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GENSYS 2.0
CRE Technology GENSYS 2.0 User Manual
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“All
-
in-one genset con
tro
l
and
para
lleling unit ”
CRE Tec
hnology believes t
hat
all information provided h
erein is correc
t an
d reliable and reserves t
he right
to
update at
any time.
CRE Tec
hnology does no
t assume any respon
sibility for its use. E
& O E.
Technic
al doc
umentati
on
GENSYS
2.0
GENSYS
2.0
COR
E
GENSYS
2.0
LT
Part Num
ber:
A53 Z0 9
0020
2
Table of Contents
Table of Contents
6
Overview
14
European Union Directive Compliance Ce
14
Environment
14
Characteristics
15
Figure 1 - Panel Cut-Out
15
Gensys 2.0 Core
16
Description
16
User Interface with Ardm 2.0
16
User Interface Using Digital Inputs
16
Table 1 - Digital Input Functions
16
Gensys 2.0 Lt
17
Description
18
Front Panel
18
Figure 2 - GENSYS 2.0 Front Panel
18
Table 2 - LCD Screen Characteristics
18
Table 3 - Display Panel Keys
19
Table 4 - Service Panel Keys
20
Table 5 - Control Panel Keys
21
Table 6 - Control Panel Led's
22
Rear Panel - Connectors
23
Figure 3 - Rear Panel
23
Table 7 -Inputs/ Outputs Description
29
User Interface
30
Figure 4 - User Interface
30
Figure 5 - Default Screen Saver
30
Security Level and Password
31
Figure 6 - Password Input Mode Display
31
Table 8 - Authorization Levels and Passwords
31
Local Navigation
32
Figure 7 - Main Menu
32
Figure 8 - Browser Link Description
32
Figure 9 - Contextual Keys for Input Mode
33
Remote Control Using Apc (Ethernet Connection )
34
Figure 10 - CRE Config Software
34
Figure 11 - Typical GENSYS 2.0 Web Pages
35
Figure 12 - Ethernet Configuration Page
39
Operating Mode
40
Assisted Manual Mode
40
Figure 13 - Assisted Manual Mode Without Main Paralleling
41
Figure 14 - Assisted Manual Mode with Main Paralleling
42
Automatic Mode
43
Test Mode
43
Semi-Automatic Mode
44
Figure 15 - Semi-Automatic Mode
44
Manual Mode
45
Start Sequence
46
Figure 16 - Typical Start Sequence for Fuel Engines
46
Predefined Configuration
48
Single Generator in Change-Over Mode
48
Figure 17 - Power Plant in Change-Over Mode Without Paralleling
48
Table 9 - Typical Basic Change-Over Configuration
48
Figure 18 - Typical Sequence in Change-Over Mode on Mains Failure
49
Figure 19 - Typical Sequence in Change-Over Mode on Start Request
50
Single Generator in No-Change-Over Mode
51
Figure 20 - Power Plant in Change-Over Without Paralleling
51
Table 10 - Typical no Change over Basic Configuration
51
Generator Paralleling with Digital Bus
52
Figure 21 - Power Plant with Several Generators
52
Table 11 - Typical Basic Multi Generator Configuration
52
Generators Paralleling with Gensys 2.0 and Parallel Line Modules
53
Figure 22 - Generator Paralleling with Parallel Lines
53
Table 12 - Typical Basic Configuration for GENSYS 2.0 with Parallel Line Modules
53
Multiple Generators with Static Paralleling
54
Figure 23 - Static Paralleling with 4 Generators Coupled Together in Emergency Situation
54
Figure 24 - Example with 4 Generators Paralleled Together in Emergency Situation
54
Table 13 - Paralleling with Mains
55
Single Generator Paralleled with Mains
56
Figure 25 - Paralleling with Mains
56
Figure 26 - Typical Sequence in no Break CO Mode on Start Request
57
Table 14 - Typical Basic Mains Paralleling Configuration
57
Figure 27 - Typical Sequence in no Break CO Mode on Mains Failure
58
Figure 28 - Typical Sequence in Permanent Mode on Mains Failure
59
Figure 29 -Typical Sequence in Permanent Mode on Start Request
60
Power Plant Paralleled with Mains Using Master 2.0 or Gcr
61
Figure 30 - Power Plant Paralleling with Mains
61
Table 15 - Paralleling with Mains Configuration
61
Figure 31 - GCR GENSYS 2.0 Wiring Diagram
62
Table 16 - GENSYS 2.0 / GCR Configuration
62
Power Plant Paralleled with Several Mains Using Master 2.0 or Gcr by Mains
63
Figure 32 - Power Plant Paralleling with Several Mains
63
Table 17 - Power Plant Paralleling with Several Mains Configuration
63
Installing and Commissioning a Gensys 2.0 Application
64
Minimum Wiring Diagram
64
Figure 33 - Minimum Wiring Diagram
64
Complete Wiring Diagram
65
Figure 34 - Complete Wiring Diagram
65
Installation Instructions
66
Figure 35 - Mounting Kit
66
Figure 36 - Mounting Brackets on GENSYS 2.0
66
Figure 37 - Earth Grounding
67
Figure 38 - Power Supply Circuit Breaker
67
Before Commissioning
68
During Commissioning
68
Figure 39 - Interconnection of All Battery Negatives
68
Dedicated I/O Lines
72
Speed Governor Interface
72
Figure 40 - Speed Output
72
Figure 41 - Connection with EFC Cummins
75
Table 18 - Speed Governor Parameters
75
Figure 42 - PWM Dynamic
76
Figure 43 - Caterpillar PEEC and ADEM Connections
76
Table 19 - PWM Parameters
76
Speed and Voltage Control with Contacts/Pulses
77
Figure 44 - Speed and Voltage Control with Contacts / Pulses
77
Table 20 - Parameters Speed and Voltage Control with Contacts / Pulses
77
Figure 45 - Speed and Voltage Control Pulses
79
Analogue AVR (Auto Voltage Regulatior) Control
80
Figure 46 - Voltage Output
80
Table 21 - AVR: Gain and Offset
80
Table 22 - AVR Parameters
82
Relay Output
83
Figure 47 - Breakers Wiring
83
Table 23 - Used Variables for Breakers Setting
83
Table 24 - Breaker Control Configuration
84
Figure 48- Undervoltage Coil
85
Crank/Fuel/Starter 2/ Starter 3 Functions
86
Water Preheat/ Pre-Lubrication/ Pre-Glow Functions
87
Figure 49 - Connections for Water Preheat, Pre Lubrication and Pre Glow
87
Air Fan
88
Figure 50 - Connection for Air Fans
88
Fuel Filling/ Coolant Filling/ Oil Filling
89
Figure 51 - Connections for Filling
89
Table 25 - Filling Parameters in Automatic Mode
89
Figure 52 - Fuel Filling Diagram
90
Table 26 - Filling Parameters in Automatic Mode with Equations
90
Analogue Load Sharing Line
91
Figure 53 - Filling Example
91
Figure 54 - Wiring Parallel Lines
91
Watchdog Output
92
O Lines
93
Digital Input
93
Table 27 - Input Parameters
93
Table 28 - Input Validity Domain
94
Table 29 - Input Direction Domain
94
Digital Outputs
97
Table 30 - Input Functions
97
Analogue Input (Via CRE Config Software)
101
Table 31 - Digital Outputs Function
101
Table 32 - Oil Pressure Calibration Points
102
Table 33 - Water Temp Calibration Points
103
Protections
106
Disable
106
Generator Electrical Fault
106
Mains Electrical Fault
106
Alarm
106
Fault (Soft Shut Down)
106
Security (Hard Shutdown)
106
Droop
106
Help + Fault (Soft Shut Down)
106
Help + Gen. Electrical Fault
107
Potential Alarms/Faults List
107
Table 34 - Potential Alarm/Fault List
110
Additional Functions
111
Load Sharing Using Integral (De-Drooping)
111
Operator Controlled Return to Mains
113
Mains Electrical Fault
113
Table 35 -Integral Inhibition
113
Table 36 -Mains Electrical Fault
113
Figure 55 - Change over with One Digital Input Setup as "Mains Electrical Fault
114
Generator Electrical Fault
115
Figure 56 - Permanent Mains Paralleling with One Digital Input Setup as "Mains Electrical Fault
115
Figure 57 - Permanent Mains Paralleling and Generator Electrical Fault
115
Table 37 - Generator Electrical Fault
115
Gensys 2.0 with External Automatic Start Module
116
Figure 58 - Wiring GENSYS 2.0 and Auto Start Module
116
Table 38 - Wiring GENSYS 2.0 and Auto Start Module
116
Figure 59 - External Start Sequence
117
Remote Start Upon External Pulse
118
Safety Inhibitions
119
Use of Bsm II with Gensys 2.0
121
Figure 60 - Wiring GENSYS 2.0 to BSM II
121
Gensys 2.0 with Tem Compact
124
Figure 61 - Wiring GENSYS 2.0 TEM
124
G59 Norm (Access Level -1)
125
Scada
125
Table 39 - Wiring GENSYS 2.0 TEM
125
How to Set Agpid
126
Figure 62 - Typical GPID Controller
126
Automatic Load / Unload
127
Figure 63 - Automatic Load/Unload
128
Figure 64- Automatic Load/Unload Sequence
128
Table 40 - Parameters Load/Unload Threshold
129
Figure 65 - Unload According Power
130
Table 41 -Parameters Used During Load/Unload According to Power
130
Heavy Consumer (Marine Sequence)
131
Table 42 - Settings Heavy Consumer
131
Figure 66 - Heavy Consumer Control with Active Power Analysis
132
Figure 67 - Heavy Consumer Control with Number of Gensets Analysis
132
Non-Essential Consumer Trip (Marine Sequence)
133
Table 43 - Settings Non-Essential Consumer
133
Figure 68 - Non Essential Consumer Trip Alarm (1)
134
Figure 69 - Non Essential Consumer Trip Alarm (2)
134
Figure 70- Non Essential Consumer Trip Output Setting
135
Figure 71 - Non Essential Consumer Trip Timers
135
Figure 72 - Non Essential Consumer Trip Diagram
135
Phase Offset (Dyn11 and Other)
136
Figure 73 - Phase Offset Example
136
Voltage System (120° Three Phases , 180° Two Phases , Single Phase )
137
Figure 74 - Voltage System
137
Table 44 - Voltage System
137
Maintenance Cycle
138
Front Panel Inhibition
139
Table 45 - Front Panel Inhibition
139
Text File & Plc
140
Introduction
140
Variable Naming
140
Text File Description
141
Table 46 - Label Definition Bloc
142
Table 47 - Custom Logo Labels
143
Table 48 - Accuracy Codes
144
Table 49 - Units Codes
144
Table 50 - Variables with Customizable Unit/Accuracy Values
146
Plc Programming Language
147
Variables
149
Table 51 - Available Instructions
149
Syntax Examples
150
Gensys 1.0 - Gensys 2.0 Compatibility
152
Resetting to Factory Parameters
154
Donwload Acustom Language File
154
Communication
155
Can Bus Good Practices
155
Figure 75 - Network Topologies
155
Table 52 - DB9 Pin out
155
Figure 76 - Example of CAN Connection between 3 Modules
156
Table 53 - Maximal Length / Communication Speed
156
Table 54 - Speed Communication (COM1 & COM2)
156
COM1: CRE Technology Inter-Modules CAN Bus
157
Table 55 - CAN Bus Fault
157
Figure 77- Example CAN Bus Fault
158
Figure 78 -Broadcasting Data between Multiple Units
158
Table 56 - Broadcast Data Sent on Inter Module CAN Bus
159
Table 57 - Broadcast Data Received from Inter Module CAN Bus
160
Figure 79 - Analogue and Digital Data Broadcast Example
161
Table 58 - Analogue and Digital Data Broadcast Example
161
Table 59 - CAN Bus Inhibition Variables
162
Figure 80 - CAN Bus Inhibition Schematic (Example)
163
Table 60 - Tie Breaker Example
163
COM2: CAN Protocols (Canopen, J1939, MTU MDEC)
164
Figure 81 - Modular Remote Canopen I/O Extension Module
165
Figure 82 - Canopen Coupler Wiring
165
Table 61 - Canopen Input and Output Variables
166
Table 62 - Canopen Configuration Example
167
Table 63 - J1939: Analog Measure or J1939
168
Table 64 - J1939: Manufacturer/Ecu List
169
Table 65 - J1939: Measurement List
172
Table 66 - Unknown SPN/FMI
173
Table 67 - J1939: Alarms/Faults List
174
Table 68 - J1939: Trames RX Custom
175
Table 69 - J1939: Custom Engine Configuration
176
Figure 83 - MDEC: GENSYS2.0 Connexion
178
Table 70 - MDEC Connexion
178
Table 71 - Important Parameters
179
Figure 84 - MDEC Screens
180
Com3: Usb
182
Com4: Ethernet
182
Com5: Modbus Rtu on Serial Port Rs485
184
Table 72- Modbus Functions Handled
184
Table 73: 32 Bits Variables (Use Function 0X10)
185
Table 74 - Modbus Configuration Parameters
185
Table 75 - COM5 Terminals
185
Table 76 - Modbus Parameters for Alerm/Fault Management
186
Table 77 - Modbus Communication Example
187
Com6: Sd Card
188
Table 78 - SD Card Backup - File Size
191
Support/Troubleshooting
195
Menu Overview
198
Menu Introduction
198
Display Menu
198
Figure 85 - Synchroscope
202
Table 79 - Active Timers 1/2
204
Table 80 - Active Timers 2/2
204
Configuration Menu
205
Table 81 - Power Plant Configuration
206
Table 82 - Automatic Load/Unload Configuration
207
Table 83 - Load Dep Stop Configuration
207
Table 84 - Generator ½ Configuration
208
Table 85 - Generator 2/2 Configuration
208
Table 86 - Generator Electrical Fault Configuration
209
Table 87 - AVR Control Configuration
209
Table 88 - Mains/Bus Configuration
210
Table 89 - Mains Electrical Fault Configuration
210
Table 90 - External/Internal Start Sequence Configuration
211
Table 91 - Configuration Reglages Démarreur
211
Table 92 - Checking before Starting Configuration
211
Table 93 - Speed Control Settings Configuration
212
Table 94 - Speed Governor Control Configuration
212
Table 95 - J1939/MDEC Configuration
213
Table 96 - J1939 Protection Configuration
213
Table 97 - Generator Protections Configuration
214
Table 98 - Mains Protections Configuration
214
Table 99 - Engine/Battery Protections Configurations
215
Table 100 - Digital Outputs Configuration
216
Table 101 - Relay Outputs Configuration
217
Table 102 - Breakers Configuration
217
Table 103 - Engine Timers Configuration
218
Table 104 - Mains Timers Configuration
219
Table 105 - Synchro Check Relay Configuration
219
Table 106 - Phase Synchro PID Configuration
220
Table 107 - Kw Sharing Loop PID Configuration
221
Table 108 - Ramp/Constant Kw PID Configuration
221
Table 109 - PID Hz Loop Configuration
222
Table 110 - PID Kvar Sharing Loop
222
Table 111 - PID Cos(Φ) Loop Configuration
222
Table 112 - Reset of Maintenance Cycle
223
Figure 86 - Modification by Variable Number
224
System Menu
225
Table 113 - Date and Time Settings
225
Table 114 - Meters Reset
225
Table 115 - Meters Preset
226
Table 116 - Screen Saver Mode
227
Table 117 - Screen Saver
227
Table 118 - Language Selection
228
Table 119 - Ethernet Configuration
229
Table 120 - Modbus Configuration
229
Figure 87 - Modbus Rights Access Screen
230
Table 121 - SD Card Configuration
230
Figure 88 - Compilation Result Screen
233
Figure 89 - Download Logo Screen
233
Dedicated Screens
234
Figure 90 - Faults Screen
235
Figure 91 - Information Screen
236
Useful Information
237
Figure 92 - Speed Regulation Details
237
Figure 93 - Voltage Regulation Details
238
Precautions
239
Figure 94 - Several Generators Warning
239
Figure 95 - One Generator with Mains Warning
239
References
241
Product Reference
241
Options
241
Accessories
242
Table 122 - Cable Reference
242
Table 123 - CRE Technology Product Reference
242
Cre Technology
243
Figure 96 - Access to CRE Technology
243
Figure 97 - CRE Technology Distributors
244
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CRE Technology GENSYS 2.0 Specifications
General
Brand
CRE Technology
Model
GENSYS 2.0
Category
Control Unit
Language
English
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