DC source 1mm² 1mm² 1mm² 1mm² 2 core shield line 11 A phase voltage input 0-300VAC 1mm² 12 B phase voltage input 0-300VAC 1mm² 13 C phase voltage input 0-300VAC 1mm² 14 Neutral zero line 15 A phase current input {S1} 0-5A(AC) 1mm² 16 A phase current output {S2} 1mm² 17 fuel solenoid relay output 18 start relay output 19 running output 20 custom output 1 21 custom output 2 22 charger excitation source output 0-5A(AC) N.O. dry contact, 3A/30VDC N.O. dry contact, 3A/30VDC N.O. dry contact, 3A/30VDC N.O. dry contact, 3A/30VDC N.O. dry contact, 3A/30VDC If not use, do not connect to cathode 23 working power source {+} 24 working power source {-} 25 Grounded 1mm² 1mm² 1mm² 1mm² 12V/24V (8~35VDC continued) 1.5mm² 1.5mm² 1mm² 1mm² 1mm² 1mm² 1mm² 1mm² NOTE: Pin No. 8 is reserved for measurement input, the measurable signal is 0~5VDC or 0~20mA or resistance signal (<2KΩ), preset to measure resistance signal, if required change propose in advance for hardware change. 3 (3P&N) 25 16 15 14 13 + - DCV (2A) F4 23 24 AUX SUPPLY （8-35VDC） ASS/1 17 RL1 FCS Fuel Battery Charger 22 ASS Crank RL2 18 RUNNING 19 RL3 Custom 1 20 RL4 Custom 1 21 RL5 4 3 2 1 Note: Battery cathode and controller shell must be grounded well. Load output F3 Oil pressure switch 12 Water temp switch F2 E.stop 11 Remote Signal F1 8 7 6 5 9 +TI485=RS485 +TI232=RS232 （ Standby） Gen P sensor 4 T-sensor phase 4-wires generator system. Standby（ 0～ 5Vdc） G Speed sensor (PICK-UP) RS CONNECTOR 10 GU310A Controller Operation Manual 2.3 Typical Wiring Diagram: (3-phase) NOTE: Above input modes of voltage and current are only suitable for 3- (3P&N) + - DCV (2A) F4 23 24 AUX SUPPLY （8-35VDC） ASS/1 17 RL1 FCS Fuel Battery Charger 22 ASS Crank 18 RL2 19 20 21 4 3 2 1 8 7 6 9 +TI485=RS485 +TI232=RS232 5 Note: Battery cathode and controller shell must be grounded well. Load output 25 16 15 RUNNING RL3 Custom 1 RL4 Custom 1 RL5 14 Oil pressure switch 13 Water temp switch 12 E.stop 11 Remote Signal F1 （ Standby） Gen P sensor 5 T-sensor phase 2-wires generator system. Standby（ 0～ 5Vdc） G Speed sensor (PICK-UP) RS CONNECTOR 10 GU310A Controller Operation Manual 2.4 Typical Wiring Diagram: (single phase) NOTE: Above input modes of voltage and current are only suitable for single GU310A Controller Operation Manual 3. Operation Panel The whole operation panel includes 3 sections: measuring parameters and running status display by LCD, operation buttons and key switch for selecting modes. 3.1 LCD Display and Control Keys: LCD wit 4 lines can display difference data information in the same time, and LCD has background-light function so that operator can clearly read information whenever at day or night. After pressing any buttons the background-light will auto turn off in a certain time. LCD display and its control buttons provide a friendly operation interface for operator, which makes operator conveniently read information and set running parameter. 3.2 LCD Displays Menu System and Running Status Tag Function Description Enter into submenu/modify/confirm modification Scroll up menu/ value ascend Scroll down menu/ value descend 3.3 Control Buttons and LED Tag Function Description AUTO Status Select AUTO operation setting mode by key switch, when controller is running in AUTO mode, According to the “remote start signal” is active or not, controller controls generator start and stop. MAN OFF MAN MAN Status Select MAN operation setting mode by key switch, when controller is running in MAN mode, controller controls generator start or stop by “START” and “STOP” buttons. OFF OFF Status Select OFF operation setting mode by key switch, when controller is running in OFF mode, controller will not be controlled by external signal or press key. OFF 6 AUTO AUTO MAN AUTO GU310A Controller Operation Manual START button/LED The button is used for MAN start Genset. When controller is set in MAN mode, press this button can start generator. STOP/RESET button The button is used for MAN stop generator. When controller is set in MAN mode, press this button can stop Genset. If occur failure output, controller can release from failure shutdown locked by continuously press this button over 2s. MUTE button Failure alarm sound-proof button, when controller occurs warning or failure alarm, alarm buzzer sounds, press this button can mute buzzer, if controller hold on fault status press the button again, alarm buzzer keeping sound. 4. Installation Guide 4.1 The dimensional drawing of install hatch on panel, showing as above attached. The controller is fixed by 2 special mounting fittings. The shock-proof equipment must be installed if the enclosure that installed on controller is directly installed on Genet body or other heavy vibrant device. 4.2 Please see above 2.3 Typical Wiring Diagram or attached drawing for wiring connecting. 4.3 The installations of P-sensor and T-sensor for engine: 端 子 Port 用途 Purpose 压力传感器 P-sensor 温度传感器 T-sensor 传感器公共点 No. 6 66 77 GU310 电 池 负 Battery 极 ( 外 壳cathode ) Sensor Com. Port (unit enclosure) 7 7 CONTROLLER GU310A Controller Operation Manual 5. Control and Operation Instruction The controller has 3 control modes: AUTO operation mode, MAN operation mode and OFF stop mode. 5.1 Operation Mode Setting: Operation Description MAN Select “AUTO” operation mode by key switch, controller then running in “AUTO” mode. OFF Select “MAN” operation mode by key switch, controller then running in “MAN” mode. OFF Select “OFF” stop mode by key switch, controller then running in “OFF” mode. OFF AUTO MAN AUTO MAN AUTO NOTE: Only can select 1 mode from above 3 modes. When controller READY Operation When controller do not detect engine data such as running speed, oil pressure, coolant temp, etc. the related data display at “0”, LCD display: Description ENGINE SPEED 0 RPM PRESSURE 0 Kpa TEMPERATURE 0 ℃ 5.2 The Process of Start Control: Operation Description When controller running in AUTO status and remote start input signal is active; (according to the setting delay) or in MAN status press “START” button (inset 3s), controller begins start procedure. Throttle relay takes action, engine fuel solenoid valve open, after delay 200 ms, start relay takes action, the start motor begins action, cranking begins. When engine running speed reaching the condition of crank disconnection, controller will stop start output and the safety-on delay begins counting. 8 Strt (Start delay) 00:08 SAFE（SAFETY-ON DELAY） 60 GU310A Controller Operation Manual When controller detects that the normal data such as RPM, output voltage, oil pressure, coolant temp of Genset have been set up, and no other failure, then LCD displays parameters that showed as right: (Scroll page can refer more details) ENGINE SPEED 1500 RPM PRESSURE 450 Kpa TEMPERATURE 70 ℃ When remote start signal is active, the start delay will be enabled and begin to counting. During the period of counting, if the remote start signal is inactive, start delay will stop counting immediately, controller stop start procedure, and return to original status after finishing the counting of fail to stop. During cranking or idle, if the remote start input signal is inactive, controller stop the following start procedure immediately and control output by closing all relays, then stop the start process, and return to original “READY” status after finishing the counting of fail to stop. NOTE: During crank, engine ignition, when the output frequency of alternator is reaches to preset frequency, start motor disconnect power. Or the start motor is disconnected power by one of the following reasons: a. b. c. The magnetic pickup device which mounted on engine flywheel detects that the frequency reach to preset frequency. The output voltage of alternator is reaches to 80% rating voltage; The low oil pressure switch of engine is open. 5.3 The Process of Fail to Start and Restart: Operation Description During the period of crank time counting, engine can not ignite, controller will not output starting signal during crank rest. LCD flashing FAIL TO START. Once crank rest time out, controller will attempt to restart engine again. Crkr （CRK-RST） 15 Above start phenomena repeat again and again until engine successful ignition and or reach the preset crank times. If any stop failures occur during start process, controller stops control output immediately, until failure eliminated and reset, then it can be operated again. 5.4 The Status of Fail to Start: Operation Description When above start phenomena repeat again and again and over the preset crank times, LCD controller will stop control output, display: FAIL TO START ALRM（ALARM ） STFL （START FAILURE） 9 GU310A Controller Operation Manual NOTE: If occur start failure, operator must check the whole Genet system to make sure failure reason, only after eliminating the failure can press “ STOP/RESET” button to unlock fault-locked status, and restart the 5.5 The Process of Auto Stop： Operation Description When the remote start input signal is inactive, cooling delay begins count down, cut off running signal. When cooling delay time out, controller switches off fuel solenoid valve immediately. The counter for fail to stop begins count down. When fail to stop time out and if engine still running, controller will sent out an alarm, or it will return to auto running status. COOL 300 STOP 20 When the remote start input signal is inactive, cooling delay begins counting, during the period, if remote start input signal is active again, cooling delay stop counting immediately, controller enter into safe monitor each parameter again, recover auto running status if normal. 5.6 The Control Process of MAN Stop： Operation Description When Genset in normal running, in “MAN” mode continuously press “STOP/RESET” button one time, controller begins cooling delay stop process, which same as auto stop. Press “STOP/RESET” button again, controller switch off fuel solenoid valve immediately, Genset start stop. The counter for fail to stop begins counting. When the counting time excesses the time of fail to stop counter, if engine still running, controller will sent out an alarm, LCD display: 10 ALARM SPFL （STOP FAILURE） GU310A Controller Operation Manual 5.7 The start and stop processes of engine, which fuel solenoid valve is N. O. type (difference from N.C. type): Start control process: When start running, the throttle relay of controller no action, fuel solenoid valve no power, means the electromagnet of solenoid valve no action. Stop control process: When controller starts at stop control process, output the power of throttle solenoid valve, fuel solenoid valve take action, engine begins stop. After delay (according to the setting fail to stop delay) throttle relay breaking, disconnect the power of throttle solenoid valve. Other control process same as engine fuel solenoid valve is N. C. type. 5.8 Idle and Preheat function Select the delay function of idle or preheat through “the setting value of idle delay”, When value is set greater than 0 is for delay function. When value is set at 0, cancel idle delay and realizing preheat function. Idle covers normal open (N.O) type and normal close (N.C) type, when the both on working is opposition on close and open status. Now we take N.C for example showing its working principle: when in READY status for idle, idle relay switch off, when controller running start procedure, idle relay takes action at the same time, start delay time out, throttle relay takes action, when start successful switch off start motor, in that time idle delay begins count down, when time out, idle relay switched off. Safety-on delay begins counting, if each parameter in normal after time out, unit running. Stop delay begins counting and idle relay no action, after cooling delay time out, idle delay begins count down, idle relay takes action at the same time, after delay expired performs stop action, after stop switch off idle relay. When stay at READY status with preheat function, preheat relay is open, the produce of start delay begins counting, preheat relay takes action at the same time, preheat relay open when the start delay reaches to crank ready, throttle relay takes action, crank attempt success and unit normal running, stop delay and preheat relay no action. 6. Measure and Display Data 6.1 The Measuring Data for Electric Section Generator phase voltage V L1-N L2-N L3-N Generator line voltage V L1-L2 L2-L3 L3-L1 Generator frequency Hz Hz Generator power factor PF L1 Generator current A L1 Generator active power kW L1 Since frequency measured from L1 phase of generator, the connection in this section must be confirmed no problem when used. 11 GU310A Controller Operation Manual 6.2 Other Measuring Data Oil pressure（kPa） Coolant temperature（℃） RPM（RPM） Running hours（RUN Hour） Battery voltage (V) This data from an external sensor This data from an external sensor This data from speed sensor Obtain from working source voltage 7. Warning and Shutdown Alarm 7.1 Warning (NOTE: Warnings are non-critical failure conditions and do not affect the operation of the generator system, they serve to draw the operators’ attention to an undesirable condition and remove it to make sure system continuous running. When Warnings occur, the status indicator light flash, but failure will not be locked and the unit will not shutdown. Once failure removed warning indicator auto turn off.) Charge Fail if controller detects that voltage has fallen below the preset “low battery warning value” from the excitation contact of auxiliary AC charger, LCD status bar displays “CHARGE FAIL”, “ALARM” LED flash. Battery Low Voltage controller detects that battery voltage has fallen below the preset “low battery warning value”; LCD status bar displays “BatL”, “ALARM” LED flash. Low Oil Pressure controller detects that the engine oil pressure has fallen below the preset “low oil pressure warning value” or oil pressure switch has closed after the safety-on timer has expired, LCD status bar displays “LOW OIL PRESSURE”, “ALARM” LED flash. High Temperature controller detects that engine coolant temperature has exceeded the preset “high coolant temperature warning value” or temperature switch has closed; LCD status bar displays “HIGH TEMPERATURE”, “ALARM” LED flash. Overspeed if the engine exceeds the preset “overspeed warning value”; LCD status bar displays “OVERSPEED”, “ALARM” LED flash. Underspeed if the engine falls below the preset “underspeed warning value”, LCD status bar displays “unSP”, “ALARM” LED flash. High Voltage if controller detects that the output voltage of generator has exceeded the preset “high voltage warning value”, LCD status bar displays “V H”, “ALARM” LED flash. Low Voltage if controller detects that the output voltage of generator has fallen below the preset “low voltage warning value”, LCD status bar displays “V L”, “ALARM” LED flash. Over Current If controller detects that the output current of generator has exceeded the preset “high current warning value”, LCD status bar displays “I H”, “ALARM” LED flash. Reserve Input If reserve auxiliary input is set as warning input, when input signal is active, LCD status bar displays “EXTP”, LCD failure bar displays “AUX D/I”, “ALARM” LED flash. 12 GU310A Controller Operation Manual 7.2 Shutdown Alarm (NOTE: shutdown failures immediately lock system and stop generator, it only can operate controller again after removing failures and press rest button to unlock) Fail to Start if engine does not fire after the preset number of crank attempts has been made, means fail to start. LCD status bar displays “FAIL TO START”, “ALARM” LED lights up, alarm buzzer sounds. Fail to Stop if engine does not stop after the stop delay expires. LCD status bar displays “SPFL”, “ALARM” LED lights up, alarm buzzer sounds. Emergency Stop when emergency stop input signal is active, controller immediately stops all relay control output except alarm, LCD status bar displays “EMERGENCY STOP”, “ALARM” LED lights up, alarm buzzer sounds. Low Oil Pressure if controller detects that the oil pressure level still falls below oil pressure alarm value or oil pressure switch is closing after the safety-on timer has expired, engine stop immediately, LCD status bar displays “LOW OIL PRESSURE”, “ALARM” LED lights up, alarm buzzer sounds. High Temperature controller detects that engine coolant temperature has exceeded the high coolant temperature alarm value or temperature switch is closing, engine stop immediately, LCD status bar displays “HIGH TEMPERATURE”, “ALARM” LED lights up, alarm buzzer sounds. Overspeed if controller detects that engine speed exceeds the overspeed alarm value, engine stop immediately. LCD status bar displays “OVERSPEED”, “ALARM” LED lights up, alarm buzzer sounds. Underspeed if controller detects that engine speed falls below the “underspeed alarm value”, engine stop immediately. LCD status bar displays “unsp”. “ALARM” LED lights up, alarm buzzer sounds. High Voltage if controller detects that the output voltage of generator has exceeded the “Gen high voltage alarm value”, engine stop after delay is confirmed, LCD status bar displays “V H”, “ALARM” LED lights up, alarm buzzer sounds. Low Voltage if controller detects that the output voltage of generator has fallen below the “Gen low voltage alarm value” after the safety-on timer has expired, engine stop after delay is confirmed, LCD status bar displays “V L”, “ALARM” LED lights up, alarm buzzer sounds. Over Current controller detects that the output current of generator has exceeded the “Gen high current alarm value”, engine stop after delay is confirmed. LCD status bar displays “I H”, “ALARM” LED lights up, alarm buzzer sounds. Reserve Input If reserve auxiliary input is set as warning input, when input signal is active, engine stop immediately, LCD status bar displays “EXT”, LCD failure bar displays “AUX D/I”, “ALARM” LED lights up, alarm buzzer sounds. NOTE: 13 GU310A Controller Operation Manual ‹ The warnings or shutdown alarms of oil pressure and coolant temp switch signal can be realized by setting No. 39 and 40 menus, the data detects from the switches status (on or off) of P-sensor and T-sensor. ‹ The warnings or shutdown alarms of the oil pressure and coolant temp analog signal can be realized by setting the parameters range on No. 32, 33, 34 and 35 menus, the data measure from the analog input ranges of P-sensor and Tsensor. ‹ The engine speed general from the frequency of pickup sensor, which mounted on engine flywheel, if system do not mount pickup sensor, controller will auto use the output voltage frequency of generator as the parameters of control and failure protection, for user convenience, some data expressed by rpm, RPM=HZ*30. ‹ Generator occur failure during running: after occur high temperature, low oil pressure, overspeed and underspeed, stop immediately no delay. During cooling delay, for underspeed and low oil pressure, only set idle delay at “0” so that no idle function can play protection function, or will not play. 8. Parameters Setting NO. Item Default Value Range 01 Current transformer CT 100 1~5000 02 Voltage rate VT 1 1~100 03 Address Addr 1 1~255 04 Volt low alarm AuL 0V AC45~9999V / 0 (not set) 05 Volt low warning AuLP 198V AC45~9999V / 0 (not set) 06 Volt high warning AuhP 253V AC45~9999V / 9999 (not set) 07 Volt high alarm Auh 9999V AC45~9999V / 9999 (not set) 08 Current high warning AIhP 9999A 0~9999A / 9999 (not set) 09 Current high alarm AIh 9999A 0~9999A / 9999 (not set) 10 Alarm delay AdLy 11 Rated speed EGSP 10S 1500 0~600S 99-9999 RPM 12 Pickup frequency tCAL 3000 1-9999 Hz 13 Set pickup now SEtt 14 Pair of poles PoLS 2 1~4 15 Fuel mode Fmod 0 0~1 / 0 (N. C.) /1 (N. O) 16 T-sensor mode Tmod 1 0~8 / 0 (not used) 17 P-sensor mode Pmod 1 0~9 / 0 (not used) 18 H-sensor mode Hmod 0 0~1/ 0 (not used) / 1 (used) 14 GU310A Controller Operation Manual 19 Start delay SdLy 10S 20 Crank attempt CAtt 3 times 21 Crank time Ctim 8S 0~30 S 22 Crank rest CrES 15S 0~300S 23 Crank disconnect CdSP 300RPM 24 Idle delay Idle 0 0~9999S 25 Safety-on delay SFto 60S 0~600S 26 Cooling delay CooL 300S 0~600S 27 Stop delay STOP 20S 0~60S 28 Underspeed alarm SPL 0 RPM 29 Underspeed warning 30 Overspeed warning 31 Overspeed alarm SPh 1710 RPM 32 Oil-P low alarm oPL 140KPa 33 Oil-P low warning oPLP 220KPa 34 Coolant warning CLhP 95℃ 0-9999 RPM / 9999 (not set) 50~300 kPa / 0 (not t) 50~300 kPa / 0 (not t) 70~160℃ / 9999 (not set) 35 Coolant alarm 105℃ 70~160℃ / 9999 (not set) 36 Battery low warning CLh Batt 1~25V / 0 (not set) 37 External alarm E1md 0 38 External analog E2md 2 39 Oil-P Stop oimd 1 0（V） / 1（ %）input (0~5V) 2（%）according to resistance sensor data define input 0~1/ 0 (warning) /1 (shutdown alarm) 40 Coolant Stop CLmd 1 0~1/ 0 (warning) /1 (shutdown alarm) 41 Custom relay 1 R1md 1 0~6 (code is defined as follows) 42 Custom relay 2 R2md 2 0~6 (code is defined as follows) 43 Voltage type Ltyp 3 1~3 44 Default settings Def 45 Firmware update 46 QUIT SPLP 1440RPM SPhP 1600 RPM 8.0V 0~300S 1~10 times 1-9999 RPM 0-9999 RPM / 0 (not set) 0-9999 RPM / 0 (not set) 0-9999 RPM / 9999 (not set) 0 (warning)/ 1(shutdown alarm) (1: single phase 3: 3-phase ) FIRM QUIT NOTE: Require restart working power source to become effective after the communication address changed. When the voltage type set at 2 is 3-phase without power display. 15 GU310A Controller Operation Manual Appendix：The code for relays is defined as follows. Code 1 Define Failure Type Over Current Output Code 2 Define Failure Type Alarm Output 3 Warning Output 4 Idle/ Preheat Output 5 Idle(N.O.) 6 Reserve NOTE: ‹ ‹ ‹ When above No. 18 set at “0” means H-sensor is not used, engine speed is set by No. 14 (PoLS); when No.14 set at “2” running speed is 1500 rpm, when No.14 set at “1” running speed is 3000 rpm. When above No. 18 set at “1” means H-sensor is used, the value of No. 12 (tCAL) set by MAN; engine speed is set by No. 11 (EGSP). When above No. 18 set at “1” means H-sensor is used, if the input value of No. 12 (tCAL) is auto set by the method of 11.6 (showed as below), both the value of No. 14 (PoLS) and No. 11(EGSP) must be correctly set. 8.1 The Definitions of P-sensor and T-sensor For P-sensor and T-sensor, according to below table different No. stand for different sensor mode, if the used sensor is not listed in the table, through software write the sensor data into controller, and both the sensor mode of No. 16 and No. 17 (see above parameters setting) should be selected as “custom” that is listed as the last mode in below table. No. P-Sensor Mode T-Sensor Mode 0 NOT USE NOT USE 1 VDO 10 bar VDO 120 degrees C 2 VDO 5 bar Datcon high 3 Datcon 10 bar Datcon low 4 Datcon 7 bar Murphy 5 Datcon 5 bar Commis 6 Murphy 7 bar TS120 7 CMB 812 KP-T01 8 KP-YV01 Custom (Base on sensor data) 9 Custom (Base on sensor data) 16 GU310A Controller Operation Manual 9. LCD display and Menu System Adopt TN type LCD can display multi-lines data information at the same time and LCD has background-light function, after pressing any buttons the background-light will auto turn off in a certain time. Press “ ” and “ ” scroll page to view each electrical parameter and engine measuring data. If no failure occurs, LCD keep displays the data of main page, when failure occurs, press “ ” scroll page to view failure information displayed by LCD status bar. For parameters setting and modify adopts gradually increase and decrease, when continuously press increase or decrease button, the single digit changed one by one, then the tens digit changed after ten single digit changed, follow this logic, and ” 2s can enter into the hundreds digit changed after ten. Continuously press“ setting status, can use “ “ ” and “ ” scroll page up and down at that time. Press ” enter into next submenu, select the required modify item, press “ into modify. When prompt key in password, key in “ ” “ ”“ “ ”“ ”(221313)，continuously press“ ” enter ” “ ” ”2s to quit setting status after finishing modification. 9.1 Static LCD display: When controller ready Operation Controller does not detect engine speed, if controller is not connected to P-sensor and T-sensor, the corresponding data display “OPEN”，LED display: Description ENGINE SPEED 0 RPM PRESSURE OPEN Kpa TEMPERATURE OPEN ℃ When controller set without P-sensor and T-sensor Operation Controller does not detect engine data, such as oil pressure, coolant temp, if controller on standby or running status the related data all display “----”, LCD display: 17 Description ENGINE SPEED 0 RPM PRESSURE --- Kpa TEMPERATURE --- ℃ GU310A Controller Operation Manual When controller normal running Operation This page displays engine related parameters Press “ ” or “ ” can switch display page Press “ ” or “ ” can switch display page Press“ ” or “ ” can switch display page Press“ ” or “ ” can switch display page Press“ ” or “ ” can switch display page Description FREQUENCY 50.0 RUN HOUR 10 BATTERY VOLT 24 ENGINE SPEED 1500 PRESSURE 450 TEMPERATURE 70 L1-N 220 L2-N 220 L3-N 220 L1- L2 380 L2- L3 380 L3- L1 380 L1 1.0 300 66 Runn A/I 10 HZ h V RPM Kpa ℃ V V V V V V PF A KW % 9.2 Setting running parameters For example: (setting current transformer rate at 1000 /5, then CT should be set at 200) Operation Continuously press “ then LCD display: Description ” 2s, enter into parameters setting menu, CT 100 100 press “ ”, then LCD display: press “ ”, prompt enter password, key in password “ “ ”“ ”“ Press“ display: ”“ ” or “ ”“ ” ” ” change parameter, change at 200, then LCD After changing press“ CT 100 ” to confirm，then press“ ” and “ ”, CT 100 PASS CT 100 200 QUIT then LCD display: Press“ ” again for quit, or continuously press “ also can quit，then LCD display: 18 ” more that 2s READY GU310A Controller Operation Manual For example: (setting controller crank attempt at 2) Operation Continuously press “ then LCD display: Press “ Press “ ” 2s, enter into parameters setting menu, ” 19 times and then press “ ” or “ CT 100 CAtt 3 ”, then LCD display: CAtt 3 PASS ” then LCD display: Key in changed password: “ Press“ Description ”“ ”“ ”“ ”“ ”“ CAtt 3 3 ” ” change parameter, change at 2 ，Press“ confirm change, and then continuously press “ ” ” 2s can quit parameters setting menu. CAtt 3 2 For example: (resume all parameters of controller to factory default) Operation Continuously press “ Description ” 2s, enter into parameters setting menu, then LCD display: DEFT Press“ ” 43 times and then LCD display: press “ ”, prompt enter password, key in password “ “ ”“ ”“ Press “ ”“ ”“ ” DEFT PASS ” 2s can quit DEFT DONE ” ” recover default, continuous press “ parameters setting menu 19 CT 100 GU310A Controller Operation Manual For example: (set controller as online program mode) Operation Continuously press “ Description ” 2s, enter into parameters setting menu, then LCD display: Press“ ” 44 times and then press “ ” one times, then LCD display: Key in changed password: “ ”“ ”“ ”“ ”“ ”“ ” CT 100 FIRM PASS FIRM (313232) Press “ ” again enter into program mode, in this mode the power supply must be make sure normal, after connecting to the communication line, using special program software correctly duplication, controller will auto repeat reset action, or will not quit FLRM UPDT ---- this status, until switch off working power source. The setting and operation method for other parameters are similar to above method. 10. Communication Function (It is an optional function, user can according to detailed condition to confirm equip or not) 10.1 Brief Introduction The controller has a “6P6C/RJ-12” communication interface , if the interface equip with TI485A（TI232A）communication interface module, controller has “RS485/RS232” industrial standard COM immediately. The communication interface adopts photoelectricity seclusion design and has circuit protection function to prevent interference from common module voltage and damage result by error connection, the RS485 adopts 9600 baud rate. The controller that has communication function has following features: z z z z 100% remote signaling, including running status and failure status. 100% remote regulating, including all settable parameters of controller. 100% telemetering data, including all measuring data of controller. 100% remote control function, covers all control functions on panel. 20 GU310A Controller Operation Manual 10.2 The Communication Connection for TI485A Controller has RS485 COM after add TI485A accessory, following typical wiring diagram: A TI485A R J11-5366 R S C O N N EC TO R R J11-5366 G U 310A C o ntro lle r R S C O N N EC TO R Tra nsfo rm te rm ina l B (R S 4 8 5) S RJ11-5366 G U 310A C o n tro lle r RS C O N N EC TO R Controller has RS232 COM after add TI232A accessory, following typical wiring diagram: RJ11-5366 RS C O N N EC TO R TI232A A b le to c o n n e c te d re sp e c tive ly M O D EM M O D EM C O M PU TER The communication interface offers user a route: from which you can get more information that can not get from panel, the matching software can display all measured parameters and status information, and can set all parameters. The controller that has RS485 COM allows 1 communication bus most connect to 247 same series of controllers by wiring connection mode, each device has one and only ID NO., only can connect to PC or MODEM by matching with another RS485/RS232 shifter in that time. Following typical wiring diagram: 21 R c o n n e c t to risiste r B M O D EM G U 310A C o n tro lle r S B A A S S R S C O N N EC TO R B B R J1 1 -53 6 6 R J1 1 -5 36 6 R S C O N N E C TO R G U 310A C o n tro lle r R J1 1-5366 R J11-53 66 A S R S C O N N EC TO R R S C O N N EC TO R TI4 8 5 A R S C O N N EC TO R R J1 1-5366 R J1 1 -53 6 6 R S C O N N EC TO R G U 310A C o n tro lle r TI4 8 5 A TI4 8 5 A A R S485/232 M O D EM C O M PU TER A b le to c o n n e c te d re sp e c tive ly GU310A Controller Operation Manual NOTE: Communication cable used high quality shielded twisted-pair cable, and its amount length must not exceed 1000m. The anode and cathode of RS485 in each controller must be correctly connected, and the cable shield only can be grounded at one side. 22 GU310A Controller Operation Manual 10.3 Communication Protocol RS485 mechanism is a kind of network format of character stream signal through between computer and hardware device. When controller working, it adopts 9600 baud rate and MODBUS-RTU communication protocol. When it is working, computer will send out a string of instruction to controller and then waiting for the return data string. NOTE: the maximum word amount of read and write, read is 40, write is 38, and write only can use continued write command 10(hex). Controller Data Cell Address Address $1000 $1001 $1002 $1003 $1004 $1005 $1006 $1007 $1008 $1009 $100A $100B $100C $100D $100E $100F $1010 $1011 $1012 $1013 $1014 $1015 $1016 $1017 $1018 $1019 $101A $101B Byte 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Content L3-N Voltage L2-N Voltage L1-N Voltage L3-L1 Voltage L2-L3 Voltage L1-L2 Voltage Reserve Reserve L1 Current Reserve Reserve L1 PF Frequency L3 VA L2 VA L1 VA L3 W L2 W L1 W L3 VAr L2 Var L1 VAr Tacho OilPress Coolant VBAT VALT AI Unit V V V V V V A A A 0.1Hz kVA kVA kVA kW kW kW kVAr kVAr kVAr RPM kPa ℃ V V mV 23 GU310A Controller Operation Manual $101C 1 $101D 1 $101E 1 $101F 1 $1020 1 $1021 1 $1022 $2001 $2002 $2003 $2004 1 1 1 1 1 Bit0—Oil pressure Bit1—Coolant temp Bit2—Emergency stop Bit3—Remote start signal Bit4—Reserve switch signal Bit0— Bit1— Bit2— Idle output Bit3— Warning output Bit4— Alarm output Bit5— Genset normal running status Bit6—engine start Bit7—engine throttle Bit0— Bit1— Bit2—STARTLED Bit3—OFF LED Bit4—AUTO LED Bit5—MAN LED Bit6— Bit7—STOP LED Bit8— Bit9—Normal running LED Bit10—Charge failure LED Bit11—Fail to start LED Bit12—Low oil pressure LED Bit13—High temperature LED Bit14—Overspeed LED Bit15—Emergency stop LED Palarm (warning code) Alarm 03：Engine stop 04：Engine start 05： Enter into TEST status 06： Enter into MAN status 07： Enter into AUTO status 08：Reset SN Comm Address Language CT V Low Alarm 24 Refer to following failure code V GU310A Controller Operation Manual $2005 $2006 $2007 $2008 $2009 $200A $200B $200C $200D $200E $200F $2010 $2011 $2012 $2014 $2016 $2017 $2018 $2019 $201A $201B $201C $201D $201E $201F $2020 $2021 $2022 $2023 $2024 $2025 $2026 $2027 $2028 $2029 $202A $202B $202C $202D $202E $202F $2030 $2031 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 V Low preALM V High preALM V High Alarm I High preALM I High Alarm Reserve Reserve Reserve Reserve Reserve Reserve Reserve Alarm delay KWH KVArH VT Pair of Poles Nominal speed Pickup frequency Fuel mode T-sensor mode P-sensor mode H-sensor mode Start delay Crank attempt Crank time Crank reset Crank disconnect Idle delay Safety-on delay Cooling delay Stop delay Under SP Alarm Under SP preALM Over SP preALM Over SP Alarm Oil-P Alarm Oil-P preALM Coolant preALM Coolant Alarm Batt low preALM RUNHr Ext．Alarm mode 25 V V V A A S kWh kVArh RPM RPM S S S RPM S S S S RPM RPM RPM RPM kPa kPa ℃ ℃ V HOUR GU310A Controller Operation Manual $2032 $2040 $2041 $2042 $2043 $2044 $2045 $2046 $2047 $2048 $2049 $204A 1 1 1 1 1 1 1 1 1 1 1 1 Ext．Analog V1 V2 V3 I1 I2 I3 Oil pressure Coolant Battery voltage Excitation charging voltage Aux. input voltage 0: V / 1 –2: % Correction Correction Correction Correction Correction Correction Correction Correction Correction Correction Correction $204B ――― $205E are P-sensor data table, according to the resistance (0.1Ω) from small to big, ordered from resistance to corresponding value to resistance. $205F ――― $2072 are T-sensor data table, according to the resistance (0.1Ω) from small to big, ordered from resistance to corresponding value to resistance. $2073 ――― $2086 are Fuel sensor data table, according to the resistance (0.1Ω) from small to big, ordered from resistance to corresponding value to resistance. Appendix: Failure Code Code 0 1 2 3 4 5 6 7 8 Failure Type NO ERROR NO PICKUP OVER SPEED UNDER SPEED P-SENSOR OPEN LOW OILPRESS T-SENSOR OPEN COOLANT TEMP START FAIL Code 9 10 11 12 13 14 26 Failure Type STOP FAIL BATTERY LOW CHARGE FAILURE V LOW V HIGH I HIGH GU310A Controller Operation Manual 11. Preparation before Start the Controller 11.1 Make sure controller is fixed well and its install meet ambient requirement. 11.2 Confirm controller all wrings connection meet electric specification and according with the “typical wiring diagram”, and especially need confirm DC supply source has correct polarity. Otherwise, it maybe damage controller. 11.3 Controller must be grounded well. 11.4 We suggest external install “E- stop” button, connecting E-stop signal input terminal to the N. O. contact of “E- stop” button, and another contact connected to the cathode of battery source. 11.5 Switch on DC working power source, make sure the preset parameters meet practical condition, such as fuel mode, and the setting of high frequency and low frequency, etc. 11.6 If H-sensor is electromagnetic mode sensor, must according to below steps to adjust the speed measuring parameter: Method 1: After switch on power source, set controller on MAN operation mode, the key switch stay at “MAN”. H-sensor input frequency (F) is calculated by the rated speed and the flywheel tooth, F= tooth * Rate speed / 60, just input this calculated value to controller directly and finish setting, detailed steps as following: Operation Description Controller in ready status: READY Continuously press “ ” 2s, enter into parameters setting menu, then LCD display: CT 100 Press“ TCAL 3000 3000 Press “ ” 11 times and then press “ ”, then LCD display: TCAL 3000 PASS ” then LCD display: Key in changed password: “ ”“ ”“ ”“ ”“ ”“ ” This time can press“ ” or “ ” change parameters, input the calculated value of H-sensor input frequency, then LCD according to setting value display: press“ “ ” make confirmation and then continuous press ” 2s can quit parameters setting menu 27 TCAL 3000 3000 TCAL 3000 READY GU310A Controller Operation Manual Method 2: Operation Controller in ready status: Description READY Continuously press “ ” 2s, enter into parameters setting menu, then LCD display: CT 100 Press“ ” 12 times, then LCD display: SETT Press“ ” 1 times again then LCD display: SETT PASS Key in changed password: “ ”“ ”“ ”“ ”“ ”“ ” Start engine, after engine running stable then press“ ”, SETT controller will compare the H-sensor speed with engine voltage frequency immediately, switch to the measuring frequency which under 1500RPM. When “DONE” disappear, finish setting immediately. Press“ press “ SETT DONE ” and then continuously ” 2s quit parameters setting men, stop Genset. NOTE: Must according to above instructions corrected set No.14 (pole of pairs), during the period of adjust the measured speed parameter, the protection of controller is imperfection, operator should take more attention to Genset running status. When abnormal occurs, stop adjust immediately, must check out failure before adjust again. If possible, we recommend the operator install a protection circuit or device in external according to the practical condition. 28 GU310A Controller Operation Manual 12. Troubleshooting Failure Phenomenon Failure Eliminate In “ MAN” mode press “ START” button or in Genset not “AUTO” mode the start remote start input signal is active or in “Test” mode no start action. 1. Check failure LED, or check LCD display to confirm has failure display or not. 2. Check DC voltage on controller no. “23” terminal, if no voltage, check related circuitry fuse. Such as low voltage, use charger charging battery, restart after battery fully charging. 3. Check DC voltage on controller no. “18” terminal when crank, if no voltage, need change controller. 4. Use DC voltage meter measures the cathode contact of the magnet on start motor, if has voltage, it is magnet failure, require change, if no voltage, check the connection of controller to confirm if loose or short. Controller LCD display: “fail to start”, diesel Diesel fail rotates but can not start or diesel to start stop after start operating. Fail to start LED on. 1. Check fuel level. 2. Check DC voltage on controller no. “17” terminal, if no voltage need change controller. 3. Check the connection of fuel control magnet and the voltage on magnet. 4. Check fuse on the side of alternator. 5. Both check fuel manifold and filter jam or not. 6. If has white smoke release from exhaust system, means fuel has gone into engine, but diesel not start. Please refer to “Diesel Manual” for further check. 7. If low ambient temp and has heat start function, please use it. 8. Once failure removed, press “RESET” button to reset control system. 29 GU310A Controller Operation Manual Diesel high temp shutdown Low oil pressure shutdown Diesel overspeed shutdown Underspeed shutdown Controller LCD display: “HIGH TEMPERATURE” , high temperature LED on. 1. Check the T-sensor mode of controller correctly set or not, if error need reset. 2. Check diesel over load or not. 3. Check radiator jam or not. 4. Check fan belt loose or tighten. 5. Check if ambient temperature meets generator usage range. 6. After diesel cooling, check coolant position, do not add a great deal of coolant into diesel before it is not cooling, or will cause serious damage to it. 7. Refer to “Diesel Manual” 8. Once failure removed, press “RESET” button to reset control system. 9. Run Genset 10 minutes under unload condition let it cooling and then load. Controller LCD display: “LOW OIL PRESSURE”, low Oil pressure LED on. 1. Check the P-sensor mode of controller is correctly set or not, if error need reset. 2. Check fuel level, if oil not enough, add oil. 3. Refer to “Diesel Manual” 4. Check oil pressure switch by test meter, if any problems change it. 5. Once failure removed, press “RESET” button to reset control system. Controller LCD display ： “OVER SPEED”, overspeed LED on. 1. Check the pickup frequency of controller is correctly set or not, if error require reset. 2. Check governor speed shaft moved or not, if moved correct it. 3. If installed electronics governor, check if level shaft can freely move, correct it if necessary. 4. Refer to “Diesel Manual”. 5. Once failure removed, press “RESET” button to reset control system. LCD display low frequency failure 1. Check the frequency input value of magnetic pickup on controller correctly set or not, if error need reset. 2. Check supply fuels enough or not. 3. Check governor speed shaft moved or not, if moved correct it. 4. If installed electronics governor, check if level shaft can freely move, correct it if necessary. 5. Adjust diesel speed when it is running. 6. Check the parameters setting for underspeed failure right or not. 30 GU310A Controller Operation Manual Low voltage shutdown LCD display low voltage failure High voltage shutdown LCD display high voltage failure Engine fail not stop Generator still running after stop, LCD display ”SPFL” 1. Switch off load on alternator, remove failure after shutdown and restart unit. 2. Check the setting value of Gen low voltage failure, make sure correct data. 3. If voltage still low, adjust generator output voltage by setting potentiometer recover to normal value. 4. Refer to “Alternator Manual” 1. Switch off load on alternator, remove failure after shutdown and restart unit. 2. Check the setting value of Gen high voltage failure, make sure correct data. 3. Check the measuring voltage of controller, if voltage normal, check load and make sure it is non capacitive (power factor compensation device will casual cause a capacitive load). 4. If voltage still low, adjust generator output voltage by setting potentiometer recover to normal value. 5. Refer to “Alternator Manual” 1. Check fuel solenoid valve on diesel (or level shaft), make sure oil channel is completely closed under close status. 2. Check fuel control solenoid, change it if necessary. 13. Technical Parameters DC working power source Voltage range: 12V/24V （8~35V）Continued Max working current：@12V 0.4A, @24V 0.2A AC input voltage：phase voltage15~300VAC RMS（AC frequency≥26 Hz） AC input frequency：3~70Hz（voltage≥15V） Control relay output 3A/30VDC Working ambient temperature -20~50℃ Storage ambient temperature -40~80℃ Version：034A081025 31