CRE Technology GENSYS 2.0 - Complete Wiring Diagram; Figure 34

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A53 Z0 9 0020 L En Technical documentation

Chapter : Installing and commissioning a GENSYS 2.0 application

9.2

Complete wiring diagram

Figure 34 - Complete wiring diagram

Main Page

Table of Contents6
Overview14
European Union Directive Compliance Ce14
Environment14
Characteristics15
Figure 1 - Panel Cut-Out15
Gensys 2.0 Core16
Description16
User Interface with Ardm 2.016
User Interface Using Digital Inputs16
Table 1 - Digital Input Functions16
Gensys 2.0 Lt17
Description18
Front Panel18
Figure 2 - GENSYS 2.0 Front Panel18
Table 2 - LCD Screen Characteristics18
Table 3 - Display Panel Keys19
Table 4 - Service Panel Keys20
Table 5 - Control Panel Keys21
Table 6 - Control Panel Led's22
Rear Panel - Connectors23
Figure 3 - Rear Panel23
Table 7 -Inputs/ Outputs Description29
User Interface30
Figure 4 - User Interface30
Figure 5 - Default Screen Saver30
Security Level and Password31
Figure 6 - Password Input Mode Display31
Table 8 - Authorization Levels and Passwords31
Local Navigation32
Figure 7 - Main Menu32
Figure 8 - Browser Link Description32
Figure 9 - Contextual Keys for Input Mode33
Remote Control Using Apc (Ethernet Connection )34
Figure 10 - CRE Config Software34
Figure 11 - Typical GENSYS 2.0 Web Pages35
Figure 12 - Ethernet Configuration Page39
Operating Mode40
Assisted Manual Mode40
Figure 13 - Assisted Manual Mode Without Main Paralleling41
Figure 14 - Assisted Manual Mode with Main Paralleling42
Automatic Mode43
Test Mode43
Semi-Automatic Mode44
Figure 15 - Semi-Automatic Mode44
Manual Mode45
Start Sequence46
Figure 16 - Typical Start Sequence for Fuel Engines46
Predefined Configuration48
Single Generator in Change-Over Mode48
Figure 17 - Power Plant in Change-Over Mode Without Paralleling48
Table 9 - Typical Basic Change-Over Configuration48
Figure 18 - Typical Sequence in Change-Over Mode on Mains Failure49
Figure 19 - Typical Sequence in Change-Over Mode on Start Request50
Single Generator in No-Change-Over Mode51
Figure 20 - Power Plant in Change-Over Without Paralleling51
Table 10 - Typical no Change over Basic Configuration51
Generator Paralleling with Digital Bus52
Figure 21 - Power Plant with Several Generators52
Table 11 - Typical Basic Multi Generator Configuration52
Generators Paralleling with Gensys 2.0 and Parallel Line Modules53
Figure 22 - Generator Paralleling with Parallel Lines53
Table 12 - Typical Basic Configuration for GENSYS 2.0 with Parallel Line Modules53
Multiple Generators with Static Paralleling54
Figure 23 - Static Paralleling with 4 Generators Coupled Together in Emergency Situation54
Figure 24 - Example with 4 Generators Paralleled Together in Emergency Situation54
Table 13 - Paralleling with Mains55
Single Generator Paralleled with Mains56
Figure 25 - Paralleling with Mains56
Figure 26 - Typical Sequence in no Break CO Mode on Start Request57
Table 14 - Typical Basic Mains Paralleling Configuration57
Figure 27 - Typical Sequence in no Break CO Mode on Mains Failure58
Figure 28 - Typical Sequence in Permanent Mode on Mains Failure59
Figure 29 -Typical Sequence in Permanent Mode on Start Request60
Power Plant Paralleled with Mains Using Master 2.0 or Gcr61
Figure 30 - Power Plant Paralleling with Mains61
Table 15 - Paralleling with Mains Configuration61
Figure 31 - GCR  GENSYS 2.0 Wiring Diagram62
Table 16 - GENSYS 2.0 / GCR Configuration62
Power Plant Paralleled with Several Mains Using Master 2.0 or Gcr by Mains63
Figure 32 - Power Plant Paralleling with Several Mains63
Table 17 - Power Plant Paralleling with Several Mains Configuration63
Installing and Commissioning a Gensys 2.0 Application64
Minimum Wiring Diagram64
Figure 33 - Minimum Wiring Diagram64
Complete Wiring Diagram65
Figure 34 - Complete Wiring Diagram65
Installation Instructions66
Figure 35 - Mounting Kit66
Figure 36 - Mounting Brackets on GENSYS 2.066
Figure 37 - Earth Grounding67
Figure 38 - Power Supply Circuit Breaker67
Before Commissioning68
During Commissioning68
Figure 39 - Interconnection of All Battery Negatives68
Dedicated I/O Lines72
Speed Governor Interface72
Figure 40 - Speed Output72
Figure 41 - Connection with EFC Cummins75
Table 18 - Speed Governor Parameters75
Figure 42 - PWM Dynamic76
Figure 43 - Caterpillar PEEC and ADEM Connections76
Table 19 - PWM Parameters76
Speed and Voltage Control with Contacts/Pulses77
Figure 44 - Speed and Voltage Control with Contacts / Pulses77
Table 20 - Parameters Speed and Voltage Control with Contacts / Pulses77
Figure 45 - Speed and Voltage Control Pulses79
Analogue AVR (Auto Voltage Regulatior) Control80
Figure 46 - Voltage Output80
Table 21 - AVR: Gain and Offset80
Table 22 - AVR Parameters82
Relay Output83
Figure 47 - Breakers Wiring83
Table 23 - Used Variables for Breakers Setting83
Table 24 - Breaker Control Configuration84
Figure 48- Undervoltage Coil85
Crank/Fuel/Starter 2/ Starter 3 Functions86
Water Preheat/ Pre-Lubrication/ Pre-Glow Functions87
Figure 49 - Connections for Water Preheat, Pre Lubrication and Pre Glow87
Air Fan88
Figure 50 - Connection for Air Fans88
Fuel Filling/ Coolant Filling/ Oil Filling89
Figure 51 - Connections for Filling89
Table 25 - Filling Parameters in Automatic Mode89
Figure 52 - Fuel Filling Diagram90
Table 26 - Filling Parameters in Automatic Mode with Equations90
Analogue Load Sharing Line91
Figure 53 - Filling Example91
Figure 54 - Wiring Parallel Lines91
Watchdog Output92
O Lines93
Digital Input93
Table 27 - Input Parameters93
Table 28 - Input Validity Domain94
Table 29 - Input Direction Domain94
Digital Outputs97
Table 30 - Input Functions97
Analogue Input (Via CRE Config Software)101
Table 31 - Digital Outputs Function101
Table 32 - Oil Pressure Calibration Points102
Table 33 - Water Temp Calibration Points103
Protections106
Disable106
Generator Electrical Fault106
Mains Electrical Fault106
Alarm106
Fault (Soft Shut Down)106
Security (Hard Shutdown)106
Droop106
Help + Fault (Soft Shut Down)106
Help + Gen. Electrical Fault107
Potential Alarms/Faults List107
Table 34 - Potential Alarm/Fault List110
Additional Functions111
Load Sharing Using Integral (De-Drooping)111
Operator Controlled Return to Mains113
Mains Electrical Fault113
Table 35 -Integral Inhibition113
Table 36 -Mains Electrical Fault113
Figure 55 - Change over with One Digital Input Setup as "Mains Electrical Fault114
Generator Electrical Fault115
Figure 56 - Permanent Mains Paralleling with One Digital Input Setup as "Mains Electrical Fault115
Figure 57 - Permanent Mains Paralleling and Generator Electrical Fault115
Table 37 - Generator Electrical Fault115
Gensys 2.0 with External Automatic Start Module116
Figure 58 - Wiring GENSYS 2.0 and Auto Start Module116
Table 38 - Wiring GENSYS 2.0 and Auto Start Module116
Figure 59 - External Start Sequence117
Remote Start Upon External Pulse118
Safety Inhibitions119
Use of Bsm II with Gensys 2.0121
Figure 60 - Wiring GENSYS 2.0 to BSM II121
Gensys 2.0 with Tem Compact124
Figure 61 - Wiring GENSYS 2.0 TEM124
G59 Norm (Access Level -1)125
Scada125
Table 39 - Wiring GENSYS 2.0 TEM125
How to Set Agpid126
Figure 62 - Typical GPID Controller126
Automatic Load / Unload127
Figure 63 - Automatic Load/Unload128
Figure 64- Automatic Load/Unload Sequence128
Table 40 - Parameters Load/Unload Threshold129
Figure 65 - Unload According Power130
Table 41 -Parameters Used During Load/Unload According to Power130
Heavy Consumer (Marine Sequence)131
Table 42 - Settings Heavy Consumer131
Figure 66 - Heavy Consumer Control with Active Power Analysis132
Figure 67 - Heavy Consumer Control with Number of Gensets Analysis132
Non-Essential Consumer Trip (Marine Sequence)133
Table 43 - Settings Non-Essential Consumer133
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 Setting135
Figure 71 - Non Essential Consumer Trip Timers135
Figure 72 - Non Essential Consumer Trip Diagram135
Phase Offset (Dyn11 and Other)136
Figure 73 - Phase Offset Example136
Voltage System (120° Three Phases , 180° Two Phases , Single Phase )137
Figure 74 - Voltage System137
Table 44 - Voltage System137
Maintenance Cycle138
Front Panel Inhibition139
Table 45 - Front Panel Inhibition139
Text File & Plc140
Introduction140
Variable Naming140
Text File Description141
Table 46 - Label Definition Bloc142
Table 47 - Custom Logo Labels143
Table 48 - Accuracy Codes144
Table 49 - Units Codes144
Table 50 - Variables with Customizable Unit/Accuracy Values146
Plc Programming Language147
Variables149
Table 51 - Available Instructions149
Syntax Examples150
Gensys 1.0 - Gensys 2.0 Compatibility152
Resetting to Factory Parameters154
Donwload Acustom Language File154
Communication155
Can Bus Good Practices155
Figure 75 - Network Topologies155
Table 52 - DB9 Pin out155
Figure 76 - Example of CAN Connection between 3 Modules156
Table 53 - Maximal Length / Communication Speed156
Table 54 - Speed Communication (COM1 & COM2)156
COM1: CRE Technology Inter-Modules CAN Bus157
Table 55 - CAN Bus Fault157
Figure 77- Example CAN Bus Fault158
Figure 78 -Broadcasting Data between Multiple Units158
Table 56 - Broadcast Data Sent on Inter Module CAN Bus159
Table 57 - Broadcast Data Received from Inter Module CAN Bus160
Figure 79 - Analogue and Digital Data Broadcast Example161
Table 58 - Analogue and Digital Data Broadcast Example161
Table 59 - CAN Bus Inhibition Variables162
Figure 80 - CAN Bus Inhibition Schematic (Example)163
Table 60 - Tie Breaker Example163
COM2: CAN Protocols (Canopen, J1939, MTU MDEC)164
Figure 81 - Modular Remote Canopen I/O Extension Module165
Figure 82 - Canopen Coupler Wiring165
Table 61 - Canopen Input and Output Variables166
Table 62 - Canopen Configuration Example167
Table 63 - J1939: Analog Measure or J1939168
Table 64 - J1939: Manufacturer/Ecu List169
Table 65 - J1939: Measurement List172
Table 66 - Unknown SPN/FMI173
Table 67 - J1939: Alarms/Faults List174
Table 68 - J1939: Trames RX Custom175
Table 69 - J1939: Custom Engine Configuration176
Figure 83 - MDEC: GENSYS2.0 Connexion178
Table 70 - MDEC Connexion178
Table 71 - Important Parameters179
Figure 84 - MDEC Screens180
Com3: Usb182
Com4: Ethernet182
Com5: Modbus Rtu on Serial Port Rs485184
Table 72- Modbus Functions Handled184
Table 73: 32 Bits Variables (Use Function 0X10)185
Table 74 - Modbus Configuration Parameters185
Table 75 - COM5 Terminals185
Table 76 - Modbus Parameters for Alerm/Fault Management186
Table 77 - Modbus Communication Example187
Com6: Sd Card188
Table 78 - SD Card Backup - File Size191
Support/Troubleshooting195
Menu Overview198
Menu Introduction198
Display Menu198
Figure 85 - Synchroscope202
Table 79 - Active Timers 1/2204
Table 80 - Active Timers 2/2204
Configuration Menu205
Table 81 - Power Plant Configuration206
Table 82 - Automatic Load/Unload Configuration207
Table 83 - Load Dep Stop Configuration207
Table 84 - Generator ½ Configuration208
Table 85 - Generator 2/2 Configuration208
Table 86 - Generator Electrical Fault Configuration209
Table 87 - AVR Control Configuration209
Table 88 - Mains/Bus Configuration210
Table 89 - Mains Electrical Fault Configuration210
Table 90 - External/Internal Start Sequence Configuration211
Table 91 - Configuration Reglages Démarreur211
Table 92 - Checking before Starting Configuration211
Table 93 - Speed Control Settings Configuration212
Table 94 - Speed Governor Control Configuration212
Table 95 - J1939/MDEC Configuration213
Table 96 - J1939 Protection Configuration213
Table 97 - Generator Protections Configuration214
Table 98 - Mains Protections Configuration214
Table 99 - Engine/Battery Protections Configurations215
Table 100 - Digital Outputs Configuration216
Table 101 - Relay Outputs Configuration217
Table 102 - Breakers Configuration217
Table 103 - Engine Timers Configuration218
Table 104 - Mains Timers Configuration219
Table 105 - Synchro Check Relay Configuration219
Table 106 - Phase Synchro PID Configuration220
Table 107 - Kw Sharing Loop PID Configuration221
Table 108 - Ramp/Constant Kw PID Configuration221
Table 109 - PID Hz Loop Configuration222
Table 110 - PID Kvar Sharing Loop222
Table 111 - PID Cos(Φ) Loop Configuration222
Table 112 - Reset of Maintenance Cycle223
Figure 86 - Modification by Variable Number224
System Menu225
Table 113 - Date and Time Settings225
Table 114 - Meters Reset225
Table 115 - Meters Preset226
Table 116 - Screen Saver Mode227
Table 117 - Screen Saver227
Table 118 - Language Selection228
Table 119 - Ethernet Configuration229
Table 120 - Modbus Configuration229
Figure 87 - Modbus Rights Access Screen230
Table 121 - SD Card Configuration230
Figure 88 - Compilation Result Screen233
Figure 89 - Download Logo Screen233
Dedicated Screens234
Figure 90 - Faults Screen235
Figure 91 - Information Screen236
Useful Information237
Figure 92 - Speed Regulation Details237
Figure 93 - Voltage Regulation Details238
Precautions239
Figure 94 - Several Generators Warning239
Figure 95 - One Generator with Mains Warning239
References241
Product Reference241
Options241
Accessories242
Table 122 - Cable Reference242
Table 123 - CRE Technology Product Reference242
Cre Technology243
Figure 96 - Access to CRE Technology243
Figure 97 - CRE Technology Distributors244

CRE Technology GENSYS 2.0 - Complete Wiring Diagram; Figure 34 - Complete Wiring Diagram

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