PRODUCT USER GUIDE - governors-america.com€¦ · PRODUCT USER GUIDE GNS2000 GNS2000E GNS2500 & GNS2500E . GNS2000 / GNS2500, Product User Guide PUG4123_A This document is subject

ENGINE

GOVERNING

SYSTEMS

GNS2000 / GNS2500 Genset Controller

Governors America Corp., 720 Silver Street, Agawam, MA 01001 phone: 413.786.5600, fax: 413.789.7736

[email protected] www.governors-america.com

PRODUCT USER GUIDE

GNS2000

GNS2000E

GNS2500 & GNS2500E

http://www.governors-america.com

GNS2000 / GNS2500, Product User Guide

PUG4123_A

This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item

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Table of Contents

1.0 General Information ...................................................................................................... 6

1.1 Description .................................................................................................................................................... 6 1.2 Product Features........................................................................................................................................... 6 1.3 Product Functions ......................................................................................................................................... 6 1.4 GNS2000 Flexibility/Family Members ........................................................................................................... 7 1.5 GNS2500 Flexibility/Family Members ........................................................................................................... 8 1.6 “E” Versions of GNS...................................................................................................................................... 8

2.0 Installation ..................................................................................................................... 9

2.1 What’s in the box........................................................................................................................................... 9 2.2 Mounting Diagrams ..................................................................................................................................... 10

2.2.1 Hole Pattern and panel cutout for GNS2X02, GNS2X04, GNS2X02D, and GNS2X04D .................. 10 2.2.2 GNS2X04B – Din Mount..................................................................................................................... 11 2.2.3 GNS2X04B – Direct Mount................................................................................................................. 12

2.3 SYSTEM Wiring .......................................................................................................................................... 13 2.3.1 GNS2000 Sample Wiring Diagram..................................................................................................... 13 2.3.2 GNS2500 Sample Wiring Diagram..................................................................................................... 14 2.3.3 Battery Wiring ..................................................................................................................................... 15 2.3.4 D+ Wiring............................................................................................................................................ 15 2.3.5 Binary Input Wiring ............................................................................................................................. 15 2.3.6 Magnetic Pickup Wiring ...................................................................................................................... 16 2.3.7 Relay Wiring ....................................................................................................................................... 16 2.3.8 Generator & Mains Voltage Wiring..................................................................................................... 16 2.3.9 Analog Input Wiring ............................................................................................................................ 17 2.3.10 Binary Output Wiring .......................................................................................................................... 17 2.3.11 CAN/J1939 Wiring .............................................................................................................................. 17 2.3.12 RS-232/RS-485 Wiring ....................................................................................................................... 18 2.3.13 Factory Installed Internal Modem Wiring............................................................................................ 18

3.0 Operation Description and Configuration................................................................. 19

3.1 Configuring the GNS for your application.................................................................................................... 19 3.2 Configuring the GNS for Battery Connection, Metering, and Protection..................................................... 19 3.3 Connecting the GNS for Emergency Stop .................................................................................................. 21 3.4 Configuring the GNS to work with an Alternator (D+) ................................................................................. 23 3.5 Configuring the GNS to Control Operating Modes...................................................................................... 26 3.6 Configuring the GNS to work with your engine ........................................................................................... 29

3.6.1 Engine Start/Stop Control Cycle......................................................................................................... 29 3.6.2 Stopped Stage.................................................................................................................................... 31 3.6.3 Prelube Stage..................................................................................................................................... 31 3.6.4 Prestart Stage..................................................................................................................................... 31 3.6.5 Crank Stage........................................................................................................................................ 31 3.6.6 Idle Stage............................................................................................................................................ 32 3.6.7 Voltage Detect Delay Stage (GNS2000 Only).................................................................................... 32 3.6.8 Running Stage.................................................................................................................................... 32 3.6.9 Supplying Load Stage ........................................................................................................................ 32 3.6.10 Cool Down Stage................................................................................................................................ 33 3.6.11 After Cool Stage ................................................................................................................................. 33 3.6.12 Engine Types...................................................................................................................................... 33


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3.7 Configuring the GNS for Engine Speed Metering and Protection............................................................... 34 3.8 Configuring the GNS to run Prelube Stage................................................................................................. 37 3.9 Configuring the GNS to run Prestart Stage................................................................................................. 39 3.10 Configuring the GNS to Start and Stop Engine........................................................................................... 41 3.11 Configuring the GNS to run Idle Stage........................................................................................................ 47 3.12 Configuring the GNS to run Cool Down Stage............................................................................................ 49 3.13 Configuring the GNS to run After Cool Stage ............................................................................................. 50 3.14 Configuring the GNS to work with ECU-based engine ............................................................................... 51 3.15 Configuring the GNS for Powering and Communicating with an J1939 ECU............................................. 52 3.16 Configuring the GNS for J1939 Monitoring ................................................................................................. 54 3.17 Configuring the GNS to Display J1939 DTCs ............................................................................................. 55 3.18 Configuring the GNS for Engine Coolant Temperature Metering and Protection....................................... 56 3.19 Configuring the GNS for Fuel Level Metering and Protection..................................................................... 61 3.20 Configuring the GNS for Oil Pressure Metering and Protection ................................................................. 65 3.21 Configuring for Engine Coolant Level Protection (and Metering) ............................................................... 68

3.21.1 Configuring Engine Coolant Level Metering and Protection using an Analog Input .......................... 68 3.21.2 Configuring the GNS for Engine Coolant Level Protection using a Binary Input ............................... 70

3.22 Configuring the GNS for Service Items - Service Time, Run Time, and Number of Starts ........................ 72 3.23 Configuring the GNS to work with your generator ...................................................................................... 73 3.24 Configuring the GNS to use a Voltage Detection Method (GNS2000 Only)............................................... 75

3.24.1 Fixed Voltage Operation..................................................................................................................... 77 3.24.1.1 High Wye, Low Wye .................................................................................................................... 78 3.24.1.2 High Delta, Low Delta.................................................................................................................. 79 3.24.1.3 High (Wild) Leg Delta .................................................................................................................. 79 3.24.1.4 High Zig-Zag, Low Zig-Zag.......................................................................................................... 80

3.24.2 Binary Voltage Select Operation ........................................................................................................ 81 3.24.2.1 High Wye, Low Wye .................................................................................................................... 84 3.24.2.2 High Delta, Low Delta.................................................................................................................. 84 3.24.2.3 High (Wild) Leg Delta .................................................................................................................. 85 3.24.2.4 High Zig-Zag, Low Zig-Zag.......................................................................................................... 85

3.24.3 Auto Voltage Detection Operation (GNS2000 Only) .......................................................................... 86 3.25 Configuring the GNS for Voltage Protection ............................................................................................... 88 3.26 Configuring the GNS for Frequency Protection .......................................................................................... 90 3.27 Configuring the GNS for Current Protection ............................................................................................... 93 3.28 Configuring the GNS for Power Protection ................................................................................................. 95 3.29 Configuring the GNS to work with your Circuit Breaker .............................................................................. 97

3.29.1 Single-Line w/No feedback................................................................................................................. 99 3.29.2 Single-Line w/feedback .................................................................................................................... 100 3.29.3 Multi-Line w/No feedback ................................................................................................................. 101 3.29.4 Multi-Line w/ feedback...................................................................................................................... 102 3.29.5 GCB Feedback Behavior.................................................................................................................. 103

3.30 Configuring the GNS for Alarm, Warning, and Status Annunciation and Control ..................................... 106 3.31 Configuring the GNS to work with Analog Inputs...................................................................................... 109 3.32 Configuring the GNS for User-Defined Protections .................................................................................. 116 3.33 Configuring the GNS for Security.............................................................................................................. 124 3.34 Configuring the GNS to transmit J1939 Data............................................................................................ 126

4.0 Reference Information .............................................................................................. 129

4.1 Security ..................................................................................................................................................... 129 4.2 Binary Input Functions .............................................................................................................................. 129 4.3 Binary Output Functions............................................................................................................................ 132

4.3.1 Binary Output Function Categories .................................................................................................. 136 4.4 Status Messages....................................................................................................................................... 138 4.5 Protections (Warnings, Alarms/Shutdowns) ............................................................................................. 138


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4.6 Set Points .................................................................................................................................................. 143

5.0 User Interface ............................................................................................................ 161

5.1 Display Features/Description .................................................................................................................... 161 5.2 Standard GNS2000 Display ...................................................................................................................... 161

5.2.1 Status LED Definitions (Standard GNS2000)................................................................................... 162 5.2.2 Button Definitions (Standard GNS2000) .......................................................................................... 162

5.3 GNS2000E Series Display ........................................................................................................................ 163 5.3.1 GNS2000E Series Additional Status LED Definitions ...................................................................... 163 5.3.2 GNS2000E Series Additional Button Definitions.............................................................................. 163

5.4 GNS2500 Display (Includes GNS2500E Series) ...................................................................................... 164 5.4.1 GNS2500 Additional Status LEDs Definitions.................................................................................. 164 5.4.2 GNS2500 Additional Button Definitions............................................................................................ 165

5.5 Special Display Functions ......................................................................................................................... 165 5.6 Menu Structure/Navigating the Menus...................................................................................................... 166 5.7 Reviewing Setpoint Values ....................................................................................................................... 167 5.8 Changing Setpoint Values......................................................................................................................... 167 5.9 Changing Operating Modes ...................................................................................................................... 167 5.10 Metering Screens ...................................................................................................................................... 167

5.10.1 Main Screen...................................................................................................................................... 167 5.10.2 Binary Output Screen ....................................................................................................................... 167 5.10.3 Binary Input Screen .......................................................................................................................... 168 5.10.4 Analog Input Screen ......................................................................................................................... 168 5.10.5 Analog Metering Screen ................................................................................................................... 168 5.10.6 J1939 Monitoring Screen(s) ............................................................................................................. 169 5.10.7 Power Screens .................................................................................................................................169 5.10.8 Generator Metering Screens ............................................................................................................ 169

5.11 Setpoint Screens....................................................................................................................................... 170 5.12 Setup/Test Screen..................................................................................................................................... 170 5.13 CAN/J1939 DTC Log Screen .................................................................................................................... 171 5.14 Event Log Screen...................................................................................................................................... 171 5.15 Alarm/Warning Screen .............................................................................................................................. 172

6.0 GNS Configuration Software – SmartVU................................................................. 173

6.1 Getting to Know SmartVU ......................................................................................................................... 173 6.2 Establishing a Connection to the GNS...................................................................................................... 174 6.3 Monitoring and Controlling the Generator .................................................................................................178 6.4 Configuring the GNS with SmartVU.......................................................................................................... 182 6.5 Using SmartVU with a J1939 Based Engine............................................................................................. 184 6.6 Trouble Shooting with SmartVU................................................................................................................ 185

7.0 Alarms/Warnings/Statuses....................................................................................... 188

7.1 Alarm Behavior.......................................................................................................................................... 188 7.2 Warning Behavior...................................................................................................................................... 188 7.3 Status ........................................................................................................................................................ 189 7.4 Alarm/Warning List .................................................................................................................................... 189 7.5 Event Logs ................................................................................................................................................ 190 7.6 Event Log Supplemental Information........................................................................................................ 191

8.0 Connectivity............................................................................................................... 193

8.1 GNS2X00 Connectivity ............................................................................................................................. 193


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8.2 RS-232 Only Port ...................................................................................................................................... 193 8.3 RS-232/RS-485 Port .................................................................................................................................194 8.4 CAN Port ................................................................................................................................................... 195 8.5 Isolation ..................................................................................................................................................... 195 8.6 Configuring the GNS200XD Remote Display for RS-232/RS-485 Operation........................................... 196 8.7 CRM/RA Configuration.............................................................................................................................. 199 8.8 JDR Family Configuration ......................................................................................................................... 199 8.9 Cell Modem Configuration......................................................................................................................... 199

9.0 Appendix A - Glossary of Terms.............................................................................. 201

10.0 Appendix B - Specifications..................................................................................... 202

11.0 Appendix C - Inputs, Outputs, and Communications ............................................ 203

11.1 Connections .............................................................................................................................................. 203 11.2 Analog Inputs ............................................................................................................................................ 204 11.3 Communications Ports .............................................................................................................................. 204 11.4 Configuring CAN Communications ........................................................................................................... 204 11.5 Physical Inputs .......................................................................................................................................... 205 11.6 Physical Outputs ....................................................................................................................................... 206

12.0 Modbus Definition..................................................................................................... 207

12.1 Measured Data Modbus Definition Table.................................................................................................. 207 12.2 Data Format Definitions............................................................................................................................. 209 12.3 Protection Bits (Warnings & Alarms)......................................................................................................... 211 12.4 Operating Mode Status ............................................................................................................................. 212

13.0 Appendix D – Troubleshooting ................................................................................ 213


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1.0 General Information

1.1 DESCRIPTION

The GNS2X00 series is a family of highly-flexible generator set controllers. The GNS is designed for both electronically and mechanically controlled engines, is ruggedly constructed with simple-to-use microprocessor technology. The GNS family is designed to be used with or without a display. All GNSs support a remote display or a connection to a monitoring console. An optional factory installed internal modem is available.

The GNS2X04B (stand alone black box) can easily be integrated to various combinations of external digital displays, analog gauges, simple indicator lights or can be utilized with no interface at all.

The most basic model in the GNS family is the GNS2000. It supports manual and remote start stop. The GNS2500 is a slightly advanced control with built in Auto Mains Failure (AMF) logic. In addition to the standard inputs and outputs of the GNS2000, the GNS2500 is equipped with inputs to monitor up to at three phases of mains power. Neither the GNS2000, nor the GNS2500 internally support synchronization to the mains and transfer power in a “bump” fashion, that is, there will be a brief period of time where the power will be disrupted.

The user interface is simple, and internally supports multiple languages. The GNS also has an advanced security model that provides multiple levels of security to prevent unauthorized or unintentional changes in the operation.

1.2 PRODUCT FEATURES

Suitable for controlling standalone generators

Fixed, Auto Detect, or binary selected generator configuration/protection modes

Integrates to engines with and without ECUs

Non-“E” versopms are resistant to high moisture, salt fog, humidity, dust, dirt, and chemical contaminants

Comprehensive generator and engine metering and protections

Multiple forms of communication (J1939, MODBUS, RS232/422, Ethernet, Modem)

Configurable inputs and outputs

Built-in relays

Remote monitoring and alerts

Compatible with wide range of senders

Highly flexible analog inputs require no external modules

Multi-language support, GNS is cable of storing and switching on-the-fly multiple languages

Multiple display support, local (RS-232) and remote (RS-232/485)

Auto Mains Failure (AMF) detection (GNS2500 series only)

1.3 PRODUCT FUNCTIONS

Automatic and Manual modes of operation


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Engine start/stop control

Generator voltage configuration and protection auto detection

Generator voltage, current, and frequency metering and protection

Engine coolant temperature metering and protection

Fuel level metering and protection

Engine RPM metering and protection

Engine run time metering

Remote monitoring and metering

Enable/Disable available on virtually all protections

Alarm/Warning list

Event log including status conditions

Modbus

J1939 CAN

o integration of engine speed, oil pressure, fuel level, and coolant temperature data from ECU

o Monitoring and display of Diagnostic Trouble codes from the ECU

o Monitoring and display of other ECU supported data for service personnel

o Transmission of all generator related data onto the bus for external devices

Analog Sender support

o Wide variety of senders supported

o Can be used for basic engine parameter (oil pressure, coolant temperature, fuel level) monitoring and protection

o Can be user defined with independent protection levels, user defined name, and user defined curve

User defined binary inputs and outputs with configurable action, delay, arming based on engine cycle.

Panel security controls

Multiple levels of security, including panel lock

Generator circuit breaker control, single/multi wire, with or without feedback

Modem communication

1.4 GNS2000 FLEXIBILITY/FAMILY MEMBERS

The GNS Series is comprised of five standard family members:

GNS2002 – Integrated one piece controller and display rated for -20C operation


GNS2004B – Controller only unit intended for mounting inside control cabinet and supported by custom user interface rated for -40C operation

GNS2002D – Display only used for remote display, rated for -20C operation



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Based on these five components, there can be numerous configuration possibilities. A few examples are listed below.

GNS2002/4/4B by itself

GNS2002/4/4B connected to a GNS2002D/4D remote display

GNS2002/4/4B connected to a PC

GNS2004B connected to two GNS2002D/4D remote displays

GNS2004B connected to one GNS2002D/4D remote display and PC

GNS2004B connected to two PCs

1.5 GNS2500 FLEXIBILITY/FAMILY MEMBERS

The GNS Series is comprised of five standard family members:



GNS2504B – Controller only unit intended for mounting inside control cabinet and supported by custom user interface rated for -40C operation



Based on these five components, there can be numerous configuration possibilities. A few examples are listed below.

GNS2502/4/4B by itself

GNS2502/4/4B connected to a GNS2502D/4D remote display

GNS2502/4/4B connected to a PC

GNS2504B connected to two GNS2502D/4D remote displays

GNS2504B connected to one GNS2502D/4D remote display and PC

GNS2504B connected to two PCs

1.6 “E” VERSIONS OF GNS

The GNS2X00E versions a virtually identical to their GNS2X00 counterpart. Configuration and operation are identical. The major difference are the operating temperature range. These devices are specified to operate in 0-70 C temperature range and does not have a conformal coat. The units also are designed to, but not tested to UL standards.


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2.0 Installation

2.1 WHAT’S IN THE BOX

1 controller – GNS2X02, GNS2X04, or GNS2X04B

1 set of mating connectors for all terminal block connectors

1 PIB4123 – Product Information Bulletin

Mounting hardware


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2.2 MOUNTING DIAGRAMS

2.2.1 Hole Pattern and panel cutout for GNS2X02, GNS2X04, GNS2X02D, and GNS2X04D

PA

NE

L C

UT

OU

T


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2.2.2 GNS2X04B – Din Mount

Back Side View


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2.2.3 GNS2X04B – Direct Mount


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2.3 SYSTEM WIRING

2.3.1 GNS2000 Sample Wiring Diagram


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2.3.2 GNS2500 Sample Wiring Diagram


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2.3.3 Battery Wiring

The Battery+ and Battery- terminals are fixed functions terminals used to provide power to the controller. In addition, the battery voltage sensed on these terminals is used by the battery protection functions within the GNS. Power for the control is typically from the 12 or 24 VDC battery used to start the engine. It should be fused with a 10 AMP fuse. The control should be wired directly from the battery to the unit with a dedicated wire. Use of bussed connections for multiple devices is not recommended as noise and high current spikes can degrade performance. (See section on battery protection to configure battery protections).

2.3.4 D+ Wiring

The D+ terminal is a fixed function terminal used to monitor the D+ terminal on the engine alternator. Wiring of D+ should be a single wire going from the D+ terminal on the alternator to the D+ terminal on the GNS (see wring diagram). When the engine is running, this terminal should be approximately at battery voltage. If it is significantly lower, this is a sign that the alternator is not operating properly.

Protection functions in the GNS can be used for alternator monitoring. This monitoring can be used to detect when the alternator stops charging the battery due to an internal alternator failure, wiring issue, or when the belt driving the alternator slips or is broken. Additionally, under certain circumstances D+ can be used to determine if the engine is running. The GNS has protections to detect if there is a problem with the D+ terminal (see section on D+ monitoring to configure protections.)

Most alternators need to be flashed when the engine is first started in order for the alternator to start producing voltage. D+ excitation control (flashing) can be accomplished by connecting battery positive to one side of a normally open relay (e.g., BO3) and the other side to the D+ terminal of the alternator. The output (e.g., BO3) should then be assigned to Starter output function (note: you can assign Starter twice, once for the actual starter, the other for D+ excitation). This tells the GNS to close the output whenever the starter is engaged, thereby exciting the alternator with the battery voltage. See the sample wiring diagram below:

2.3.5 Binary Input Wiring

The binary inputs have two states of operation HI and LO. The HI state is achieved when battery+ is applied to the input or the input is left open. The LO state is achieved when battery- is applied to the input. The inputs are typically driven by a contact closure to Battery- as shown below, but signals from other electronics can be tied directly to these input. See diagram below. These inputs are assigned a function at the factory and can only be changed by using the GAC configuration software, SmartVU. Current function assignment can be seen by viewing the Binary Input Screen on the GNS display. In addition, each input has a defined polarity to indicate which state (HI or LO) activates the assigned function. The polarity of the inputs can only be changed by using the GAC configuration software, SmartVU (see section on configuring binary inputs to change function or polarity).


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2.3.6 Magnetic Pickup Wiring

The Magnetic Pickup inputs are fixed function terminals used to monitor signals from magnetic pickups. The magnetic pickups are mounted on the flywheel housing and used to monitor engine speed. Wiring for these terminals should be dedicated twisted shielded wires from the pickup to the terminals on the GNS. The grounding of the shield must be done at only one end of the shield. Sharing of pickup signals is not recommended (see section on engine operation and engine speed protections for configuring protections and pickup inputs).

2.3.7 Relay Wiring

The relay outputs are part of the binary output functions and are used by the GNS to signal status or to control external equipment. There are four relays, two Form A, and two Form C. The GNS unit is labeled with the contact state when un-powered. The relays have two states of operation, ON and OFF. When un-powered they are in the OFF state. When activated by the GNS, the relay will switch to the ON state. The output states can be inverted by changing the polarity of the binary output using the GAC Configuration Software, SmartVU. Also using SmartVU, the assigned functions of these outputs can be changed. The current assigned function can be seen on the GNS display under the Binary Output screen (see section on configuring binary outputs to change function or polarity). Wiring of these terminals depends on the load being driven. Based on the load, protective devices may be needed in order to protect the contacts from damage and to improve reliability.

The generator current inputs are fixed functions terminals dedicated to measuring the generator current. The inputs have a maximum continuous rating of 5A. The inputs require the use of current transformers (CT) to step down the current to a usable level. The inputs work with CTs that have a 5A secondary. The exact ratio of the CT can be configured in the unit to allow the display of primary current levels (see section on configuring CT rations. Wiring of the CTs is shown in the Basic Wiring Diagram). Note that one side of all of the CTs must be grounded external to the GNS.

2.3.8 Generator & Mains Voltage Wiring

The generator and mains voltage inputs are fixed function terminals dedicated to measuring the generator and mains voltage (mains voltage inputs are provided on the GNS2500 only). The inputs are rated for a maximum of 600V Line-Line. Generators that will exceed this level must use potential transformers (PT) to step the voltage down below the maximum. The exact ratio of the PT can be configured within the unit to allow the display of primary voltage levels (See section on configuring PT ratios. Wiring of the generator voltage with PT is shown in the Basic Wiring Diagram). The voltage inputs can be wired to the following configurations.

3 phase, 4 Wire Wye – wire generator phases and neutral to corresponding GNS phase and neutral terminals.

3 Phase, 3 Wire Delta – wire generator phases to corresponding GNS phase terminals. No neutral is needed, the GNS with synthesize an internal neutral.

3 Phase, 4 Wire High (Wild) Leg Delta – Wire generator phases and neutral to corresponding GNS phase and neutral terminals. The high (wild) leg of the configuration must be identified in the GNS configuration (see section on configuring generator voltages).

1 Phase, 3 Wire Zigzag – Wire generator phases and neutral to corresponding GNS phase and neutral terminals. The unused phase input must be wired to neutral and the corresponding phase must be identified in the GNS configuration (see section on configuring generator voltages).

1 Phase, 3 wire Double-Delta – This configuration looks (to the GNS) and is wired identical to the Zigzag configuration.


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If PTs are required, then they can be wired into the voltage inputs, and configured on the user interface.

For systems with both generator and voltage inputs, the PT’s and wiring configurations must be identical.

2.3.9 Analog Input Wiring

The analog inputs are flexible inputs that can be configured to read signals from various analog senders and electronic sources. The inputs can be configured to work with 0-5VDC, 4-20mA, resistive senders and Type K Thermocouples. Each input requires a signal and a reference. If a reference is not provided as is the case for a single wire sender, then the reference terminal needs to be wired to ground.

On the back of the GNS there are four switches to enable 4-20mA operation. For all inputs, other than the dipswitch must OFF.

2.3.10 Binary Output Wiring

The binary outputs are used by the GNS to signal status or to control external equipment. The binary outputs have two states of operation ON and OFF. In their OFF state, the output is open, in their ON state, the output is closed to ground and will sink up to 500 mADC. The output states can be inverted by changing the polarity of the binary output using the GAC Configuration Software, SmartVU. Also using SmartVU, the assigned functions of these outputs can be changed. The current assigned function can be seen on the GNS display under the Binary Output screen. These outputs are assigned a function at the factory and can only be changed by using the GAC configuration software, SmartVU (see section on configuring binary outputs to change function or polarity). Wiring of these terminals depends on the load being driven. Based on the load, protective devices may be needed in order to protect the outputs from damage and to improve reliability.

2.3.11 CAN/J1939 Wiring

The CAN Bus is a two wire multiplex databus used to transmit various information between electronic devices. In most generator set applications, it is used to read information from the engine ECU. Wiring of the CAN bus should be done in a bus topography and not daisy-chain nor star. It must be done by wiring a twisted shielded pair between the ECU and the corresponding pins on the GNS. The shield must only be grounded on one end. A terminal is provided on the GNS for that purpose. If any units that are to be connected to the CAN bus do not share the same ground reference then an isolator is needed to prevent damage to the units. In addition, termination resistors need to be added to the two ends of the physical bus. There is a 120 Ohm termination resistor installed in the unit that can be enabled or disabled. See the diagram below. It is important that two and only two 120 Ohm terminating resistors be used. Some ECU have a built-in resistors, some do not. The bus can easily be checked by connecting an Ohm-meter across the H and L signals on the bus (with all units unpowered). The meter should read about 60 Ohms if termination resistors are installed (See section on configuring binary outputs to change function or polarity).


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2.3.12 RS-232/RS-485 Wiring

The serial ports on the GNS are typically used to connect to the GAC configuration software, SmartVU. When connecting the unit to a PC running SmartVU, the serial port of the PC is connected to the serial port on the GNS using a standard Female to Female, Null Modem serial cable available from many computer supply locations.

There are many other uses for these ports such as I/O expansion, supervisory system integrations etc. (please refer to the Connectivity section for complete details on these additional uses for the communication ports).

2.3.13 Factory Installed Internal Modem Wiring

The GNS Series offers the option of having a factory-installed modem capable of direct connection to the phone line. This helps eliminate the extra wiring of cables and power and mounting of another device. To connect the modem to the phone line, use a standard telephone cord with RJ11 connector. Attach one end to the phone line and the other end plugs directly into the RJ11 jack on the back of the GNS. The SmartVU software must be run to configure the port to use the modem (see connectivity section for further information).


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3.0 Operation Description and Configuration

3.1 CONFIGURING THE GNS FOR YOUR APPLICATION

Configuring the GNS for your application involves a few major steps. Connecting the GNS to power, configuring the GNS for Emergency Stop, configuring the GNS to work with your engine, configuring the GNS to work with your generator, configuring the GNS to work with your circuit breaker, configuring any application specific functionality, and any other miscellaneous configuration. Some of the steps can be done directly on the unit, some cannot. All steps can be done from the GAC configuration software SmartVU.

3.2 CONFIGURING THE GNS FOR BATTERY CONNECTION, METERING, AND PROTECTION

Description:

The GNS operates from an 8-32VDC power source. This is typically the same battery used to start the engine. The power to the GNS should be fused. The GNS has built in ride thru protection that allows it to operate during the short duration power dropout that can occur during engine starts. In addition to providing power for the GNS, the battery terminals can be used to monitor the battery voltage and warn if the battery voltage is too high or too low. These protections can be used to protect against external battery charger failures, alternator failures, connection of the wrong voltage battery, or help to detect weak batteries before they cause a problem.

Additionally, the GNS is equipped with a D+ terminal that can be used to monitor the alternator condition. It can be used to detect an alternator issue before the battery voltage drops too low. See section on Configuring the GNS to work with alternator.

Requirements:

To enable Battery Protections: Set setpoints BATTERY OVER VOLTAGE WARNING, and BATTERY UNDER VOLTAGE WARNING to desired values using either the display or SmartVU and enable warnings in the Warnings/Alarms tab of the configuration meter in SmartVU.

To disable Battery Protections: Disable the warnings in the Warnings/Alarms tab of the configuration meter in SmartVU.

Wiring Requirements:

Refer to the wiring section for Battery Wiring for proper battery wiring.

Refer to the wiring section for Binary Output wiring for proper wiring of any desired binary outputs.

Meters:

Display – The battery voltage reading can be found on Screen: Analog Metering -> BATTERY VOLT


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SmartVU - The meter for Battery Voltage is shown below.

Protections & Holdoffs:

These protections are active whenever the unit is powered and not in OFF Mode. Additionally, they are automatically disabled during the cranking cycle to prevent nuisance tripping.

Battery Under Voltage Warning – If the battery voltage drops to the level specified by the BATTERY UNDER VOLTAGE WARNING setpoint for the period of time set by the BATTERY DELAY setpoint, and the Battery Under Voltage Warning protection is enabled, the GNS will trigger a warning and turn on the Battery Under Voltage Warning output.

Battery Over Voltage Warning – If the battery voltage rises to the level specified by the BATTERY OVER VOLTAGE WARNING setpoint for the period of time set by the BATTERY DELAY setpoint, and the Battery Over Voltage Warning protection is enabled, the GNS will trigger a warning and turn on the Battery Over Voltage Warning output.

Setpoints:

Battery Over Voltage Warning BATT OVER VOLT – Threshold for the battery over voltage warning.

Battery Under Voltage Warning BATT UNDER VOLT – Threshold for the battery under voltage warning.

Battery Delay BATTERY DELAY – Time, in seconds, the battery voltage will have to exceed the set points for the Battery under/over warnings to activate.

Binary Input Functions: None

Binary Output Functions:

Battery Under Voltage Warning BATT UV WN – Active when protection Battery Under Voltage Warning is active.

Battery Over Voltage Warning BATT OV WN – Active when protection Battery Over Voltage Warning is active.

Status Messages: None

Alternate Uses:

The Battery Under Voltage protection can be used to detect if a battery charger has failed and the battery voltage has dropped to a low voltage condition. Typically this level should be set such that the engine will still start allowing the engine alternator to recharge the battery until the battery charger is repaired.


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The Battery Over Voltage protection can be used to determine if the engine alternator has failed and is charging the battery at higher than recommended voltages, or there is a mismatch between the alternator, battery, and starter.

3.3 CONNECTING THE GNS FOR EMERGENCY STOP

Emergency Stop (ESTOP) is way to immediately bring the system to a complete halt in an attempt to prevent damage or harm should something malfunction in the system. This is typically accomplished by removing all power from the system by routing battery power through an easily accessible series of red mushroom switches. See wiring section for possible ESTOP wiring options. With more and more electronics becoming part of the standard system, it sometimes is important to keep the electronics running during an ESTOP condition so that additional data may be gathered to allow proper analysis of the causing fault condition. Removing power to the electronics does not allow this. The GNS provides basically three different ways that ESTOP can be handled.

ESTOP Option A (Recommended) - Killing the Power of the GNS

Route power for the GNS through the ESTOP switches and during an ESTOP condition, all power to the GNS will be removed. Any faults that occurred before power is removed will be recorded in non-volatile memory will be viewable after the GNS is powered up.

No configuration of the GNS is needed

ESTOP Option B – Powered GNS, ESTOP Kills Fuel

Route power for all systems that present a hazard through the ESTOP switches, but route power for the GNS separately. This typically involves having power for fuel solenoids routed through ESTOP switches. Then assign a Binary Input on the GNS to the ESTOP function and wire it to the ESTOP switch. Upon activation of the ESTOP switch, the signal to the binary input will be negated. The controller will detect this, and command an immediate shutdown of the system including turning off the fuel (if configured to control fuel). In this scenario, the GNS will be logging all data associated with the fault as well as the ESTOP event.

Requirements:

To enable Emergency Stop Operation:

Assign a Binary Input to function ESTOP, and a Binary Output to Fuel. Binary Output function Fuel is the mechanism in which the control shuts down the engine. This output should be used to enable and disable the fuel solenoid on the engine. If the fuel solenoid is controlled by another device, then the Binary Output Fuel may be used to control that device or effect its operation.


Refer to Binary Input Wiring and Binary Output Wiring sections for proper wiring of inputs and outputs.

Meters:

Display – The status of the ESTOP function can be found on Screen: Binary Input States -> ESTOP


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SmartVU - The status of the ESTOP function can be found on the meters shown below. If activated, the color will blink RED.

Setpoints: None

Protections: None

Binary Input Functions:

ESTOP ESTOP – Immediately shuts down engine, cuts fuel, and displays alarm. Fault Reset needed to clear condition.


Fuel FUEL – Activated when engine is required to run. Used to control fuel solenoid


Alternate Uses: None

ESTOP Option C – GNS Powered, Power Routes Through GNS, GNS Performs ESTOP

Same as Option B but use Binary Input 1 for ESTOP, Binary Output 1 for Fuel, and install the ESTOP jumper. This will act the same way as b) except should a failure in the GNS prevent the system from commanding the fuel off, the jumper will directly connect the ESTOP Binary Input to the Fuel Binary Output. Therefore the Fuel output will be turned off directly by the ESTOP input by hardware regardless of the controller action.

Wiring Requirements, Meters, Setpoints, Protections, Binary Input Functions, Binary Output Functions, Status Messages, Alternate Uses:

Same as option b) above

The ESTOP feature on the GNS provides a mechanism to allow control of the fuel solenoid by the GNS, and at the same time provide a direct hardware path between the ESTOP input and the fuel solenoid output. Using the method allows the ESTOP input to command the GNS to stop immediately, and also (through hardware only) to directly command the fuel solenoid off. Therefore even on a controller failure, the ESTOP input is in direct control of the fuel solenoid, provided the


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failure is not with the ESTOP input or Fuel Solenoid output. Underneath the circular cover on the connector side of the unit, there is a jumper that connects binary input 1 to binary output 1. By default, this jumper is installed. If binary input 1 is assigned to E-Stop, and binary output is assigned Fuel, by design, opening the E-Stop will electronically cut fuel to the engine. Removing this jumper disables the feature. The picture below shows the jumper in the disabled position.

3.4 CONFIGURING THE GNS TO WORK WITH AN ALTERNATOR (D+)

Description:

The D+ terminal on the alternator can be used to monitor the status of the alternator and alternator drive belt. This information can be used within the control for a couple of purposes; Engine Started, and Alternator Belt Break Detection. As the engine starts the alternator will begin to produce power that is used to recharge the battery. As it produces power, the D+ terminal on the alternator will rise to battery voltage. This voltage can be detected and used to indicate that the engine has started. If the voltage should drop during engine running, it is typically an indication that the alternator has failed, or the belt driving the alternator has broken and the alternator has stop producing power. Both of these functions can be used independently of each other.

The D+ terminal can be used for both engine running detection and alternator failure. The following chart shows how to configure the controller for the desired functions:


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Function D+ Setpoint

Alternator Warning

Protection Charger Fail

Binary Output D+ Flashing

(alt use)

Engine running detection only Enabled Disabled Not used Not available

Engine Running and belt break detection Enabled Enabled Can be used Not available

Belt break detection Only Belt Break Enabled Can be used Available

No D+ function Disabled Disabled Not used Available

Requirements:

To enable Belt Break only protection:

Set setpoint D+ FUNCTION to BELT BREAK, setpoint ALTERNATOR FAIL DELAY, and enable the Alternator Warning protection. Optionally external notification can be signal be assigning the Charger Failure function to a Binary Output.

To enable engine start detection only:

Set setpoint D+ FUNCTION to ENABLED, and disable Alternator Warning protection.

To disable all alternator functions:

Set setpoint D+ FUNCTION to DISABLED.


Refer to D+ Wiring section for proper wiring of D+ sensing and alternator flashing control.

Refer to Binary Output Wiring section for proper wiring of outputs.

Meters:

Display – There is no indication of D+ status on the display.

SmartVU - There is no indication of D+ status in SmartVU.

Setpoints:

ALTERNATOR FAIL DELAY ALT FAIL DLY – Time, in seconds, D+ terminal can be 0V, before GNS will report a failure.

D+ FUNCTION D+ – This is the configuration of the D+ terminal. When Enabled the terminal is use as an engine running detection and belt break detection. Once the terminal has detected engine running, the belt break / charger failure detection begins. Belt Break Detection uses this terminal as a charger failure only. When disabled, the terminal does nothing.

ENABLED EN – D+ terminal is used for both engine running detection and belt break detection. When selected, D+ flashing function described below cannot be used.

BELT BREAK BELT – D+ terminal is used for belt break detection only. D+ flashing described below can be used.

DISABLED DIS - D+ terminal is not used and D+ flashing as described below can be used on the D+ terminal before triggering a alternator fail fault.

Protections:


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Alternator Warning – GNS is no longer receiving a voltage on the D+ input.



CHARGER FAIL CHG FAIL – Active when protection Charger Failure is active.


Alternate Uses:

D+ Flashing – Although the GNS does not directly support the flashing of the alternator, it can still be accomplished using the starter function and external wiring.

Note: When using the starter function to flash the alternator, the D+ function cannot be used to detect engine started and must be disabled, or set to detect belt break only.


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3.5 CONFIGURING THE GNS TO CONTROL OPERATING MODES

Description:

The GNS2000 has three operating modes (OFF, Manual, and Auto). The GNS2500 has four operating modes (OFF, Manual, Auto, and Test). The following table describes these modes:

Mode Description Notes/Additional Requirements

OFF Controller does not respond to any inputs or commands.

Used to configure the unit while in its application

Manual The controller operates only on customer commands for starting, stopping, and breaker control (if equipped).

In Manual Mode, the controller responds to the user inputs for starting, stopping, and breaker control. The user can control the engine using the start and stop buttons on the user interface, remote start and stop through binary inputs, and remote commands through the PC interface.

All start criteria is followed.

Once the engine is started it will sit unloaded and await additional user commands.

Special Behaviors Supported If the start button is depressed twice the Prestart functions will be skipped and the engine will immediately issue the crank. If start pressed during idle, idle will be skipped if idle override is not active. If stop pressed, breaker will open and cool down will begin. If stop pressed during cool down, cool down will be aborted and engine stopped.

Auto GNS2000: In Auto Mode the GNS will automatically operate the generator set based on changes to the start/stop input.

GNS2500: In Auto Mode the GNS will automatically operate the generator set based on loss of mains.t

While in this mode the GNS will respond to the Remote Start/Stop input. The GNS will not respond to the Start input on the front panel. The user will be able to view and change set points. The user will not be able to start the engine and the engine will be shut down if switched to this mode from any other mode. The Stop button is not active.

Test (GNS2500 Only)

Simulate a mains failure. By entering this mode and pressing the start button the GNS2500 will start the engine and bring the set to rated speed. The GNS2500 will not control the breaker as if in AMF operation (the MCB will remain closed, the GCB will remain open). The genset will remain running until the user commands stop. At that time the genset will follow it’s configure stop sequence.

1. Should the utility fail, and the protection is enabled, while in Test mode the GNS will take over control and switch to Auto mode and be in AMF operation.

2. Manual control of the MCB and GCB is not allowed in Test mode.

Operating mode change requests can come from user requests from the display, binary inputs, or commands via the SmartVU software. Because discrete inputs are physical connections, it is possible to tie the input to either a momentary or level sensitive switch. Care must be taken when using a combination of commands and discrete switches.


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Changes through the communication ports (from SmartVU or the displays) are treated as pulses, similar to momentary switches. They can be easily overwritten by a binary input request which can be a momentary or a fixed level.

A more typical use for the binary inputs would be to tie the inputs to a rotary selector switch allowing the user to select OFF, MAN, or AUTO. An excellent option is to have a momentary position after MAN that is tied to a remote start binary input. This allows the user to switch the set into manual mode and start the unit.

If remote control is necessary, adding a “remote” position should be considered. Essentially, this position is not tied to any input, thus allowing remote changing of modes via the communication ports.

A fully configured switch would be as follows:

AUTO – tied to the AUTO mode binary input

REMOTE – not tied to any input (in this position the user can change the mode from remote displays and SmartVU.

OFF – tied to the OFF mode binary input, or removes power

MAN – tied to the MAN mode binary input

START (momentary) – tied to Remote Start binary input, additional contact would maintain the MAN mode binary input active.

Common tied to Battery Ground

Requirements:

The GNS2002/2004 have a display which allows changing of the modes if desired. No additional control needs to be provided unless alternate control or restriction is desired.

The GNS2004B is a display-less version of the control and therefore there is no default way of controlling the modes. Several options are available which include using SmartVU to set the mode during commissioning, adding a remote display to the unit, or wiring the Binary Inputs to affect any desired mode changes.


Refer to the Binary Input wiring section for proper wiring requirement if the operating mode is to be controlled by the Binary Inputs.

Meters:

On the Display, the current operating mode is shown in the upper right hand corner. To change this, press Enter, then use the right and left arrows to change the mode. Then press the Enter key again to permanently save the change.

Note: the mode changes take effect immediately and do not require the user to press Enter. Pressing Enter only makes the changes permanent.


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In SmartVU the current mode can be found on the following meter identified by Start Mode.

Setpoints: None

Protections: None


OFF MODE OFF MODE – Puts controller in Off Mode. After release, controller operation follows Off Mode operation until new mode requested

MANUAL MODE MANUAL – Put controller in Manual Mode. After release, controller operation follows Manual Mode operation until new mode requested

AUTO MODE AUTO – Puts controller in Auto Mode. After release, controller operation follows Auto Mode operation until new mode requested

Binary Output Functions: None


Alternate Uses:

This function is a dedicated function within the controller. However, there are several methods in which the controller can be configured to change or prohibit mode changes.

Display Only – This is the most common method in which the mode can be changed. It involves using the display mounted keys to change the operating mode.

Binary Inputs – This method uses momentary switches wired to the binary inputs. Pressing any of the switches will change the mode to the desired mode. These switches can be used in parallel with the display mounted controls. In the case of the GNS2004B (which may not have a display), this would be a common way to affect mode changes.

SmartVU – SmartVU can be used to request a mode change. It will work in parallel with any momentary Binary inputs and the display mounted controls. This method can be used to change the mode remotely as well.

All of the above methods rely on momentary mode change requests. This means, that once the mode is changed, the request will be removed, leaving the control in the requested mode until the next request. In doing so, mode change requests can come from any of the three sources at any time. To prevent mode changes from occurring, the Binary Inputs would be used to force the mode to stay in one of the desired mode, by wiring the binary input to constant level. At that point, any mode change requests, will be ignored. Some further examples are listed below.

MAN mode only – Wire a Binary Input assigned the function MAN Mode directly to ground. This will force the mode to always be MAN. This can be done when only one mode is desired, but can


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only be done for one mode. Do not wire more than one mode to a non-switch voltage. This method is typically used when the GNS2004B is used as it does not have a display, or when the set builder does not want the mode to be switched.

AUTO and OFF mode only – Wire a toggle switch to two Binary Inputs. One would be assign function OFF Mode and be active low, the other would be assigned AUTO Mode and be active high. When the switch applies a low signal to both inputs, the controller will see OFF Mode active, and AUTO Mode inactive (due to the active high polarity). This will force the mode to OFF. When the switch applies a high level is applied to both inputs, the controller will see OFF Mode inactive, and AUTO Mode active (due to the active high polarity). This will force the mode to AUTO. MAN mode cannot be selected. This scheme can be used for any two of the modes as well as OFF and AUTO. This method can also be used as an interlock. By using the interlocking device’s switch as the switch to control the modes. In this manner, if the interlock is not in the correct position, the controller will be forced into the off mode. Once the interlock is restored, the controller will be returned to its normal mode allow the set to be started again.

AUTO, OFF, MAN/START operation – Wire a four position rotary switch (with the fourth position momentary) to Binary Inputs configured for AUTO Mode, OFF Mode, MAN Mode, and Remote Start. With the switch in the OFF position, the controller will be forced to the OFF mode. This position can also be used to control the power instead if desired. With the switch in the AUTO position, the controller will be forced into AUTO mode waiting for a remote start input. With the switch in the MAN mode, either the display start button can be used, or the switch can momentarily be advanced to the Start position to assert the Remote Start input causing the set to start.

This is only a sample of the possible configuration options for operating mode control. All methods must be verified to affect the desired operation.

3.6 CONFIGURING THE GNS TO WORK WITH YOUR ENGINE

3.6.1 Engine Start/Stop Control Cycle

The engine start/stop control sub-system in the GNS is capable of controlling all stages of engine starting and stopping. Many of the stages can be enabled or disable as needed and most stages have configurable options for controlling how each stage operates. The stages are:

1. Stopped

2. Prelube (optional)

3. Prestart (optional)

4. Crank

5. Idle (optional)

6. Voltage Detect Delay (optional)

7. Running

8. Supplying Load (w/ GCB closed)

9. Cool Down (optional)

10. After Cool (optional)

Each stage is independently configurable, but if enabled, the stage will be executed in both MAN and AUTO mode. MAN mode has the additional capability to shorten some of the stages, and both modes can have some of the stages lengthen by asserting binary input override functions.


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3.6.2 Stopped Stage

In the Stopped stage, the control is waiting for a start request. This request comes from different sources depending on the control mode.

AUTO Mode – GNS2000: In AUTO mode the start request can only come from a Binary Input assigned Remote Start/Stop function. GNS2500: In AUTO mode, the start request comes from loss of mains.

MAN Mode – In MAN mode, the start request can come from several different sources.

1. Binary Input assigned Remote Start function

2. Display Start Button

3. SmartVU Start Button

OFF Mode – In OFF mode, all start requests are ignored.

While in the Stopped Stage, the control is still monitoring certain protections functions and still is metering available information.

Exit from the Stopped Stage is achieved when one of the valid start requests has been acknowledged. At that point, the control advances to the Prestart Stage if configured, otherwise it will advance to the Crank Stage.

3.6.3 Prelube Stage

The Prelube Stage is an optional stage that runs whenever the engine has been stopped for a period of time and the control is in the MAN or AUTO modes. The Prelube output can be used to run auxiliary equipment, such as lubrication equipment but can also be used to signal any equipment that needs to be run periodically. After each cycle, the control will wait for a “pause time” before activating the cycle again. This will continue as long as the engine is stopped. Once started, a Prelube cycle cannot be stopped; any start requests will be queued and the engine will automatically start once the cycle is complete. If a start request is accidentally queued, it can be cancelled by issuing a stop request.

Exit from the Prelube stage is only accomplished by waiting for the configured period. Any start request (asserted during Prelube stage or not) will be acted on.

See Configuring the GNS for Prelube Stage for details on configuring the Prelube stage.

3.6.4 Prestart Stage

The Prestart stage is an optional stage used to run any starting aids such as glow plugs before the Crank Stage begins. There can be up to four Prestart Stages configured. All stages will run simultaneously but the start time for each stage is timed so that all Prestart stages END at the same time. In MAN Mode, the Prestart Stage can be shortened after it is started, by issuing another start request. At that point the Prestart Stage will immediately end provided no Prestart Overrides are active.

See Configuring the GNS for Prestart Stage for details on configuring the Prestart stage.

3.6.5 Crank Stage

The Crank Stage is a mandatory stage used to perform cranking of the engine until the engine either starts, or exhausts all of the configured crank attempts. The length of cranking and resting during this stage as well as how many crank attempts to perform are all configurable. The criteria used to determine if the engine has started can use up to three different sources to accommodate a wide range of application. The


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Crank stage is the only stage that operates differently based on whether a diesel or gaseous engine type is selected in the configuration.

Exit from this stage is accomplished by meeting the engine started criteria, exhausting all crank attempts, or requesting a stop.

See Configuring the GNS to start and Stop Engine for details on configuring the Crank and Stopped Stages.

3.6.6 Idle Stage

The Idle Stage is an optional stage used to warm the engine up prior to putting it under load. The stage is entered as soon as the engine is considered started and will run for the configured period of time. During this stage any Binary Outputs assigned the Idle function will activate allowing control of idle speed by the ECU or speed governor. This stage can also be extended by activating the binary input function Idle Override. Once activated during the Idle Stage, the Idle Binary Output will stay active until the override is removed and the idle period has elapsed. In MAN Mode, the Idle Stage can be shortened after it is started, by issuing another start request. At that point the Idle Stage will immediately end provided no Idle Overrides are active.

Exit from the Idle Stage is accomplished once the configured period has elapsed and any override removed.

See Configuring the GNS for Idle Stage for details on configuring the Idle Stage.

3.6.7 Voltage Detect Delay Stage (GNS2000 Only)

The Voltage Detect Delay Stage is entered once the idle stage has completed. During this stage the control is waiting for the engine to reach nominal speed and the configured voltage detect delay time to elapse (if the voltage detection scheme is set to Binary Voltage Selection, or Auto Voltage Detection).

Exit from the Voltage Detect Delay Stage is accomplished once the engine has reached nominal speed and the voltage detect delay time has elapsed.

See Configuring the GNS to use a Voltage Detection Method, and Configuring the GNS for Engine Speed Metering and Protection for details on configuring the Voltage Detection Delay Stage options.

3.6.8 Running Stage

The Running Stage is entered once the engine has reached nominal speed and the voltage detect delay time has elapsed. During this stage the engine is running at rated speed with the breaker open and generator protections are active. In AUTO mode, the breaker close request will occur automatically once this stage is entered. In MAN Mode, the user must request breaker closure through the GNS display Close GCB button, Close GCB button in SmartVU, or activating a Binary Input assigned to the GCB Close Request function. Once the GCB has closed, the Supplying Load Stage will be entered.

Alternatively the Running Stage can be exited by requesting the generator to stop. When a Stop Request has been received, the Cooling Stage will be entered. When in MAN mode, the stop request can come from the GNS display STOP button, SmartVU software STOP button, or a Binary Input assigned the Remote Stop function. When in AUTO mode, the stop request will come from the Binary Input assigned the Remote Start/Stop function.

3.6.9 Supplying Load Stage

The Supplying Load Stage is entered once the GCB has been closed. During this stage the engine is running at rated speed with the breaker closed and generator protections active.


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Exit from the Supplying Load Stage is accomplished once a stop request has been issued. Once issued, the Cool Down Stage will be entered. When in AUTO mode, the stop request will come from the Binary Input assigned the Remote Start/Stop function. When in MAN mode, the stop request can come from the GNS display STOP button, SmartVU software STOP button, or a Binary Input assigned the Remote Stop function. If the breaker is closed, it will automatically be requested to open.

Alternatively, in MAN mode only, exit from Supplying Load Stage is accomplished when a request GCB Open Request is issued. The open GCB request can come from the GNS display OPEN GCB button, SmartVU software OPEN GCB button, or a Binary Input assigned the GCB Open Request function. After the GCB opens, the Running Stage will be re-entered.

3.6.10 Cool Down Stage

The Cool Down Stage is an optional stage used to cool the engine down prior to stopping. The stage is entered when the breaker is open after a stop request. It will run for the configured period of time. The Cool Down Stage can be configured to run the engine at idle speed or rated speed. If configured for idle speed, any Binary Outputs assigned the idle function will be activate allowing control of idle speed by the ECU or speed governor. In MAN Mode, the Cool Down Stage can be shortened after it is started, by issuing another stop request. At that point the Cool Down Stage will immediately end. Also in MAN mode, the Cool Down Stage can be aborted and the Running Stage reentered by issuing another start request.

Exit from the Cool Down Stage is accomplished once the configured period has elapsed or another start request issued.

See Configuring the GNS for Cool Down Stage for details on configuring the Cool Down Stage options.

3.6.11 After Cool Stage

The After Cool Stage is an optional stage used to run auxiliary equipment after the engine stops. Typically this may include engine room ventilation equipment, etc. The After Cool stage is entered when the Cool Down Stage completes. It will run for the configured period of time. During this stage, any Binary Output assigned the After Cool function will activate until the stage is complete. The After Cool Stage can be aborted and the engine restarted by issuing another start request.

Exit from the After Cool Stage is accomplished once the configured period has elapsed, or a start request has been issued.

See Configuring the GNS for After Cool Stage for details on configuring the After Cool Stage Options.

3.6.12 Engine Types

Configuration of the GNS to work with your engine involves an understanding of the type of engine used. There are some major differences between engines that require that the GNS be configured to match. These differences are Gaseous or Diesel, and ECU-Based or traditional. The GNS family of products is capable of working with all these different types of engines but the controller must be configured correctly.

Many of the functions of the GNS are configured the same regardless of the type of engine used. Those functions are listed below.

D+

Prelube

Prestart

Idling


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Cooling

After Cool

Service Hours, Engine Hours, Number of Starts

Some of the functions are specific to Gaseous engines and they are listed below

Starting and Stopping the engine

The remaining functions are configured differently based on whether the engine is ECU-based or not. These functions are listed below.

Engine Speed

Oil Pressure

Coolant Temperature

Fuel Level

J1939 Monitoring

3.7 CONFIGURING THE GNS FOR ENGINE SPEED METERING AND PROTECTION

Description

The GNS is capable of monitoring engine speed from up to three different sources; Magnetic Pickup, Generator frequency, or an ECU. One, two, or all three sources may be used to determine engine speed. They are assigned a priority, and if the highest priority source should fail, the system shall automatically drop to the next highest priority source until all sources have been exhausted. At any given time, only one source is being used by the system to compute engine speed. This value is the system engine speed and is used by the controller. All other sources will be ignored until a failure occurs. The only engine speed available to be viewed by the operator is what the controller is currently using as the system engine speed. No indication of the source used is given.

Requirements

To enable engine speed metering:

Set setpoints SPEED INPUT:MASTER to the primary source for engine speed. Optionally setpoints SPEED INPUT:SECOND, and SPEED INPUT:THIRD can be set to other sources in case the primary source fails. If Magnetic P/U selected as source, setpoint TEETH needs to be set to match the number of teeth on the flywheel. Set ENGINE SPEED setpoint to the nominal or rated engine speed. Typically for a 4 pole genset, the Engine Speed it is 1800 RPM for 60Hz and 1500 RPM for 50Hz operation.

To enable engine speed protections:

In order to have engine speed protections, it is required that engine speed metering be correctly setup. Once this is setup, the protections can be enabled by setting setpoint OVERSPEED, and RPM DISCONNECT to the desired % of setpoint ENGINE SPEED, and enable the corresponding protections.

Note: Setpoint RPM DISCONNECT is used to determine engine started as well.


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To disable engine speed protections:

Disable protections in Warnings/Alarms tab of configuration meter in SmartVU.

Wiring Requirements

Refer to the following sections on how to wire up the corresponding speed sensing input:

ECM – See CAN/J1939 wiring

Magnetic Pickup – See Magnetic Pickup wiring

Generator – See Generator Voltage Wiring


Meters:

Display – The current engine speed can be found on Screen: Main Screen -> RPM

SmartVU - The meter for Engine Speed is shown below.

Setpoints:

ENGINE PROT DELAY ENG PROT DLY – The amount of time give to detect Over Speed and Under Speed conditions.

ENGINE SPEED ENGINE SPEED – The rated speed of the application. This parameter is typically set to 1800 for 60Hz applications and 1500 for 50Hz applications for 4 pole machines. It is used by overspeed and underspeed protections, and engine speed computation from generator frequency. Other setpoints are % of this speed. Also used by GNS to determine when to advance from Voltage Detect Delay Stage to Running Stage.

OVERSPEED OVERSPEED – Speed threshold, expressed in percent, of ENGINE SPEED. When reached, engine is in an over speed condition.

RPM DISCONNECT RPM DISCONNECT - The percent of ENGINE SPEED at which the engine will have to exceed before the starter is disengaged. This is also the set point for under speed.

SPEED INPUT:MASTER SPEED INPUTS:MASTER – Primary input to use for determining speed.

SPEED INPUT:SECOND SPEED INPUTS:SECOND – Secondary input to use for determining speed. The secondary input is used only when the primary speed selection is unavailable or fails.


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SPEED INPUT:THIRD SPEED INPUTS:TERTIARY – Tertiary input to use for determining speed. The tertiary input used only when the primary and secondary speed selections are unavailable or fail.

Possible choices are:

MAGNETIC PICKUP MAG - Engine speed is determined from the dedicated magnetic pickup input on the GNS. Be sure to set the TEETH setpoint.

GENERATOR GEN – Engine speed is determined from the frequency calculated on the generator voltage inputs. It is converted to engine speed by the following formula

Engine Speed = Frequency measured * Engine Speed / Nominal Frequency

ECM ECM – Engine speed is determined from the ECU by monitoring the J1939 standard EEC1 Engine Speed Parameter. To use this source, the CAN Bus must be wired to the ECU and GNS, and the ECU address specified (see J1939 section for details).

NOT SPECIFIED N/A – No source is selected for engine speed. At least one source should be specified for normal applications.

TEETH GEAR TEETH – Number of teeth on the flywheel of the engine. Used to compute RPM from mag pickup signal.

Protections:

Holdoffs: These protections are enabled whenever the controller is not in Off Mode and under the following conditions.

Overspeed protection is enabled after the engine has started.

Underspeed protection is enabled when the engine has reached nominal speed.

Speed Sensor Failure protection is enabled whenever the engine is rotating.

CAN Bus Error Alarm – This protection is activated when any of the configured ECU data (Oil Pressure, Engine Temperature, Fuel Level, Engine Speed) is not being received properly for the time specified by CAN1 ERROR DELAY from the address configured by CAN1 J1939 ECU ADDRESS.

CAN Bus Error Warning – This protection is activated when any of the configured ECU data (Oil Pressure, Engine Temperature, Fuel Level, Engine Speed) is not being received properly for the time specified by CAN1 ERROR DELAY from the address configured by CAN1 J1939 ECU ADDRESS.

Overspeed Alarm – This protection is activated when the engine reaches the speed specified by the OVER SPEED set point for the amount time specified by the ENGINE PROTECT DELAY set point

Underspeed Alarm This protection is activated when a running engine dips to the speed specified by the RPM DISCONNECT set point for the amount of time specified by ENGINE PROTECT DELAY set point.

Speed Sensor Fail Warning/Alarm- This protection is activated when the GNS detects no activity on the magnetic pickup for one second (note: this protection should only be activated if the magnetic pickup is assigned).



Over Speed OVR SPD – Active when protection Over Speed is active.


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Under Speed UND SPD - Active when protection Under Speed is active.

Status Messages:

The following status messages can be logged in the event logged to aid in troubleshooting and to provide information on the generator’s actions. Each status can be enabled or disabled with the configuration software. Any supporting data logged with the event, is described in the Status Messages section as well as the exact message displayed.

None


3.8 CONFIGURING THE GNS TO RUN PRELUBE STAGE

Description:

The Prelube Stage in the GNS runs periodically when the engine is stopped. It can be used for any periodic cycle that needs to be run when the engine is not running. Typical uses are to run lubrication equipment so that the engine is not running on dry bearings when first commanded to start. Once a Prelube Stage has started, it cannot be interrupted. If a start is requested, it will be queued up and will begin the start cycle once the Prelube Stage has completed.

Requirements:

To enable Prelube Stage:

Set setpoints PRELUBE PERIOD, and PRELUBE PAUSE to non-zero values. This will cause the Prelube Stage to run regardless of whether a binary output is assigned to Prelube function. If a signal is needed for external equipment, then a Binary Output should be assigned to Prelube function.

To disable Prelube Stage:

Set setpoints PRELUBE PERIOD and PRELUBE PAUSE to 0. The Prelube Stage will no longer run even if a Binary Output is assigned to Prelube function.


Refer to Binary Output Wiring section for proper wiring of outputs.


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Meters:

Display – The status of Prelube function and any pending starts is shown on the Main Screen. The status of any Prelube output can be found on the screen: Binary Output States -> PRELUBE

SmartVU - The meter showing the status of the Prelube function and any pending starts is shown below Operating Mode Status -> ENGINE:

Setpoints:

PRELUBE PERIOD PRELUBE PERIOD – Time, in seconds, the engine will perform Prelube. When Prelube time is set to zero, the function is disabled.

PRELUBE PAUSE PRELUBE PAUSE – The time the engine will pause, in minutes, between Prelubes. When set point is set to 0 (zero), function is disabled.

Protections: None



PRELUBE PRELUBE – Activated during Prelube stage. Used to periodically signal external components while the engine is off i.e. Oil lubing systems.

Status Messages: The following status messages can be logged in the event logged to aid in troubleshooting and to provide information on the generator’s actions. Each status can be enabled or disabled with the configuration software. Any supporting data logged with the event, is described in the Status Messages section as well as the exact message displayed.

PRELUBE PRELUBE – The controller has entered the Prelube stage.

Alternate Uses:


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SMS Messaging Status – This function can be used to notify service personal that the SMS messaging function is working properly. When the GNS is equipped with a cell modem, service personnel can be notified if any alarm, warning, or status has been entered into the log. If the set is a standby set, then the set may not run for several weeks, or it could be that the set attempted to run, but failed and the SMS link is broken, so no notification was received. By configuring a Prelube cycle to run periodically (i.e. every two weeks), and enabling the Prelube status to be logged. When the set does not run for a two week period, the Prelube cycle will run (doing nothing) and log a Prelube status message. This entry in the log can trigger a SMS text message stating that a Prelube cycle has run, effectively verifying that there are no issues with the set (because you would have received other SMS messages) and that the cellular link is working (because you have received this message). If configured this way, and a SMS message is not received every two weeks, something needs to be check in the application as there could be an issue with the cellular link and/or the generator set.

Poll ECU when not running – See Section Configuring the GNS to run Prestart Cycle.

3.9 CONFIGURING THE GNS TO RUN PRESTART STAGE

Description:

The Prestart Stage in the GNS can be used to run any equipment that is needed before cranking of the engine begins. Typically glow plugs and other starting aids can be run. There are 4 independent Prestart functions that can be run. Based on their configured Prestart periods, they will all begin at different time but will all end at the same time. For example, if Prestart 1 is configured for 10 secs, and Prestart 2 is configured for 20 seconds. Then when a start command is issued, Prestart 2 will turn on for 10 seconds, then Prestart 1 will turn on as well as Prestart 2. They will both run for the next 10 seconds (for a total of 20 seconds for Prestart 2). At that time the Prestarts will turn off and the Crank Stage will begin. Each Prestart Stage has an independent Prestart Override function, which can be assigned to any Binary Input, and used to extend the length of time the control stays in that Prestart Stage. As long as the override is active, the corresponding Binary Output will remain active and the control will stay in the Prestart Stage. Once it is inactive, and the Prestart Period has elapsed, the control will end the Prestart Stage. The Prestart timer is not stopped by the override but continues to run during the override.

Requirements:

To enable Prestart Stage:

Set any of the setpoints Prestart Period 1 – 4 to a non-zero value. This will cause the Prestart Stage to run regardless of whether a binary output is assigned to Prestart function. If a signal is needed for external equipment, then a binary output should be assigned to Prestart function.

To disable Prestart Stage:

Set setpoints for all Prestart Period 1 - 4 to 0. The Prestart Stage will no longer run even if a binary output is assigned to the Prestart function.



Meters:


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Display – The state of the Prestart Stage can be found on screen: Main Screen. If a Prestart Override is active, the timer display will count down to 0 and remain at zero as long as the override is active. The status of any assigned Prestart binary inputs and outputs can be found on screens: Binary Output States, Binary Input States next to their assign function.

SmartVU - The state of the Prestart Stage can be found on the following meter. If a Prestart Override is active, the timer display will count down to 0 and remain at zero as long as the override is active. Operating Mode Status -> ENGINE

Setpoints:

PRESTART PERIOD 1 PRESTART PER1



PRESTART PERIOD 4 PRESTART PER4 - Time, in seconds, the output will be enabled before cranking the engine.

Note: these are used for engine heaters, glow plugs, etc. The GNS calculates the start time for each Prestart so the all end at the same time.

Protections: None


PRESTART OVERRIDE 1 PSTART-O1



PRESTART OVERRIDE 4 PSTART-O4 - Extends Prestart operation until signal released.

Note: Each Prestart has a corresponding period, output, and override input.


PRESTART 1 PSTART 1

PRESTART 2 PSTART 2

PRESTART 3 PSTART 3


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PRESTART 4 PSTART 4 - Activated during Prestart state before cranking. Used to signal external engine Prestart equipment.

Note: Prestarts are timed to all END at the same time, not start. Any Prestart output can be extended by activating the corresponding Prestart override input.

Note: Each Prestart has a corresponding period, output, and override input.

Status Messages:


PRESTART OVERRIDE PRESTART OVERRIDE - A Prestart override input has been activated when the controller was in a Prestart stage.

Alternate Uses:

Engine Start Warning – this function could be used to warn users that the engine is about to start. By configuring a Prestart for 3 seconds, and then wiring a lamp or buzzer to the Prestart output, every time the engine was commanded to start, 3 seconds before cranking the lamp or buzzer would sound. This would run independently of any other Prestart functions.

Temperature Based Prestart function – This function could be used to activate the Prestart function whenever the engine temperature is too low, and continue this until the temperature is no longer considered too low. To accomplish this, configure a minimum Prestart time of 1 second, wire the low coolant temperature warning output to the Prestart override input. When the engine is commanded to start, the Prestart cycle will run for just 1 second, then if the coolant temperature is too low, the Prestart override will turn on and hold the control in the Prestart cycle until the coolant temperature reached an acceptable temperature and the low coolant temperature warning would go away. At that point the Prestart override will be released and the cranking will begin.

Delay Before Cranking – This function can be used to delay the cranking of the engine. By configuring a Prestart cycle, the cranking cycles can be delay by any configured amount of time and even extended indefinitely using the Prestart override.

Enable ECU before Crank Stage – This function can be used to enable ECU before cranking the engine. Some ECU manufacturers require that the ECU run before the engine cranks to allow the data available by J1939 to stabilize. By configuring a short Prestart, and using a user-defined input to condition a Binary Output on the engine being in Prestart, Crank, Idle, Running, or Cooling the output can be used to control the ECU power. Should a fault occur that requires a shutdown, the engine will be commanded to a stopping state and this will disable the output. Additionally, a Prelube Stage could be added to allow the unit to periodically poll the ECU for current metered data.

3.10 CONFIGURING THE GNS TO START AND STOP ENGINE

Description:

Configuring the GNS to control starting and stopping the engine require knowledge of how the fuel is controlled for the engine. Fuel control is the main feature used to enable the engine to run, and is the mechanism used to stop the engine. Starting the engine is the only stage of the engine cycle that needs to know whether the engine is a gaseous fuel engine or not. If it is a gaseous fuel engine, there are several other features that are enabled to properly control a gaseous engine differently than a diesel engine.


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Starting the engine requires proper control over fuel and the starter motor. In addition, several criteria are used to determine if the engine has started. Once commanded to stop, the control will remove the fuel from the engine and monitor its speed to determine if the engine has stopped.

The following describes the Engine Start Criteria that is used to determine whether the engine should be started, and how the crank cycle will operate.

1. If the engine is in a Prelube function and a start command arrives the controller will wait until this Prelube time expires to initiate the start.

2. Once the start has been initiated the controller will issue the Prestart command(s) if the engine should have any Prestart stage enabled.

3. The Prestart output(s) will be active for the corresponding Prestart time.

4. Each individual Prestart output will have a Prestart Override that will be checked at this time and is being continually checked throughout the Prestart Time.

5. Once all the Prestart outputs are deactivated the engine will begin to crank.

6. The starter and fuel solenoid outputs will be activated (per Engine Type described in set points).

7. If RPM is not measured, by one of the selected methods within three seconds of the Starter output being activated, a Crank Fail will be displayed and the engine will go to its Crank Rest Time.

8. Subsequent Crank attempts will still be initiated until the Engine Running Criteria is met or the GNS exhausts all crank attempts and issues an Over Crank protection.

9. If RPM is detected, the controller will leave the Starter output activated till one of the Engine Run Criteria is satisfied or the Crank Time expires.

10. If the Crank Time expires the controller will begin the Crank Rest.

11. Once this time expires another Crank cycle will be initiated.

12. This cycle will continue until the number of crank cycles equals the Attempts parameter set in set points, or the engine meets the Engine Run Criteria.

13. If the number of start cycles completed equals Attempts an Over Crank alarm is issued and will have to be cleared using Fault Reset in order for another start cycle to begin.

Engine Running Criteria

The engine will be considered running if one of the four following items is satisfied. Once the engine has met one of these items it will go to an Idle stage (if enabled).

1. The engine RPM as measured by the mag P/U input, generator frequency, or received from J1939 exceeds the RPM DISCONNECT setpoint.

2. The engine oil pressure exceeds the OIL DISCONNECT setpoint

3. The D+ terminal detects engine running. The D+ will only be used if the D+ FUNCTION setpoint is enabled for engine running detection.

Requirements:

To enable start control:

Starter control involves assigning the outputs to signal fuel and cranking, configuring the crank cycles, defining the criteria for considering the engine started, and enabling the gaseous fuel feature if needed.

Assigning outputs - Assign at least one Binary Output to the Starter function, and one output to the Fuel Function.


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Configure the crank cycle - Set the setpoints CRANK PERIOD, CRANK PAUSE, CRANK ATTEMPTS to the desired crank cycle requirements.

Set engine started criteria - Set setpoints for Engine Speed as many of the other setpoints are a percentage of this setpoint. Set RPM DISCONNECT, OIL DISCONNECT, D+ function

Enable Gaseous fuel control if needed – The Gaseous control features of the GNS allow for altered control of the fuel solenoid, and cranking accommodating gaseous fuel systems. By selecting GAS for the setpoint ENGINE TYPE, several features are enabled.

First, the fuel solenoid is not turned on until the RPM reaches the setpoint GAS RPM, and stays above this level for the time defined by setpoint GAS RPM DELAY. Once the conditions or speed and time have been met, the fuel solenoid will turn on.

Second, if the crank time elapses without a valid start, the fuel is turned off, and the starter remains engaged, cranking the engine for the time defined by setpoint VENT PERIOD. This time is allowed to ventilate the engine of any unburned gaseous mixture.


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The following diagram shows the difference between the diesel and gas start cycles. As can be seen in the diagram, the crank pause does not begin until the vent period has elapsed, and the time the engine is cranking is longer when GAS is selected as it must run during the vent period to ventilate the engine.

Prestart Crank Period Crank Pause

Diesel Starter

Fuel

Prestart Crank Period Vent Period Crank Pause

Gas Starter

Fuel

Gas RPM reached

Gas Delay Elapsed

Gas Delay

To enable crank protections: Enable the warning or alarm for Crank Fail or Overcrank. Crank fail is triggered if there is no Engine RPM sensed after 3 seconds of cranking. Overcrank is triggered when all engine crank cycles have be performed. These faults can be used to signal external equipment that there has been a failure of the engine to start when commanded by assigning the Overcrank and/or Crank Fail function to any available binary outputs.

To enable stop protections: Enable the warning or alarm for Stop Fail and define the longest time it takes for the engine to stop rotating in the setpoint STOP PERIOD. After this time has elapsed, and the engine RPM has not reached 0 then this fault will be triggered. This fault can be used to signal external equipment that there has been a failure of the engine to stop when commanded by assigning the Stop Fail function to any available binary outputs.



Meters:

Display – The meters for engine RPM and operating mode can be found on Screen: Main Screen -> RPM


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SmartVU - The meters for engine RPM and operating mode are shown below. Operating Mode Status -> ENGINE SPEED

Setpoints:

Crank Attempts CRANK ATTEMPTS – Number of times the controller will go through the Crank – Pause cycle

Crank Pause CRANK PAUSE - Time, in seconds, the controller will wait before issuing another crank cycle.

Crank Period CRANK PERIOD – Time, in seconds, the controller will try to start the engine before pausing.

D+ D+ - This is the configuration of the D+ terminal. When Enabled the terminal is use as an engine running detection and belt break detection. Once the terminal has detected engine running, the belt break / charger failure detection begins. Belt Break Detection uses this terminal as a charger failure only. When disabled, the terminal does nothing.

The following options are available:

Disabled DIS – When selected, the D+ input does not perform any function.

Belt Break BELT –When selected, the D+ input will provide alternator belt break detection.

Enabled EN –When selected, the D+ input will provide engine started and belt break detection.

ENGINE SPEED ENGINE SPEED – The rated speed of the application. This parameter is typically set to 1800 for 60Hz applications and 1500 for 50Hz applications. It is used by overspeed and underspeed protections, and engine speed computation from generator frequency. Other setpoints are % of this speed

Engine Type ENGINE TYPE – Indicates type of fuel used by the engine. If DIESEL is chosen the Fuel Solenoid output will activate during CRANK PERIOD and deactivated during a Crank Pause. It will also be deactivated when an emergency stop is issued or if the engine is to be stopped. It will also deactivate if the engine fails to start. If GAS is chosen the fuel solenoid output will be activated during CRANK PERIOD but only after the engine has exceeded the GAS RPM for GAS RPM DELAY.


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The Fuel Solenoid output will deactivate during CRANK PAUSE. It will also be deactivated when an emergency stop is issued or if the engine is to be stopped. It will also deactivate if the engine fails to start. After a failed crank, the engine will be ventilated for VENT PERIOD by running the starter with Fuel Solenoid off.

Diesel DIESEL – This setting enables the starting strategy for a diesel engine where the starter and fuel outputs activate and deactivate at the same time.

Gas GAS – This setting enables the starting strategy for a gas engine which delays the introduction of fuel until after the engine has reached a defined RPM, and continues the starter for a period of time after CRANK PERIOD to allow ventilation of the engine.

Gas RPM GAS RPM – RPM the engine must exceed for the fuel solenoid output to activate when GAS is selected in ENGINE TYPE.

Gas RPM Delay GAS RPM DELAY - Time, in seconds, that the engine must exceed the GAS RPM before the Fuel solenoid is activated when GAS is selected in ENGINE TYPE

Oil Disconnect OIL DISCONN – The Oil Pressure that will have to be exceeded before the starter is disengaged.

NOTE: When one of following parameters (RPM DISCONNECT, D+, or OIL DISCONNECT) are exceeded the engine is considered running and the starter is disengaged

RPM Disconnect RPM DISCONNECT – The percent of ENGINE SPEED at which the engine will have to exceed before the starter is disengaged. This is also the set point for under speed.

NOTE: When one of following parameters (RPM DISCONNECT, D+, or OIL DISCONNECT) are exceeded the engine is considered running and the starter is disengaged

Stop Period STOP PERIOD – Time, in seconds, engine is given to come to a complete stop. If this time is exceeded, the Stop Fail protection is triggered.

Vent Period VENT PERIOD - Extra time, in seconds the Starter will be activated if the engine fails to start after fuel deactivates when GAS is selected in ENGINE TYPE. This is used for venting excess gas.

Protections:

Holdoffs:

Crank Fail Alarm – This protection is activated when the GNS detects no RPM after 3 seconds of cranking.

Overcrank Alarm – Activated when the GNS exhausts the number of cranking cycles configured. This means the GNS has cranked the engine specified by the CRANK ATTEMPTS set point, each crank has been attempted for the amount of time specified by the CRANK PERIOD set point, and the GNS has waited in between each crank for the amount of time specified by the CRANK PAUSE set point.

Stop Fail Warning, Stop Fail Alarm – This protection is activated when the engine is reading RPM after the engine should have stopped. There are no set points.


Remote Start REM START - Start request for manual mode


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Remote Start/Stop REM S/S – Allows user to start and stop the engine while in auto mode.

Note: Must not be assigned to more than one input.

Remote Stop REM STOP - Stop request for manual mode


Crank Failed CRK FAIL – Active when protection Crank Fail is active.

Overcrank OVR CRANK – Active when protection Over Crank is active.

Starter STARTER – Activated during engine cranking state to control starter motor.

Stop Fail STOPFAIL – Active when protection Stop Fail is active.

Stop Solenoid STOP SOL – Activated to stop the engine, deactivated when engine is stopped.

Status Messages:


Engine Started ENGINE STARTED – The engine has completed its cranking stage and is proceeding to idle or rated speed.

Gas RPM Reached– The engine has reached the RPM specified by the Gas RPM set point

Gas Venting – Recorded when a gaseous engine fails to start and enters the gas venting cycle.

Nominal Speed Reached REACHED NOMINAL SPEED - The engine has reached the nominal operating speed.

Start Command START COMMAND - The controller has received a request to start the engine either from the input or remote command

Stop Command STOP COMMAND - Recorded when the controller has commanded a stop of the generator set.


3.11 CONFIGURING THE GNS TO RUN IDLE STAGE

Description:

The Idle Stage in the GNS can be used to warm up the engine before applying load. Based on the configured Idle period, the control will remain in the Idle stage for that time. If an Idle Override function is assigned to any Binary Input the control will remain in the Idle Stage as long as the override is active. If it is no longer active, then the Idle Stage will complete when the time elapses. The idle timer is not stopped by the override but continues to run during the override. In addition, the Idle Stage can be shortened in MAN Mode if no override is active by requesting start again. At that time the Idle Stage will end immediately. During the Idle Stage, any Binary Outputs assigned the Idle function will be active.


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Requirements:

To enable Idle Stage:

Set the setpoint Idle Period to a non-zero value. This will cause the Idle Stage to run regardless of whether a binary output is assigned to idle function. If a signal is needed for external equipment, then a binary output should be assigned to idle function.

To disable Idle Stage:

Set setpoint for Idle Period to 0. The Idle Stage will no longer run even if a binary output is assigned to the Idle function.



Meters:

Display – The status of the Idle Stage can be found on Main Screen represented by IDLE followed by the timer. If an Idle override is active then the stage is represented by IDLE OVR. The status of the Binary Inputs and Outputs can be found on screens Binary Input States and Binary Output States next to their assigned functions.

SmartVU - The status of the Idle Stage can be found on the following meter. This should be formatted the same as other examples Operating Mode Status -> ENGINE

Setpoints:

IDLE PERIOD IDLE PERIOD – Time the Idle output will be active to keep the engine at an idle rpm. The time does not begin until the start criteria is satisfied.

Protections: None


IDLE OVERRIDE IDLE OVR - Extends idle operation until signal released.


IDLE IDLE - Activated when GNS is in idle state or cooling state if cooling at idle is enabled. Used to signal engine to go to idle speed.

Status Messages: The following status messages can be logged in the event logged to aid in troubleshooting and to provide information on the generator’s actions. Each status can be enabled or


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disabled with the configuration software. Any supporting data logged with the event, is described in the Status Messages section as well as the exact message displayed.

IDLE SPEED OVERRIDE IDLE SPD OVERRIDE – The idle override input function has been triggered.

Alternate Uses:

Temperature Based Idle function – This function could be used to activate the idle function whenever the engine temperature is too low, and continue this until the temperature is no longer considered too low. To accomplish this, configure a minimum idle period of 1 second, wire the low coolant temperature warning output to the idle override input. When the engine starts, the idle stage will run for just 1 second, then if the coolant temperature is too low, the idle override will turn on and hold the control in the idle stage until the coolant temperature reaches an acceptable temperature and the low coolant temperature warning deactivates. At that point the idle override will be released and the engine will accelerate to nominal speed.

3.12 CONFIGURING THE GNS TO RUN COOL DOWN STAGE

Description:

The Cool Down Stage in the GNS can be used to cool down the engine before stopping. Based on the configured cool down period, the control will remain in the Cool Down Stage for that time. The engine can be commanded to cool at rated speed or idle speed with the IDLE COOLING setpoint. If IDLE COOLING is ENABLED, then any Binary Outputs assigned the Idle function will be active during this period. This allows the ECU or Governor to be commanded to idle speed. In addition, the Cool Down Stage can be shortened in MAN Mode by issuing a stop request again. At that time the Cool Down Stage will end immediately.

Requirements:

To enable Cool Down Stage:

Set setpoint COOLING PERIOD to non-zero value. If the engine should cool at idle speed, enable IDLE COOLING setpoint and assign a Binary Output to Idle function. Typically one Binary Output is assigned the Idle function and used to control the idle speed of the engine. It will be asserted during the Idle Stage as well as during the Cooling Stage if the setpoint IDLE COOLING is ENABLED.


Set setpoint COOLING PERIOD to zero.


Refer to Binary Output Wiring sections for proper wiring of outputs.

Meters:

Display – The status of the Cool Down Stage can be found on Main Screen represented by COOLING followed by the timer. The status of the Binary Outputs can be found on screens Binary Output States next to their assigned functions.

SmartVU - The status of the Cool Down Stage can be found on the following meter. Operating Mode Status -> ENGINE


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Setpoints:

COOLING PERIOD COOLING PERIOD – Time, in seconds, engine will run, unloaded, to cool the engine. This can be linked to the Idle if it is desired to run at idle speed for cooling.

IDLE COOLING IDLE COOLING – Enables or disables the idle output during the cooling period (this cools the engine at idle speed).

Protections: None



IDLE IDLE – Activated when GNS is in idle state or cooling state if cooling at idle is enabled. Used to signal engine to go to idle speed.


COOL DOWN – The engine has reached the cool down stage


3.13 CONFIGURING THE GNS TO RUN AFTER COOL STAGE

Description:

The After Cool Stage in the GNS can be used to control auxiliary equipment after the engine has stopped. Typically it is used for running ventilation fans, etc, that may need to be run for a period of time after the engine stops to ventilate the room or remove any excess heat. The After Cool Stage is a time based stage that will run for its configured time. During this time, any Binary Output configured for After Cool function will be active. In addition, the After Cool Stage can be shortened in MAN Mode by issuing a stop request again. At that time the After Cool Stage will end immediately.

Requirements:

To enable After Cool Stage:

Set setpoint AFTER COOL PERIOD to non-zero value.


Set setpoint AFTER COOL PERIOD to 0.


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Meters:

Display – The status of the After Cool Stage can be found on Main Screen represented by AFTERCOOL followed by the timer. The status of the Binary Outputs can be found on screen Binary Output States next to their assigned functions.

SmartVU - The status of the After Cool Stage can be found on the following meter. Operating Mode Status -> ENGINE

Setpoints:

AFTER COOL PERIOD AFT COOL PER – Time, in seconds, the after cool output will be active after the engine is stopped.

Protections: None



AFTER COOL AFT COOL – Active during After Cool stage.


AFTER COOL – The engine has reached the after cool stage.


3.14 CONFIGURING THE GNS TO WORK WITH ECU-BASED ENGINE

Description:

Newer electronic engines have an ECU that is capable of fully managing the operation of the engine and protecting the engine from damage. These ECUs typically can communicate with other components in the system by using CAN bus communication. The most popular protocol used on the CAN bus is SAE J1939. Using this protocol, the ECU can transmit numerous engine related data over the CAN bus removing the need to have additional sensors on the engine to monitor key engine parameters. The GNS easily integrates with these ECUs and can utilize much of the data provided. The GNS supports J1939 based engine control through the following features.


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CAN/J1939 Bus communication monitoring – The GNS can monitor the CAN bus for disruptions of communications and trip a fault if communication has stopped completely for the configured time. In addition the address of the ECU is configurable although most ECUs are configured for address 0. See the section on Configuring the GNS for CAN Bus

Parameter Metering and Protection – The GNS can look for critical standard J1939 parameters that are needed for control and use these in place of dedicated sensors. The GNS can then apply additional protections if desired or leave only the protections provided by the ECU itself. The following parameters are needed by the control and can be sourced from the engine ECU by J1939.

Engine Speed

Oil Pressure

Coolant Temperature

Fuel Level

See the sections on Configuring the GNS for Engine Speed Metering and Protection, Configuring the GNS for Engine Coolant Metering and Protection, Configuring the GNS for Fuel Level Metering and Protection, and Configuring the GNS for Oil Pressure Metering and Protection.

Parameter Metering – The GNS can monitor up to 10 parameters being sent on the J1939 bus. These parameters are not used by the control for any purpose, but are used to display their current values on the screen. See the section on Configuring the GNS for J1939 monitoring.

Diagnostic Monitoring – The GNS can monitor the diagnostic data coming from the engine ECU and display the Diagnostic Trouble Codes (DTCs) being sent. See the section on Configuring the GNS to Display J1939 DTCs.

3.15 CONFIGURING THE GNS FOR POWERING AND COMMUNICATING WITH AN J1939 ECU

The GNS has many J1939 features that operate independently but share a common set of configuration information to make the CAN/J1939 bus operate properly. Once operating properly, any of the additional features will operate independently. If the bus is not configured properly, then none of the features will work. Basic setup of the CAN bus has three requirements. There must be a connection between the units. The ECU must be powered. And the GNS configured to talk to the ECU.

Requirements

To enable the CAN/J1939 bus the ECU address must be defined and the wiring for the bus must be connected. Control of ECU power must be considered as there are several possible options. All other configuration information is automatically handled by the GNS. It should be noted that the CAN bus can only communicate with ECUs that follow SAE J1939 standard.

Wiring Requirements

Refer to the CAN/J1939 Wiring section on how to wire up the CAN/J1939 Bus between units


There are three different ways the ECU can be powered.

Option A

Power the ECU with its own dedicated connection to the battery so that it is always powered. In this option, the GNS should be configured to use a Binary Output configured for the Fuel function to


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signal the ECU that it should be operating. With this option, the ECU power is controlled independent from the GNS and the GNS only sends a signal to indicate that the ECU should start and run the engine. If the GNS detects a fault, it will remove the signal, and the ECU should stop the engine. If the ECU is always powered when the GNS is powered, then protections ECU Offline, and CAN1 Bus Error can be enabled to monitor communications between the ECU and the GNS.

Option B

Control the ECU power with the GNS. Use the Binary Output configured for the Fuel function. This is similar to option A, except the GNS is in control of the ECU power and not just signaling the ECU for starting and stopping. When the GNS wants to start the engine, the Fuel output will power the ECU. When the GNS wants to stop the engine the fuel output will deactivate, removing power from the ECU. With this option, because the ECU is not always powered when the GNS is powered, the protections for ECU Offline, and CAN1 Bus Error must be disabled or set to a warning.

To power the ECU periodically to read status, configure a Prelube cycle to run for the amount of time needed to read the data from the ECU, and configure the Prelube pause to be the period of time between status updates. Then configure a Binary Output to the Prelube function and use this output in addition to the normal Fuel output to control power to the ECU. Alternatively, instead of using a binary output for the Prelube function, configure the Prelube cycle in addition to the other active states for a user-defined protection as described in Option C below.

Option C

This option is used when the ECU must be powered before crank to allow data on the J1939 bus coming from the ECU to stabilize. Although the GNS does not directly provide a function for independently controlling an ECU, through the use of a couple of configurable inputs and outputs, and user defined protections a highly configurable implementation can be achieved.

To power the ECU before cranking the engine: Configure an unused Prestart function for 1 second more than the amount of time it is desired that the ECU be power before cranking begins. Do not configure an output for this Prestart function.

Configure an unused User-defined input for warning with a 1 second delay, set its active time to be during all engine running states and Prestart, and name the user defined ECU Pwr.

Assign an unused Binary Input to the function ECU Pwr Warning and wire this to Battery-

Assign an unused Binary Output to the function ECU Pwr Warning and wire this to control the ECU power.

Whenever the engine is requested to run, the Prestart function will run first, because the user defined is conditioned on Prestart, it will not active until the Prestart stage runs, and will remain active while the engine is running. This user defined will control the power to the ECU.

To power the ECU periodically to read status with this option, configure a Prelube cycle to run for the amount of time needed to read the data from the ECU, and configure the Prelube pause to be the period of time between status updates. Instead of configuring a Prelube function to a binary output, add the Prelube state as another active state when the user defined should be active.

Now in addition to activating the ECU Pwr Warning output during Prestart and all running states, the output will also be active during the Prelube state.

Meters: None

Setpoints:

CAN1 ERROR DELAY – The amount of time to wait after losing CAN data before triggering a fault.


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CAN1 J1939 ECU ADDRESS – The source address the GNS looks for when attempting to read data from the ECU.

Protections:

ECU OffLine – This protection is activated when the GNS stops receiving any data from the address configured by setpoint CAN1 J1939 ECU ADDRESS for an extended period of time.





3.16 CONFIGURING THE GNS FOR J1939 MONITORING

Description:

The GNS can display the values of up to 10 parameters from the J1939 Bus. The parameters can be any of the parameters currently being used by the control (Engine speed, Coolant Temperature, Oil Pressure, or Fuel Level), or it can be any other parameter available on the J1939 bus. Parameters such as Oil Temperature, Turbo (Boost) Pressure, and Coolant Level are just a few of the more common ones. These parameters are only displayed and are not used by any protection functions. The parameters can also be manufacturer specific parameters. The configuration of which parameters to display is done by the GNS configuration software, SmartVU. The configured parameters can be viewed on the GNS displays as well as within SmartVU.

Requirements:

In order for this function to work, the CAN Bus must be configured properly. Refer to the section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.

Using SmartVU software, select the ECU from the list, then select up to 10 of the parameters available from that ECU. Save this data to the GNS.


Refer to the CAN/J1939 Wiring section on how to wire up the CAN/J1939 Bus.

Meters:

If an ECU is configured, the following screen will be shown with a list of up to the first five parameters. If there are more than five parameters defined, an additional screen will be shown.

Note: the configured ECU will be shown on the top line of any J1939 Monitoring screens.


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Setpoints:

Configuration of the ECU type and parameters to display is done through the GNS configuration software, SmartVU.

Protections: None





3.17 CONFIGURING THE GNS TO DISPLAY J1939 DTCS

Description:

Whenever the GNS is connected to a J1939 Bus it will monitor the Bus for DTCs from the ECU with address specified by CAN1 J1939 ECU ADDRESS. This function cannot be disabled. Monitoring of DTCs is done periodically as the J1939 protocol requires that ECUs automatically broadcast active DTCs, and previously active ones are broadcast when requested. The GNS is constantly monitoring for these active DTCs, and will request previously active DTCs when requested by the operator.

Requirements:

In order for this function to work, the CAN Bus must be configured properly. Refer to the section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.

There are no requirements for this feature other than general configuration of the CAN bus needed by any CAN bus-related feature.


Refer to the CAN/J1939 Wiring section on how to wire up the CAN/J1939 Bus.

Meters:

The DTCs can be seen on the display by navigating to the DTC screen. If any DTCs are active they will show up on this screen. Pressing the Enter key switches the mode to request previously active DTCs. Each DTCs will be shown numerically, and can be configured to show it in English nomenclature as well. Pressing the Fault Reset while on this screen will request that the ECU clear its memory of previously active DTCs, in J1939 terminology, it will send a DM3 message. Some manufacturers will honor this request, and some will not.

The DTCs can be seen in SmartVU on the following meter. If any DTCs are active they will show up on this screen. Selecting the appropriate radio button allows viewing of active DTCs and previously active DTCs. Each DTCs will be shown numerically, and English nomenclature as well.


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Setpoints:

SPN FAULT CONVERSION CONVERT METHOD – The method the GNS uses to convert fault data from the ECU

Protections: None





3.18 CONFIGURING THE GNS FOR ENGINE COOLANT TEMPERATURE METERING AND PROTECTION

Description:

The engine coolant temperature is not used by any built-in control functions and is only used to protect the engine from damage due to high temperature and to trigger external equipment if the temperature is too low. The source of the engine coolant temperature can be any one of the four analogs inputs or from a J1939-based ECU. If source is J1939, then the analog input can be used for any other function.

Note: The units for temperature can be configured for oF, or oC independently on each display and within SmartVU. See Sections User Interface and GNS Configuration Software for setting the temperature units.

Note: Analog input protection features are independent protection functions applicable to the analog inputs only. Use the provided system coolant temperature protections for standard coolant protection.

Note: The ECM Monitoring function is not related to the engine coolant temperature protection function and does not need to be configured for the metering or protections to function properly.

System Parameters


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For several key parameters, the GNS has multiple sources of inputs. Based on the source selected, one input will be used as a System parameter. This parameter will have dedicated protection functions, and will be used in the control logic as necessary. Additionally, some of the input sources independent protections that apply only to those inputs.

The sources of information for the coolant temperature control logic are the Engine Coolant Temperature (Analog 1 – 4, J1939), the setpoint used to configure the System Coolant Temperature (Coolant Temperature), and the protections that apply to the System Coolant Temperature regardless of the source (Low Coolant Temperature Warning, Low Coolant Temperature Alarm, Low Coolant Delay, High Coolant Temperature Warning, High Coolant Temperature Alarm, High Coolant Temperature Delay). All these setpoints are used to configure and protect the System Coolant Temperature. Any analog channel that is not being used as the source of the System Coolant Temperature can be used to monitor and protect any other analog signal by configuring the independent analog protections. If an analog channel is being used as the source of the System Coolant Temperature, it can have additional protections at the analog input level as well. But the protections at the analog level work differently than the protections at the system level. This is due to the fact that at the system level, it is understood by the GNS that this parameter represents Coolant Temperature and it applies different logic based on that, such as hold-offs and engine stages where the protections should be active. At the analog level it is not known what the input will be used for and therefore a range of generic protections are available.


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Requirements:

To enable engine coolant temperature metering from analog input:

Set setpoint COOLANT TEMPERATURE to ANALOG INPUT X where X indicates the analog input channel connected to the coolant temperature sender, and configure the analog input to match the sender. See Section Configuring the GNS to work with Analog Inputs.

To enable engine coolant temperature metering from J1939 ECU:

Note: In order for this function to work, the CAN Bus must be configured properly. Refer to the Section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.

Set setpoint COOLANT TEMPERATURE to CAN J1939, and configure the general ECU communication.

To enable high engine coolant temperature protection:

In order to use the protection function, there must be valid coolant temperature metering. This should be verified before attempting to protect on coolant temperature. Set setpoints HIGH COOL TEMP ALARM and/or WARNING to desired values and enable the corresponding protection(s). Both warning and alarms can be enabled at the same time.

To enable low engine coolant temperature protection:

In order to use the protection function, there must be valid coolant temperature metering. This should be verified before attempting to protect on coolant temperature. Set setpoints LOW COOL TEMP ALARM and/or WARNING to desired values and enable the corresponding protection(s). Both warning and alarms can be enabled at the same time.

To disable engine coolant temperature protection:

To disable any engine coolant temperature protection, disable the corresponding warning or alarm protection in SmartVU.

To disable engine coolant temperature metering:

To disable engine coolant temperature metering, select NOT ASSIGNED for the COOLANT TEMPERATURE setpoint. All coolant temperature protections must be disabled and the coolant temperature meters will show ambient temperature.


Refer to the following sections on how to wire up the corresponding coolant temperature input:

CAN/J1939 – See CAN/J1939 wiring

Analog Input – See Analog Input Wiring


Meters:


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Display – The meter showing the engine coolant temperature is found on screens: Analog Metering -> COOLANT TEMP, and if the source of engine coolant temperature is one of the analog inputs it can also be found on screen: Analog Input -> COOLANT TEMP

SmartVU - The meter showing the engine coolant temperature is shown below. If any warnings or alarms are enabled, the will be shown on the meter in yellow (warning) or red (alarm).

Setpoints:

COOLANT TEMPERATURE – The source of the system coolant temperature. This temperature is used by the coolant temperature protection.

NOT ASSIGNED – No coolant temperature used. System will used on-board temperature sensor for temperature input.

CAN J1939 – Coolant temperature will be provided by the ECU and will be taken from the standard parameter Engine Coolant Temperature defined by J1939

ANALOG INPUT 1 –

ANALOG INPUT 2 –

ANALOG INPUT 3 –

ANALOG INPUT 4 – Coolant temperature will be sensed from the analog channel selected. Configure the analog input for temperature, and load the map corresponding to the sensor used.

HIGH COOL TEMP ALARM HI TEMP ALARM – Coolant temperature at which the High Temp Alarm is triggered.

HIGH COOL TEMP DELAY HI TEMP DELAY – Time, in seconds, the High Coolant Temperature Warning or Alarm condition must be present before the GNS will report the failure.

HIGH COOL TEMP WARNING HI TEMP WARN – Coolant temperature at which the High Temp Warning is triggered.


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LOW COOL TEMP ALARM LO TEMP ALARM – Coolant temperature at which the Low Temp Alarm is triggered.

LOW COOL TEMP DELAY LO TEMP DELAY – Time, in seconds, the Low Coolant Temperature Warning or Alarm condition must be present before the GNS will report the failure.

LOW COOL TEMP WARNING LO TEMP WARN – Coolant temperature at which the Low Temp Warning is triggered.


Low coolant temperature protection is active all of the time (engine running or stopped) except when the control is in Off mode.

High coolant temperature protection is active after a 1 min hold off from engine started.



Low Coolant Temperature Warning - Activated when the coolant temperature reaches the value set by the LOW COOLANT TEMP set point for the amount of time specified by the COOLANT TEMP DELAY set point.

Low Coolant Temperature Alarm – Activated when the coolant temperature reaches the value set by the LOW COOLANT TEMP set point for the amount of time specified by the COOLANT TEMP DELAY set point.

High Coolant Temperature Warning - Activated when the coolant temperature reaches the value set by the HIGH COOLANT TEMP set point for the amount of time specified by the COOLANT TEMP DELAY set point.

High Coolant Temperature Alarm - Activated when the coolant temperature reaches the value set by the HIGH COOLANT TEMP set point for the amount of time specified by the COOLANT TEMP DELAY set point.



High Cool Temp Warning HI TMP WN- Active when protection High Coolant Temperature Warning is active.

High Cool Temp Alarm HI TMP AL- Active when protection High Coolant Temperature Alarm is latched.

Low Cool Temp Warning LO TMP WN - Active when protection Low Coolant Temperature Warning is active.

Low Coolant Temperature Alarm LO TMP AL - Active when protection Low Coolant Temperature Alarm is active.



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Alternate Uses:

Temperature Based Prestart function – See Section Configuring the GNS to run Prestart Stage alternate uses.

3.19 CONFIGURING THE GNS FOR FUEL LEVEL METERING AND PROTECTION

Description:

The fuel level is not used by any built-in control functions and is only used to protect the engine from running out of fuel. The source of fuel level can be any one of the four analogs inputs or from a J1939-based ECU. If source is J1939, then the analog input can be used for any other function.

Note: Analog input protection features are independent protection functions applicable to the analog inputs only. Use the system provided fuel level protections for standard fuel level protection.

Note: The ECM Monitoring function is not related to the fuel level protection function and does not need to be configured for the fuel level metering or protections to function properly.

System Parameters


The sources of information for the fuel control logic are of the Fuel Level (Analog 1 – 4, J1939), the setpoint used to configure the source of the System Fuel Level (Fuel Level), and the protections that apply to the System Fuel Level regardless of the source (Low Fuel Level Warning, Low Fuel Level Alarm, and Low Fuel Delay). All these setpoints are used to configure and protect the System Fuel Level. Any analog channel that is not being used as the source of the System Fuel Level can be used to monitor and protect any other analog signal by configuring the independent analog protections. If an analog channel is being used as the source of the System Fuel Level, it can have additional protections at the analog input level as well. But the protections at the analog level work differently than the protections at the system level. This is due to the fact that at the system level, it is understood by the GNS that this parameter represents Fuel Level and it applies different logic based on that. At the analog level it is not known what the input will be used for and therefore a range of generic protections are available.

Requirements:

To enable fuel level metering from analog input:

Set setpoint FUEL LEVEL to ANALOG INPUT X where X indicates the analog input channel connected to the fuel level sender, and configure the analog input to match the sender. See Section Configuring the GNS to work with Analog Inputs.

To enable fuel level metering from J1939 ECU:

Note:In order for this function to work, the CAN Bus must be configured properly. Refer to the section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.

Set setpoint FUEL LEVEL to CAN J1939, and configure the general ECU communication.

To enable low fuel level protection:


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In order to use the protection function, there must be valid fuel level metering. This should be verified before attempting to protect on fuel level. Set setpoints LOW FUEL ALARM and/or WARNING to desired values and enable the corresponding protection(s). Both warning and alarms can be enabled at the same time.

To disable low fuel level protection:

To disable any fuel level protection disable the corresponding warning or alarm protection in SmartVU.

To disable fuel level metering:

To disable fuel level metering, select NOT ASSIGNED for the FUEL LEVEL setpoint. All fuel level protections must be disabled and the fuel level meters will read 0%.






Meters:

Display – The meter showing the fuel level is found on screen: Analog Metering -> FUEL LEVEL, and if the source of fuel level is one of the analog inputs it can also be found on screen: Analog Input.

SmartVU - The meter showing the fuel level is shown below. If any warnings or alarms are enabled, the will be shown on the meter in yellow (warning) or red (alarm).

Setpoints:


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FUEL LEVEL – The source of the system fuel level. This level is used by the fuel level protection.

NOT ASSIGNED – No fuel level used. System will display 0% for fuel level.

CAN J1939 – Fuel level will be provided by the ECU and will be taken from the standard parameter Fuel Level defined by J1939

ANALOG INPUT 1 –

ANALOG INPUT 2 –

ANALOG INPUT 3 –

ANALOG INPUT 4 – Fuel level will be sensed from the analog channel selected. Configure the analog input for %, and load the map corresponding to the sensor used.

LOW FUEL LEVEL ALARM LO FUEL ALARM – Percent of fuel at which GNS will report a Low Fuel Alarm.

LOW FUEL LEVEL WARNING LO FUEL WARN – Percent of fuel at which GNS will report a Low Fuel Warning.

LOW FUEL LEVEL DELAY LO FUEL DELAY – Time, in seconds, the Low Fuel Warning or Alarm condition must be present before the GNS will report the failure.


The fuel level protections are always active except when the control is in Off mode.



Low Fuel Level Warning - Activated when the fuel level reaches the level specified by the LOW FUEL LEVEL set point for the amount of time specified by the LOW FUEL DELAY set point.

Low Fuel Level Alarm – Activated when the fuel level reaches the level specified by the LOW FUEL LEVEL set point for the amount of time specified by the LOW FUEL DELAY set point.



LOW FUEL LEVEL WARNING L FUEL WN - Active when protection Low Coolant Temperature Warning is active.

LOW FUEL LEVEL ALARM L FUEL AL - Active when protection Low Fuel Level Alarm is active.

Note: Binary Output function Fuel is not related to fuel level metering or protection and is used to control the fuel solenoid on the engine.


Alternate Uses:


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Auxiliary Fuel Pump Control – In some applications it is necessary to activate a transfer pump when the fuel level in a day tank is low. The Low Fuel Level Warning can be used to trigger the auxiliary pump, which could run off of an external timer or have another input to monitor for high fuel level. Some of this can be accomplished in combination with user-defined protections. See Section Configuring the GNS for User-Defined Protections.


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3.20 CONFIGURING THE GNS FOR OIL PRESSURE METERING AND PROTECTION

Description:

The Oil Pressure can be used for detection of engine started and to protect the engine from low oil pressure. The source of oil pressure can be any one of the four analogs inputs or from a J1939-based ECU. If source is J1939, then the analog input can be used for any other function.

Note: The units for pressure can be configured for PSI, or bar independently on each display and within SmartVU. See Sections User Interface and GNS Configuration Software - SmartVU for setting the pressure units.

Note: Analog input protection features are independent protection functions applicable to the analog inputs only. Use the system provided oil pressure protections for standard oil pressure protection.

Note: The ECM Monitoring function is not related to the oil pressure protection function and does not need to be configured for the oil pressure metering or protections to function properly.

System Parameters


The sources of information for the oil pressure control logic are the Oil Pressure (Analog 1 – 4, J1939), the setpoint used to configure the source of the System Oil Pressure (Oil Pressure), and the protections that apply to the System Oil Pressure regardless of the source (Low Oil Pressure Warning, Low Oil Pressure Alarm, and Low Oil Pressure Delay). All these setpoints are used to configure and protect the System Oil Pressure. Any analog channel that is not being used as the source of the System Oil Pressure can be used to monitor and protect any other analog signal by configuring the independent analog protections. If an analog channel is being used as the source of the System Oil Pressure, it can have additional protections at the analog input level as well. But the protections at the analog level work differently than the protections at the system level. This is due to the fact that at the system level, it is understood by the GNS that this parameter represents Oil Pressure and it applies different logic based on that, such as active engine stages, and hold-off times. At the analog level it is not known what the input will be used for and therefore a range of generic protections are available.

Requirements:

To enable oil pressure metering from analog input:

Set setpoint OIL PRESSURE to ANALOG INPUT X where X indicates the analog input channel connected to the Oil Pressure sender, and configure the analog input to match the sender. See Section Configuring the GNS to work with Analog Inputs.

To enable oil pressure metering from J1939 ECU:

Note:In order for this function to work, the CAN Bus must be configured properly. Refer to the section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.


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Set setpoint OIL PRESSURE to CAN J1939, and configure the general ECU communication.

To enable low oil pressure protection:

In order to use the protection function, there must be valid oil pressure metering. This should be verified before attempting to protect on oil pressure. Set setpoints LOW OIL PRESSURE ALARM and/or WARNING to desired values and enable the corresponding protection(s). Both warning and alarms can be enabled at the same time.

To disable low oil pressure protection:

To disable any oil pressure protection, disable the corresponding warning or alarm protection in SmartVU.

To disable oil pressure metering:

To disable oil pressure metering, select NOT ASSIGNED for the OIL PRESSURE setpoint. All Oil Pressure protections must be disabled and the Oil Pressure meters will show 0.






Meters:

Display – The meter showing the Oil Pressure is found on screen: Analog Metering -> OIL

PRESSURE, and if the source of Oil Pressure is one of the analog inputs it can also be found on screen: Analog Input.

SmartVU - The meter showing the Oil Pressure is shown below. If any warnings or alarms are enabled, the will be shown on the meter in yellow (warning) or red (alarm).


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Setpoints:

OIL PRESSURE – The source of the system oil pressure. This pressure is used by the oil pressure protection, and start detection

NOT ASSIGNED – No oil pressure used. System will display 0% for oil pressure.

CAN J1939 – Oil Pressure will be provided by the ECU and will be taken from the standard parameter Oil Pressure defined by J1939

ANALOG INPUT 1 –

ANALOG INPUT 2 –

ANALOG INPUT 3 –

ANALOG INPUT 4 – Oil Pressure will be sensed from the analog channel selected. Configure the analog input for pressure, and load the map corresponding to the sensor used.

LOW OIL PRESSURE ALARM LO OIL P ALARM – Pressure level at which the Low Oil Pressure Alarm is triggered.

LOW OIL PRESSURE WARNING LO OIL P WARN – Pressure level at which the Low Oil Pressure Warning is triggered.

LOW OIL PRESSURE DELAY LO OIL P DELAY – Time, in seconds, the Low Oil Pressure Warning or Alarm condition must be present before the GNS will report the failure.

Protections& Holdoffs:

The Oil pressure protections are active when the engine has started for at least 5 seconds.



Low Oil Pressure Warning - This protection is activated when the oil pressure reaches the value specified by the LOW OIL PRESSURE set point for the amount of time specified by the OIL PRESSURE DELAY set point.

Low Oil Pressure Alarm – This protection is activated when the oil pressure reaches the value specified by the LOW OIL PRESSURE set point for the amount of time specified by the OIL PRESSURE DELAY set point.


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LOW OIL PRESSURE WARNING LO OP WN - Active when protection Low Oil Pressure Warning is active.

LOW OIL PRESSURE ALARM LO OP AL - Active when protection Low Oil Pressure Alarm is active.



3.21 CONFIGURING FOR ENGINE COOLANT LEVEL PROTECTION (AND METERING)

The engine coolant level metering and protection is not a standard function of the GNS, but the GNS can easily be configured to work with engine coolant level using a user-defined digital (allowing protection only) or analog input (allowing metering and protection functions).

Note: Analog input protection features are independent protection functions applicable to the analog inputs only.

3.21.1 Configuring Engine Coolant Level Metering and Protection using an Analog Input

Requirements:

To enable engine coolant level metering and protection from analog input:

Configure an unused analog input to match the coolant level sender. Set the name to Cool Level. Enable the protections for the analog channel that you are using and set the protections levels as needed. See section Configuring the GNS to work with Analog Inputs.

Note: Configuration of the analog channels and the analog channel protections can only be done by using the GNS configuration software SmartVU.


Refer to the following sections on how to wire up the corresponding coolant level input:



Meters:

Display – The meter showing the coolant level is found on screen: Analog Input -> COOLANT LEVEL


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SmartVU - The meter showing the engine coolant Level is shown below and is the meter for the Analog Input channel configured as coolant level. If any warnings or alarms are enabled, the will be shown on the meter in yellow (warning) or red (alarm).

Setpoints:

All of the required information for configuring a user-defined analog input can be found on the Configuration Meter, notebook tab Analog Input Config by selecting the desired analog input channel from the drop down list at the top of the meter in SmartVU.

All of the required information for configuring analog coolant level protections can be found on the Configuration Meter, notebook tab User Protection, by selecting the desired analog input channel from the drop down list at the top of the meter in SmartVU


Holdoffs for user defines can be configured by disabling the protection during unwanted operating stages.

There are high and low warnings and alarms that can be set. In addition, the action to take on an alarm, the warning and alarm delay, and the operating states during which the warning or alarm is active can be set as well. All of the required information for configuring analog coolant level protections can be found on the Configuration Meter, notebook tab User Protection, by selecting the desired analog input channel from the drop down list at the top of the meter in SmartVU



COOL LEVEL UNDER WARNING COOL LEVEL V WN- Active when protection User Defined X Warning is active.

Note: The number represents the user defined number and not the binary output number. Any user defined can be assigned to any binary input or output.

COOL LEVEL OVER WARNING COOL LEVEL ^ WN- Active when protection User Defined X Warning is active.


COOL LEVEL UNDER ALARM COOL LEVEL V AL- Active when protection User Defined X Alarm is active.



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COOL LEVEL OVER ALARM COOL LEVEL ÂL- Active when protection User Defined X Alarm is active.


Note: The names shown here are based on the names defined in the text above. The actual names shown in SmartVU and on the Display will be the name configured for the User-Defined input. If no name is configured, they will be displayed as “Analog X Under Warning”, “Analog X Over Warning”, “Analog X Under Alarm”, or “Analog X Over Alarm”. The GNS automatically appends the “Under Warning”, “Over Warning”, “Under Alarm”, or “Over Alarm” text to the end of the user defined name to annunciate the desired fault.


3.21.2 Configuring the GNS for Engine Coolant Level Protection using a Binary Input

Requirements:

To enable low engine coolant level protection from Binary Input:

Select an unused user-defined binary input. Set the name to Cool Level. Enable the protection type (Warning, Alarm), and if actions to take if configured for alarm. Set the operating states where this protection should be active. Select an unused binary input and select the input function label Cool Level Warning or Coolant Level Alarm based on which protection was selected above. In addition, there are equivalent Binary Output functions with the same name that can be used to signal external equipment of the same condition.


Refer to the following sections on how to wire up the corresponding coolant level input:

Binary Input – Binary Input Wiring


Meters:

Display –The status of the input can be found on the Binary Input State screen.

SmartVU - The status of the input can be found on the External Discrete Input Levels meter


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Setpoints:

For binary coolant level protection, all of the required information can be found on the Configuration Meter, notebook tab User Protection, by selecting the desired user-defined from the drop down list found at the top of the meter in SmartVU.


Holdoffs for user defines can be configured by disabling the protection during unwanted operating stages.

Protections can be set for warning and alarm conditions that would be triggered if the input becomes active. In addition, the action to take on an alarm, the warning and alarm delay, and during which operating states the warning or alarm is active can be set as well.


COOL LEVEL WARNING COOL LEVEL WN- When this input is active, and the Coolant Level Warning is enabled, the coolant Level protection will be triggered.

COOL LEVEL ALARM COOL LEVEL- When this input is active, and the Coolant Level Warning is enabled, the coolant Level protection will be triggered.

Note: The names shown here are based on the names defined in the text above. The actual names shown in SmartVU and on the Display will be the name configured for the User-Defined input. If no name is configured, they will be displayed as “User Defined X Warning” or “User Defined X Alarm”. The GNS automatically appends the “Warning” or “Alarm” text to the end of the user defined name to allow selection of the desired function.


COOL LEVEL WARNING COOL LEVEL WN- Active when protection User Defined X Warning is active.


COOL LEVEL ALARM COOL LEVEL AL- Active when protection User Defined X Alarm is active.

Note: The names shown here are based on the names defined in the text above. The actual names shown in SmartVU and on the Display will be the name configured for the User-Defined input. If no name is configured, they will be displayed as “User Defined X Warning” or “User Defined X Alarm”. The GNS automatically appends the “Warning” or “Alarm” text to the end of the user defined name to allow selection of the desired function.


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3.22 CONFIGURING THE GNS FOR SERVICE ITEMS - SERVICE TIME, RUN TIME, AND NUMBER OF STARTS

The GNS provides a number of features that can assist with engine servicing. It can monitor the number of successful starts the control has made, the number of running hours on the engine, and the time until the next service operation. The running hours are also used to time stamp each entry in the history log so that a relative timeframe between events can be established. See Section Alarms/Warnings/Statuses – Event Logs for additional information. When the service hours expire, a protection can be enabled to trigger, and log the event. This protection will retrigger and log a new event every time the engine is started with 0 service hours.

Requirements:

To enable Engine Service Protection: Set setpoint SERVICE HOURS to the number of hours until the next service, and enable the protection.

To disable Engine Service Protection: Disable the protection

To reset Engine Service Protection: Set setpoint SERVICE HOURS to the next service time.



Meters:

Display – The follow screens show the status of service items:

Analog Metering-> Serv. Hrs

Analog Metering-> Run Hrs

Analog Metering-> Number Starts

The status of the Binary Inputs and Outputs can be found on screens Binary Input States and Binary Output States next to their assigned functions.

SmartVU - The status of the service items can be found on the following meters.


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Setpoints:

SERVICE HOURS SERV. HRS – Time, in hours to next required service. Once this counter expires a warning will be displayed. This set point counts down to zero. A persistent warning will be displayed until a new value is loaded for next service time.

ENGINE RUN TIME RUN HRS- Used to set the number of hours on the engine.

NUMBER OF STARTS – The number of times the unit has been successfully started since the last time the counter was set to zero.


This protection is only active when the engine is running.

Engine Service Warning – This protection is activated when the number of hours specified by the NEXT SERVICE TIME reaches zero.


None


Service Required SRV REQ – Active when protection Service Required is active.


Alternate Uses:None

3.23 CONFIGURING THE GNS TO WORK WITH YOUR GENERATOR

The GNS family is designed to be very flexible and adaptable to a wide range of generators and configurations. Even though the generator is in one configuration at a time, many applications require that the generator be reconfigured on-site to operate at different voltages, or in different configurations. The GNS has features that allow it to adapt to these changes without requiring reconfiguration of the controller. The main feature that accomplishes this is the voltage detection strategies that allow the controller to respond to changes in the generator configuration automatically.


Refer to the following sections on how to wire up the corresponding voltage and current inputs:

Generator Voltage Input – See Generator Voltage Wiring

Generator Current Input – See Generator Current Wiring

Refer to Binary Input Wiring sections for proper wiring of binary inputs.

Meters:

Display – The following screens show the voltage, current, and power measurements on the GNS.

The Main Screen shows the measured L-N, and L-L voltages, phase currents, and optionally total power as shown below.


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The Generator Metering screens show the measured voltages, currents, and frequencies. The Power Screens show the measured power as shown below

SmartVU - The meters showing L-N, L-L voltages, phase currents, and power are shown below. If any warnings or alarms are enabled, they will be shown on the meter in yellow (warning) or red (alarm).

Setpoints:

Refer to the appropriate voltage detect method section for setpoint configuration.

Protections:

Auto Voltage Detect Warning (GNS2000 Only) – This protection is activated when setpoint VOLTAGE DETECTION is ENABLED and the GNS cannot determine the configuration of the wiring or operating voltages after VOLTAGE DETECTION TIME has elapsed.


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Auto Voltage Detect Alarm (GNS2000 Only) - This protection is activated when setpoint VOLTAGE DETECTION is ENABLED and the GNS cannot determine the configuration of the wiring or operating voltages after VOLTAGE DETECTION TIME has elapsed.

Phase Wiring Voltage Warning – Activated when the GNS detects an improper phase relationship between the generator voltage inputs.

Phase Wiring Voltage Alarm – Activated when the GNS detects an improper phase relationship between the generator voltage inputs.

Phase Wiring Current Warning – Activated when the GNS detects an improper phase relationship between the generator current inputs.

Phase Wiring Current Alarm – Activated when the GNS detects an improper phase relationship between the generator current inputs.


Only Binary Voltage Select Operation uses binary inputs. Refer to that section for functionality.




3.24 CONFIGURING THE GNS TO USE A VOLTAGE DETECTION METHOD (GNS2000 ONLY)

The GNS family provides three methods for determining the nominal operating voltage, rated current, and rated power of the generator set: Auto Voltage Detection, Fixed Voltage, and Binary Voltage Select. All three methods are present in the controller but only one can be used at any given time. Each method computes nominal operating conditions for power, current, voltage, and generator configuration differently. The following table shows how the controller determines the nominal operating points for each of the parameters based on the voltage detection method used. These nominal values are then used by the protection logic as the 100% value for protections setpoints.

The decision of which method to use largely depends on the application. If the application has only one configuration such as a standby generator, then Fixed Voltage Configuration would be best. If the generator requires constant voltage changes, such as a rental generator, then binary voltage select or auto voltage detection should be used. Which one depends on whether auxiliary contacts are available on the voltage selector switch.

Method Rated Current Rated Voltage Generator Configuration Notes

Fixed Voltage

User Specified User Specified User Specified No check is made to validate relationship between power, current, and voltage

Auto Voltage Detection

Computed from voltage and generator configuration detected on voltage inputs, using power rating corresponding to detected generator configuration.

Detected after generator reaches rated speed and VOLTAGE DETECT DELAY TIME elapses

Detected after generator reaches rated speed and VOLTAGE DETECT DELAY TIME elapses

Amount of time to wait before voltage detection is user configurable to allow manual voltage adjustment


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Binary Voltage Select

Computed from voltage and generator configuration selected from Voltage Selection Table, using power rating corresponding to selected generator configuration.

Selected from Voltage Selection Table based on Voltage Select Binary Inputs

Selected from Voltage Selection Table based on Voltage Select Binary Inputs

2, 3, or 4 different voltages/configurations are possible. For single voltage configuration, used Fixed Voltage method.

All three methods use the same two setpoints for determining the power rating of the generator. Based on the generator configuration specified by the user (Fixed), detected (Auto detect), or selected (Binary Select), the corresponding power setpoint will be used. For Zig-Zag configurations GENERATOR NOMINAL POWER SINGLE PHASE will be used. For Wye, Delta, and High Leg Delta, GENERATOR NOMINAL POWER 3 PHASE will be used.

The selection of which method the controller will use for configuring the nominal values is controlled through a few setpoints. Based on those setpoints the controller will use the method identified and set the nominal values accordingly. The following table shows which setpoints are used to select the method, and which setpoints are used once that method is selected to compute the nominal values.


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Setpoints used to select

voltage configuration method Setpoints used to compute nominal values

Method Binary Inputs

Gen Nominal Voltage

Gen Nominal Current Gen Config

Voltage Selection Table

Gen Nominal Power 3 Phase

Gen Nominal Power Single Phase

Fixed Voltage No Voltage Selects defined

Required Required Required Not Used Required Required

Auto Voltage Detection

Not Used Not Used Not Used Not Used Not Used Required Required

Binary Voltage Select

At least 1 and at most 2 Voltage Selects defined

Not Used Not Used Not Used Required Required Required

All methods require that setpoints SINGLE PHASE ZERO LEG, HIGH LEG DELTA be set if either of those configurations are used.

3.24.1 Fixed Voltage Operation

In fixed voltage operation the GNS has a fixed configuration which indicates the operating voltage, current, power, frequency, and wiring configuration of the generator. The GNS will establish generator protections based on those setpoints.

Setpoints:

The following setpoints are set the same in Fixed Voltage Configuration regardless of what wiring configuration the generator is. In the subsections that follow, any configuration specific setpoints are described in each subsection pertaining to the wiring configuration selected.

CT RATIO – Set the primary and secondary setpoints to match the current transformer specification. All currents displayed will be adjusted by the ratio to show the currents as seen on the primary side of the CTs.

CT RATIO GEN PRIMARY CT RATIO PRIMARY - The primary rating of the Current Transformer.

CT RATIO GEN SECONDARY CT RATIO SECONDARY - The secondary rating of the Current Transformer.

GENERATOR MINIMUM VOLTAGE MIN VOLTAGE - The percentage of the nominal voltage at which all voltages detected beneath this value will be considered 0 volts.

GENERATOR NOMINAL FREQUENCY NOMINAL FREQ - The nominal frequency of the application. Used for under/over frequency protections and to compute speed of engine from generator frequency.

GENERATOR NOMINAL POWER 3 PHASE NOM PWR 3PH - This is the nominal power for the system when a three phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.

GENERATOR NOMINAL POWER SINGLE PHASE NOM PWR 1PH - This is the nominal power for the system when a single phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.


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PT RATIO – When Potential Transformers (PT) are used, set the primary and secondary setpoints to match the transformer specification. All voltages displayed will be adjusted by the ratio to show the voltages as seen on the primary side of the PTs.

PT RATIO GEN PRIMARY PT RATIO PRIMARY - The primary rating of the Potential Transformer

PT RATIO GEN SECONDARY PT RATIO SECONDARY - The secondary rating of the Potential Transformer

VOLTAGE DETECTION DELAY TIME V DET DELAY - Time, in seconds, the controller will wait before determining the Voltage and Connection of the system in Auto Voltage Detection and Binary Voltage Selection methods. Voltage Detect Time does not begin countdown until the engine has reached nominal speed and idle period has elapsed.

VOLTAGE DETECTION VOLT DETECT – This setpoint will activate the controller for Auto Voltage Detection method.



Protections:





3.24.1.1 High Wye, Low Wye


Setpoints:

GENERATOR NOMINAL VOLTAGE NOMINAL VOLT - Set to L-N voltage. This voltage represents 100% voltage in voltage protection functions.

GENERATOR NOMINAL CURRENT NOMINAL AMPS - Set to maximum continuous phase current allowed. This current represents 100% current in current protection functions.


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GENERATOR CONFIGURATION GEN CONFIG - Set to Wye.

HIGH LEG DELTA HIGH LEG – Not used in this configuration.

SINGLE PHASE ZERO LEG ZERO LEG - Not used in this configuration.

Note: No Binary inputs can be configured for VOLTAGE SELECT 1, VOLTAGE SELECT 2

Note: This configuration uses the setpoint GENERATOR NOMINAL POWER 3 PHASE for the 100% value in power protection functions

3.24.1.2 High Delta, Low Delta


GENERATOR NOMINAL VOLTAGE NOMINAL VOLT - Set to L-L / Sqrt(3) voltage. This voltage represents 100% voltage in voltage protection functions.

GENERATOR NOMINAL CURRENT NOMINAL AMPS - Set to maximum continuous line current allowed. This current represents 100% current in current protection functions.

GENERATOR CONFIGURATION GEN CONFIG - Set to Delta.

HIGH LEG DELTA HIGH LEG – Not used in this configuration.




3.24.1.3 High (Wild) Leg Delta



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GENERATOR NOMINAL VOLTAGE NOMINAL VOLT - Set to L-N voltage of lines that are common to center-tapped leg. Due to the grounding of the center-tap of one leg, the actual values representing 100% voltage in the voltage protection functions varies.

The two lines that are common to the center-tapped leg have a 100% protection value equal to the nominal voltage specified.

The line opposite the center-tapped leg (identified as the high or wild leg) has a 100% protection value equal to the nominal voltage specified X sqrt(3).

GENERATOR NOMINAL CURRENT NOMINAL AMPS - Set to maximum continuous line current allowed. This current represents 100% current in current protection functions.

GENERATOR CONFIGURATION GEN CONFIG - Set to High Leg Delta.

HIGH LEG DELTA HIGH LEG – Set to leg that is opposite the center-tapped leg.




3.24.1.4 High Zig-Zag, Low Zig-Zag


GENERATOR NOMINAL VOLTAGE NOMINAL VOLT - Set to L-N voltage. This voltage represents 100% voltage in voltage protection functions.

GENERATOR NOMINAL CURRENT NOMINAL AMPS - Set to maximum continuous phase current allowed. This current represents 100% current in current protection functions.

GENERATOR CONFIGURATION GEN CONFIG - Set to Zig-Zag.

HIGH LEG DELTA HIGH LEG – Not required for this configuration.

SINGLE PHASE ZERO LEG ZERO LEG - Set to phase input that is not connected to generator. This input should be connected to neutral terminal.


Note: This configuration uses the setpoint GENERATOR NOMINAL POWER SINGLE PHASE for the 100% value in power protection functions.


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3.24.2 Binary Voltage Select Operation

In binary voltage select operation, up to two binary inputs are wired to auxiliary contacts on the generator voltage selector switch. The position of the switch is detected by the controller and the configuration is automatically set to match the switch position.

The GNS provides an option to allow the user to assign binary inputs to indicate the voltage to operate (see Voltage Select Input Functions). These inputs can then be wired to auxiliary contacts on the voltage selector switch allowing the controller to detect the voltage selector switch position and automatically set the voltage, power, and current. For example, a rental generator has a voltage selector switch with the following positions; 277/480Y, 120/208HD, 120/240D, 120/240Z. Set the Voltage Selection Table up as follows.

Voltage Generator Configuration 277/480Y 277 Wye

120/208HD 120 High Leg Delta 120/240D 139 Delta 120/240Z 120 Zig-Zag

To use the binary voltage select scheme, you must disable VOLTAGE DETECTION and assign one or two binary inputs to the Voltage Select 1, 2 functions. Based on the state of the Voltage Select inputs, one of the four entries in the Voltage Selection Table will be used during startup to set the nominal voltage, nominal current, nominal power, and generator configuration. Each entry in the Voltage Selection Table has a corresponding L-N voltage setting and a wiring configuration setting.

Voltage Select Binary Inputs Voltage Select 1 Voltage Select 2 Entry from Voltage Selection Table

0 0 1 0 1 2 1 0 3 1 1 4

Nominal Voltage: This is the voltage selected from the Voltage Selection Table based on the Voltage Select inputs and modified based on the wiring configuration. This voltage represents the 100% voltage setting in voltage protection functions. It is computed as follows:

Wye: VSEL= value from table

Delta: VSEL= value from table

Zig-Zag: VSEL = value from table

High Leg Delta: VSEL = value from table for non-high legs,

VSEL = value from table * v3 for high leg

Nominal Power: This is the nominal power computed from setpoint GENERATOR NOMINAL POWER 3 PHASE or GENERATOR NOMINAL POWER SINGLE PHASE and the wiring configuration selected from the Voltage Selection Table based on the Voltage Select inputs. This power represents the 100% power setting in power protection functions. It is computed as follows:

Wye: Pnom = GENERATOR NOMINAL POWER 3 PHASE

Delta: Pnom = GENERATOR NOMINAL POWER 3 PHASE

Zig-Zag: Pnom = GENERATOR NOMINAL POWER SINGLE PHASE

High Leg Delta: Pnom = GENERATOR NOMINAL POWER 3 PHASE


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Nominal Current: This is the nominal current computed from the nominal power computed above, and the voltage selected from the Voltage Selection Table based on the Voltage Select inputs (VSEL) and modified based on the wiring configuration. This current represents the 100% current setting in current protection functions. It is computed as follows:

Wye: INOM = (PNOM / 0.8) / VSEL * 1000 / 3

Delta: INOM = (PNOM / 0.8) / VSEL * 1000 / 3

Zig-Zag: INOM = (PNOM / 1.0) / VSEL * 1000 / 2

High Leg Delta: INOM = (PNOM / 0.8) / VSEL * 2 / v3 * 1000 / 3

The Voltage Selection Table has four entries. Each entry specifies the wiring configuration and L-N voltage for that configuration. During startup, the Voltage Select 1, and 2 are read from the binary input, and based on these values, one of four entries is selected from the table. Once selected, the entry setpoints for wiring configuration and voltage are used to compute the nominal voltage, nominal power, and nominal current for the protection functions. The following sections show how to configure the two settings for each entry in the Voltage Selection Table based on the generator configuration selected.

Setpoints:

The following setpoints are set the same in Binary Voltage Select operation regardless of what wiring configuration the generator is. In the subsections that follow, any wiring configuration specific setpoints are described in each subsection pertaining to the wiring configuration selected.

CT RATIO – Set the primary and secondary setpoints to match the current transformer specification. All currents displayed will be adjusted by the ratio to show the currents as seen on the primary side of the CTs.



GENERATOR CONFIGURATION GEN CONFIG - Not used in this configuration.

GENERATOR MINIMUM VOLTAGE MIN VOLTAGE - The percentage of the nominal voltage at which all voltages detected beneath this value will be considered 0 volts

GENERATOR NOMINAL CURRENT NOMINAL AMPS - Not used in this configuration.




GENERATOR NOMINAL VOLTAGE NOMINAL VOLT - Not used in this configuration. Voltage for this configuration and associated protections are determined from the Voltage Select Binary Inputs and the Voltage Select Table.


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HIGH LEG DELTA HIGH LEG – This is to denote which leg will be used as the high leg (wild leg) when high leg delta configuration is selected or detected.

PT RATIO – When Potential Transformers (PT) are used, set the primary and secondary setpoints to match the transformer specification. All voltages displayed will be adjusted by the ratio to show the voltages as seen on the primary side of the PTs.

PT RATIO GEN PRIMARY PT RATIO PRIMARY - The primary rating of the Potential Transformer

PT RATIO GEN SECONDARY PT RATIO SECONDARY - The secondary rating of the Potential Transformer

SINGLE PHASE ZERO LEG ZERO LEG – Indicates leg to use when measuring zero volts when single phase is selected or is being detected.

VOLTAGE DETECTION VOLT DETECT – Set to DISABLEDMAN.

VOLTAGE DETECTION DELAY TIME V DET DELAY – Time, in seconds, the controller will wait before determining the Voltage and Connection of the system in Auto Voltage Detection and Binary Voltage Selection methods. Voltage Detect Time does not begin countdown until the engine has reached nominal speed and idle period has elapsed.


Note: At least 1 Voltage Select Input must be assigned to a binary input

Note: Voltage Select 1 and Voltage Select 2 must not be assigned to more than one input.

VOLTAGE SELECT 1 V SEL 1

VOLTAGE SELECT 2 V SEL 2 – Used to select entry from Voltage Selection Table when using Binary Voltage Select method.


Protections:






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3.24.2.1 High Wye, Low Wye


Note: the Voltage Selection Table entries can only be set using the GAC configuration software SmartVU.

VOLTAGE SELECT X WIRING – Set to WYE

VOLTAGE SELECT X NOM VOLT – Set to L-N voltage

3.24.2.2 High Delta, Low Delta



VOLTAGE SELECT X WIRING – Set to DELTA

VOLTAGE SELECT X NOM VOLT – Set to L-L voltage / Sqrt(3)


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3.24.2.3 High (Wild) Leg Delta



Note: Setpoint HIGH LEG DELTA must be set to leg opposite neutral connection.

VOLTAGE SELECT X WIRING – Set to HIGH LEG DELTA


3.24.2.4 High Zig-Zag, Low Zig-Zag



Note: Setpoint SINGLE PHASE ZERO LEG must be set to leg opposite neutral connection.

VOLTAGE SELECT X WIRING – Set to ZIG-ZAG



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3.24.3 Auto Voltage Detection Operation (GNS2000 Only)

Description:

In Auto Voltage Detection operation the controller monitors the voltage inputs, and after the set has reached nominal speed for the configured amount of time, it samples the voltage inputs and compares them to the auto detection table. If the voltages match one of the configurations, then that configuration is use to compute the nominal values for voltage, current, and power. The following table lists the valid configurations that can be detected.

The controller samples the voltages and compares them to the high and low limits in the table. If all of the phase voltages are within limits then the corresponding 3-phase configuration is selected and the nominal voltage is set to the value identified in the table.

If two of the three voltages are within limits and the third phase matches the High Leg Delta setpoint and the voltage is within limits for that leg, then the configuration is set to High Leg Delta and the voltage is set to the nominal from the table.

If two of the three voltages are within limits and the third phase matches the Single Phase Zero Leg setpoint and the voltage is zero for that leg, then the configuration is set to Zig-Zag and the voltage is set to the nominal from the table.

After detecting the configuration and nominal voltage, nominal power and currents are then computed.

Configuration Hz Phases Nominal VAC Low VAC High

60 Hz, 3 Phase

High Wye 60 3 277 249 305

Wild Leg Delta 60 3 208/1201 187/1081 229/1321

Low Wye 60 3 138 129 152

Low Wye 2 60 3 120 108 128

High Delta 60 3 139 129 152

Low Delta 60 3 69 62 76

60 Hz, Single Phase

Zig Zag 60 1 120 108 132

50 Hz, 3 Phase

High Wye 50 3 231 208 254

Wild Leg Delta 50 3 173/1001 156/901 190/1101

Low Wye 50 3 115 104 127

High Delta 50 3 115 104 127

Low Delta 50 3 58 52 64

50 Hz, Single Phase

Zig Zag 50 1 100 90 110

Notes:

1Nominal voltage for High Leg Delta is specified as voltage between Neutral and the high leg and Neutral and non-high leg.

!! Warning: If voltage auto detection is used, it is strongly recommended you enable the “Voltage Auto Detect” fail protection !!


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Setpoints:

In Auto Voltage Detection operation, there are no setpoints that are set based on the generator configuration as it is not known what the configuration is until the generator starts.

CT Ratio – Set the primary and secondary setpoints to match the current transformer specification. All currents displayed will be adjusted by the ratio to show the currents as seen on the primary side of the CTs.



GENERATOR CONFIGURATION GEN CONFIG – Not used in this configuration.

GENERATOR MINIMUM VOLTAGE MIN VOLTAGE - The percentage of the nominal voltage at which all voltages detected beneath this value will be considered 0 volts.

GENERATOR NOMINAL CURRENT NOMINAL AMPS – Not used in this configuration.




GENERATOR NOMINAL VOLTAGE NOMINAL VOLT – Not used in this configuration.

HIGH LEG DELTA HIGH LEG – This is to denote which leg will be used as the high leg (wild leg) when high leg delta configuration is selected or detected.

PT RATIO – When Auto Voltage Detection is enabled, the PT Ratio is automatically forced to 1:1.

PT RATIO GEN PRIMARY PT RATIO PRIMARY– Not used in this configuration.

PT RATIO GEN SECONDARY PT RATIO SECONDARY– Not used in this configuration.

SINGLE PHASE ZERO LEG ZERO LEG – Indicates leg to use when measuring zero volts when single phase is selected or is being detected.

VOLTAGE DETECTION VOLT DETECT – Set to ENABLED (AUTO).

VOLTAGE DETECTION DELAY TIME V DET DELAY – Time, in seconds, the controller will wait before determining the Voltage and Connection of the system in Auto Voltage Detection and Binary Voltage Selection methods. Voltage Detect Time does not begin countdown until the engine has reached nominal speed and idle period has elapsed.



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Protections:

Auto Voltage Detect Warning – This protection is activated when setpoint VOLTAGE DETECTION is enabled and the GNS cannot determine the configuration of the wiring or operating voltages after VOLTAGE DETECTION TIME has elapsed.

Auto Voltage Detect Alarm - This protection is activated when setpoint VOLTAGE DETECTION is enabled and the GNS cannot determine the configuration of the wiring or operating voltages after VOLTAGE DETECTION TIME has elapsed.





3.25 CONFIGURING THE GNS FOR VOLTAGE PROTECTION

The controller provides several functions for protecting the generator voltage. All of the protection functions are based on the nominal voltage which represents the 100% point for protection purposes. Under and Over protections are then set based on a percentage of nominal voltage.

Requirements:

To enable any of the protections defined, first set the corresponding protection setpoint, and then enable the protection within SmartVU. To disable, the corresponding protection can be disabled in SmartVU. Setpoints can be adjusted either thru SmartVU or the GNS display. But the protection enable/disable can only be done through SmartVU.

All voltage protections are based on a percentage of Nominal Voltage. There are three methods in which nominal voltage can be set; Fixed, Auto Detect, and Binary Select. Each of the methods uses a different set of setpoint and operating conditions to determine nominal voltage. Please refer to the section “Configuring the GNS to use a Voltage Detection Method” for more information.


See the Binary Output Wiring section for instructions on wiring the binary outputs used to signal alarms and warnings.

See the Voltage Wiring section for instructions on wiring the generator voltage inputs.

Meters:

The status of any warning or alarm can be seen on the alarm/warning screen of the GNS. If the warning or alarm is active or inactive it will be shown in the list. Pressing Fault Reset will clear inactive alarms and warnings and signal the controller that it can restart the generator if necessary.


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Setpoints:

The following setpoints use the nominal voltage to compute protection values.

GENERATOR OVER VOLTAGE ALARM OVER VOLT ALM – The percent of nominal voltage to trigger the over voltage alarm.

GENERATOR OVER VOLTAGE WARNING OVER VOLT WARN - The percent of nominal voltage to trigger the over voltage warning.

GENERATOR UNDER/OVER VOLTAGE DELAY U/O VOLT DELAY - Time, in seconds, that the generator will have to exceed the over/under voltage limits in order for the corresponding warning or alarm to activate.

GENERATOR UNDER VOLTAGE ALARM UNDER VOLT ALM - The percent of nominal voltage to trigger the under voltage alarm.

GENERATOR UNDER VOLTAGE WARNING UNDER VOLT WARN - The percent of nominal voltage to trigger the under voltage warning.

GENERATOR VOLTAGE UNBALANCE ALARM VOLT UNBAL ALARM - The maximum allowable percent difference in voltage between any two active legs.

GENERATOR VOLTAGE UNBALANCE DELAY VOLT UNBAL DLY - Time, in seconds, the voltage must be in the unbalance condition before the alarm is activated.


These protections are only active when the engine has reached the Running state

Generator Over Voltage Alarm – This protection is activated when the generator voltage reaches the values specified by the GENERATOR OVER VOLTAGE ALARM or GENERATOR OVER VOLTAGE WARNING set points for the time specified by the GENERATOR UNDER/OVER VOLTAGE DELAY set point.

Generator Over Voltage Warning – This protection is activated when the generator voltage reaches the values specified by the GENERATOR OVER VOLTAGE ALARM or GENERATOR OVER VOLTAGE WARNING set points for the time specified by the GENERATOR UNDER/OVER VOLTAGE DELAY set point.

Generator Unbalance Voltage Alarm - This protection is activated when the GNS detects an unbalance in the generator voltage that reaches GENERATOR VOLTAGE UNBALANCE ALARM for the time specified by the GENERATOR VOLTAGE UNBALANCE DELAY set point.

Generator Under Voltage Alarm – This protection is activated when the generator voltage reaches the values specified by the GENERATOR UNDER VOLTAGE ALARM or GENERATOR UNDER VOLTAGE WARNING set points for the time specified by the GENERATOR VOLTAGE DELAY set point.


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Generator Under Voltage Warning – This protection is activated when the generator voltage reaches the values specified by the GENERATOR UNDER VOLTAGE ALARM or GENERATOR UNDER VOLTAGE WARNING set points for the time specified by the GENERATOR VOLTAGE DELAY set point.



Generator Over Voltage Alarm GEN OV A – Active when protection Generator Over Voltage Alarm is active.

Generator Over Voltage Warning GEN OV WN – Active when protection Generator Over Voltage Warning is active.

Gen Unbalance Voltage Alarm GEN UBV A – Active when protection Generator Unbalanced Voltage Alarm is active.

Generator Under Vltg Alarm GEN UV A – Active when protection Generator Under Voltage Alarm is active.

Generator Under Vltg Warning GEN UV WN – Active when protection Generator Under Voltage Warning is active.



3.26 CONFIGURING THE GNS FOR FREQUENCY PROTECTION

The controller provides several functions for protecting the generator frequency. All of the protection functions are based on the nominal frequency which represents the 100% point for protection purposes. Under and Over protections are then set based on a percentage of nominal frequency.

Requirements:




See the Voltage Wiring section for instructions on wiring the generator voltage inputs where the generator frequency is derived from.

Meters:



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Setpoints:

GENERATOR FREQUENCY DELAY FREQ DELAY - Time, in seconds, that the generator will have to exceed the above limits in order for the corresponding warning or alarm to activate.

GENERATOR NOMINAL FREQUENCY NOMINAL FREQ – The nominal frequency of the application. Used for under/over frequency protections and to compute speed of engine from generator frequency.

GENERATOR OVER FREQUENCY ALARM OVER FREQ ALM - The percent of nominal frequency limit for the generator to go into an over frequency alarm condition.

GENERATOR OVER FREQUENCY WARNING OVER FREQ WARN - The percent of nominal frequency Limit for the generator to go into an over Frequency warning condition.

GENERATOR UNDER FREQUENCY ALARM UNDER FREQ ALM - The percent of nominal frequency Limit for the generator to go into an under Frequency alarm condition.

GENERATOR UNDER FREQUENCY WARNING UNDER FREQ WARN - The percent of nominal frequency limit for the generator to go into an under Frequency warning condition.



Generator Over Frequency Alarm – This protection is activated when the frequency on any of the phases reaches the values specified by the GENERATOR OVER FREQUENCY ALARM or GENERATOR OVER FREQUENCY WARNING set points for the amount of time specified by the GENERATOR FREQUENCY DELAY set point.

Generator Over Frequency Warning – This protection is activated when the frequency on any of the phases reaches the values specified by the GENERATOR OVER FREQUENCY ALARM or GENERATOR OVER FREQUENCY WARNING set points for the amount of time specified by the GENERATOR FREQUENCY DELAY set point.

Generator Under Frequency Alarm – This protection is activated when the frequency on any of the phases reaches the values specified by the GENERATOR UNDER FREQUENCY ALARM or GENERATOR UNDER FREQUENCY WARNING set points for the amount of time specified by the GENERATOR FREQUENCY DELAY set point.

Generator Under Frequency Warning – This protection is activated when the frequency on any of the phases reaches the values specified by the GENERATOR UNDER FREQUENCY ALARM or GENERATOR UNDER FREQUENCY WARNING set points for the amount of time specified by the GENERATOR FREQUENCY DELAY set point.




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Generator Over Frequency Alarm GEN OF A – Active when protection Generator Over Frequency Alarm is active.

Generator Over Frequency Warning GEN OF WN – Active when protection Generator Over Frequency Warning is active.

Generator Under Frequency Alarm GEN UF A – Active when protection Generator Under Frequency Alarm is active.

Generator Under Frequency Warning GEN UF WN – Active when protection Generator Under Frequency Warning is active




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3.27 CONFIGURING THE GNS FOR CURRENT PROTECTION

Description: The controller provides several functions for protecting the generator from over current. All of the protection functions are based on the nominal current which represents the 100% point for protection purposes. Over protections are then set based on a percentage of nominal current.

Table 1 - IDMT Levels

Amps Seconds

1.001 13,500

1.002 6,750

1.004 3,375

1.008 1,687

1.016 844

1.032 422

1.060 225

1.120 113

1.250 54

1.500 27

2.000 13.5

4.000 4.5

6.000 2.7

8.000 1.928

10.00 1.5

20.00 0.711

Requirements:


All current protections are based on a percentage of Nominal Current. There are three methods in which nominal current can be set; Fixed, Auto Detect, and Binary Select. Each of the methods uses a different set of setpoints and operating conditions to determine nominal current. Please refer to the section “Configuring the GNS to use a Voltage Detection Method” for more information.


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See the Current Wiring section for instructions on wiring the generator current inputs.

Meters:


Setpoints:

The following setpoints use the nominal current to compute protection values.

GENERATOR CURRENT UNBALANCE ALARM CURR UNBAL – The maximum allowable percent difference in current between any two active legs.

GENERATOR CURRENT UNBALANCE DELAY CURR UNBAL DLY – Time, in seconds, the current must be in the unbalance condition before the alarm is activated.

GENERATOR OVER CURRENT ALARM OVER CURR ALM – The over current protection, as soon as this level is exceeded for the Generator Over Current Delay time the genset shutdowns.

GENERATOR OVER CURRENT DELAY OVER CURR DLY – Time, in seconds, the current must be in the over current state before the alarm is activated.

INVERSE DEFINITE MIN TIME IDMT – Time dependent curve for over current protection.



Generator Over Current Alarm– Activated when the current reaches the percentage of nominal current specified by the GENERATOR OVER CURRENT ALARM set point for the time specified by the GENERATOR OVER CURRENT DELAY set point.

Generator Unbalance Current Alarm – This protection is activated when the GNS detects an unbalance in the generator current that reaches GENERATOR CURRENT UNBALANCE ALARM for the time specified by the GENERATOR CURRENT UNBALANCE DELAY set point.

Over Current IDMT Warning – The GNS is equipped with an Inverse Definite Minimum Time Over Current (IDMT) algorithm. The response time of this protection is based on the amount of current the GNS is detecting. The higher the current the faster the over current response. The lower the current the slower the response. The current v. response times can be found in the “IDMT Response Table” section of this manual.


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Over Current IDMT Alarm – The GNS is equipped with an Inverse Definite Minimum Time Over Current (IDMT) algorithm. The response time of this protection is based on the amount of current the GNS is detecting. The higher the current the faster the over current response. The lower the current the slower the response. The current v. response times can be found in the “IDMT Response Table” section of this manual.

Short Circuit Warning - Activated when the GNS detects a short circuit in the wiring to the load.

Short Circuit Alarm - Activated when the GNS detects a short circuit in the wiring to the load.



Over Current OVR CURR – Active when protection Over Current is active.

Unbalance Current Alarm UNB C A – Active when protection Generator Unbalanced Current Alarm is active.



3.28 CONFIGURING THE GNS FOR POWER PROTECTION

The controller provides several functions for protecting the generator from overload. All of the protection functions are based on the nominal power which represents the 100% point for protection purposes. Over protections are then set based on a percentage of nominal power.

1. Enter Power rating at 0.8 PF for three phase power, and 1.0 PF for single phase power.

2a. If PF of load is the same as specified PF then no adjustments necessary.

2b. If PF of load is different than specified PF then adjust setpoints as follows:

Recompute rated power at load PF using:

KWProt(%) = (PFLoad / PFGNS) * (100% + Overload Protection(%))

For example:

A generator rated at 50 KW @ 0.8 PF is driving a 0.6 PF load. Therefore set must be derated by 0.6/0.8 = .75 = 75%. Overload protection is required at 10% overload. Therefore protection should be provided at 75% * 110% = 82.5%.

KWProt(%) = (0.6/0.8) * (100% + 10%)

KWProt(%) = 82.5%

Requirements:



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All power protections are based on a percentage of Nominal Power. Nominal power is configured through two setpoints GENERATOR NOMINAL POWER 3 PHASE, and GENERATOR NOMINAL POWER SINGLE PHASE.



Meters:


Setpoints:

GENERATOR NOMINAL POWER 3 PHASE NOM PWR 3PH – This is the nominal power for the system when a three phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.

GENERATOR NOMINAL POWER SINGLE PHASE NOM PWR 1PH – This is the nominal power for the system when a single phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.

GENERATOR OVERLOAD ALARM OVERLOAD ALARM - The percentage of Nominal Power where the generator is considered in an overload condition and is shutdown. When the kW reaches this level the controller will open the GCB, cool the engine, and stop.

GENERATOR OVERLOAD WARNING OVERLOAD WARN - The percentage of Nominal Power where a overload warning will be triggered.

GENERATOR OVERLOAD DELAY OVERLOAD DLY - Time, in seconds, the generator will have to be in the overload condition before the warning or alarm will be activated.



Over Load Warning – Activated when the power reaches the values specified by the OVERLOAD ALARM or OVERLOAD WARNING set points for the amount of time specified by the OVERLOAD DELAY set point.

Over Load Alarm – Activated when the power reaches the values specified by the OVERLOAD ALARM or OVERLOAD WARNING set points for the amount of time specified by the OVERLOAD DELAY set point.



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Overload Alarm OVRLD A – Active when protection Generator Overload Alarm is active.



3.29 CONFIGURING THE GNS TO WORK WITH YOUR CIRCUIT BREAKER

The GNS is capable of supporting a wide variety of circuit breakers. The configuration of the circuit breaker can only be done using SmartVU software. These include single-line, multi-line, both with and without feedback. The terms single-line and multi-line are used to describe the number of signals used to control the breaker.

In Single-line operation, a single control line is used to indicate whether the breaker should be open or closed. It is a level controlled signal in that in one state, the breaker should be open, and in the other, the breaker should be closed. Tripping of the breaker by the GNS is accomplished by signaling that the breaker should be open.

In Multi-Line operation, there are separate signals that indicate that the breaker should be opened, another for breaker close, and a third for breaker trip. These signals will only turn on for a period of time to affect the change, and then turn off.

In both single-line and multi-line modes, there is an option to have feedback monitoring. F/B monitoring uses another set of signals to indicate the actual position of the GCB. In single-line mode, there is one signal that indicates the actual position of the breaker. One state indicates open, the other indicates closed. In multi-line mode, separate signals indicate open, closed, and tripped status. These signals always represent the state of the GCB whereas the control signals only pulse the output until the feedback indicates the requested position, then they turn off. An external trip of the breaker is detected when the breaker is commanded to be closed, and the feedback indicates that it has now opened or tripped.

In AUTO mode the control of the breaker is done completely by the GNS and does not allow any user input. Once the engine has reached nominal speed, and no alarms are active, then the breaker is signaled to close. Upon removal of the Remote Start/Stop signal, the breaker will be signaled to open, and the set shutdown. No user interaction is allowed.

In MAN mode, the user is required to manually start the set. After the engine has reached the Running Stage, the user can request breaker closure either through a Binary Input assigned to GCB Close Request function, or SmartVU software. Opening the breaker is done automatically when an alarm occurs, or the user issues a stop request. Optionally, another Binary Input is assigned GCB Open Request function that can be used to open the breaker but not stop the engine. Using this additional input, the user can open and close the breaker without affecting engine operation. Typically, a momentary UP/DOWN switch with a center OFF position is used to request breaker position. With the switch in the center position, no requests are made and the breaker stays in the same position. When the switch is pressed up momentarily, the GCB Close Request input is activated, and the GNS will signal GCB close if all other conditions are acceptable. When the switch is pressed down momentarily, the GCB Open Request input is activated, and the GNS will signal GCB open.

The Configuration Notebook Meter is shown below, with the Gen Circuit Breaker page selected. This page is where the GCB is configured. The information from above can be used to configure the type of GCB installed.


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The following diagrams show the different operation of the breakers


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3.29.1 Single-Line w/No feedback

GCB Control: Single-Line

GCB F/B Monitoring: Unchecked

GCB Open/Close (BO)

GCB Close request (BI)

GCB Open Request (BI)

GCB Assumed

position

GCB F/B Delay GCB F/B Delay

In Single-Line w/no feedback operation, there is only a single line controlling the GCB. There are no feedback signals. It is the simplest form of GCB operation. Because there is no feedback, there is no way for the GNS to determine if the GCB has been opened externally or whether the commended breaker change occurred.

The GCB Open/Close signal is conditioned on the system being in the running state and no alarms active. Once the close request is received from the user, or from the GNS logic, the GCB Open/Close control line will signal the GCB to close. It will wait until the GCB FEEDBACK DELAY time has elapsed and then assume that the breaker is in the correct state. When the breaker needs to be opened, the GCB Open/Close control line will signal the GCB to open. It will wait until the GCB FEEDBACK DELAY time has elapsed, and then assume that the breaker is in the correct state.


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3.29.2 Single-Line w/feedback

GCB Control: Single-Line

GCB F/B Monitoring: Checked

GCB Open/Close (BO)



GCB Feedback Open/Close (BI)

GCB F/B Delay

GCB F/B Delay

GCB F/B Delay

GCB Ext Trip

In Single-Line w/feedback operation, there is only a single line controlling the GCB and a single line monitoring the breaker. Because there is feedback, the GNS can determine if the GCB has been opened externally or whether the commanded breaker change has been successful. Upon an external or unsuccessful change of breaker state, the GNS can signal a warning or alarm.

The GCB Open/Close signal is conditioned on the system being in the running state and no alarms active. Once the close request is received from the user, or from the GNS logic, the GCB Open/Close control line will signal the GCB to close. It will wait until the GCB FEEDBACK DELAY time has elapsed and then if the breaker is not in the correct position, it will trip a GCB Fault alarm if enabled. When the breaker needs to be opened, the GCB Open/Close control line will signal the GCB to open. It will wait until the GCB FEEDBACK DELAY time has elapsed and then if the breaker is not in the correct position, it will trip a GCB Fault alarm if enabled.

In addition, because of the feedback monitoring, if the breaker state should change without being commanded by the GNS, then a GCB Fault will be triggered if enabled.


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3.29.3 Multi-Line w/No feedback

GCB Control: Multi-Line

GCB F/B Monitoring: Unchecked

GCB Open (BO)

GCB Close (BO)

GCB Trip (BO)



GCB Assumed position

GCB F/B Delay

GCB F/B Delay

In Multi-Line w/no feedback operation, there multiple lines controlling the GCB. There is a separate signal to control opening, closing and tripping of the GCB. The GCB Open and GCB Close control signals are activated for the time specified by the GCB FEEDBACK DELAY and then turned off. The GCB is then assumed to be in that position. There are no feedback signals. Because there is no feedback, there is no way for the GNS to determine if the GCB has been opened externally or whether the commended breaker change occurred.

The GCB Close signal is conditioned on the system being in the running state and no alarms active. Once the close request is received from the user, or from the GNS logic, the GCB Close control line will signal the GCB to close. It will wait until the GCB FEEDBACK DELAY time has elapsed and then assume that the breaker is in the correct state. When the breaker needs to be opened, the GCB Open control line will signal the GCB to open. It will wait until the GCB FEEDBACK DELAY time has elapsed, and then assume that the breaker is in the correct state.


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3.29.4 Multi-Line w/ feedback

GCB Control: Multi-Line

GCB F/B Monitoring: Checked

GCB Open (BO)

GCB Close (BO)

GCB Trip (BO)



GCB Feedback Open (BI)

GCB Feedback Close (BI)

GCB Feedback Trip (BI)

GCB F/B Delay

GCB F/B Delay

GCB F/B Delay

GCB Ext Trip

In Multi-Line w/feedback operation, there are multiple lines controlling the GCB and multiple lines monitoring the breaker. There is a separate signal to control opening, closing and tripping of the GCB. The GCB Open and GCB Close control signals are activated for the time specified by the GCB FEEDBACK DELAY and then turned off. Because there is feedback, the GNS can determine if the GCB has been opened externally or whether the commanded breaker change has been successful. Upon an external or unsuccessful change of breaker state, the GNS can signal a warning or alarm.

The GCB Close signal is conditioned on the system being in the running state and no alarms active. Once the close request is received from the user, or from the GNS logic, the GCB Close control line will signal the GCB to close. It will wait until the GCB FEEDBACK DELAY time has elapsed and then if the breaker is not in the correct position, it will trip a GCB Fault alarm if enabled. When the breaker needs to be opened, the GCB Open control line will signal the GCB to open. It will wait until the GCB FEEDBACK DELAY time has elapsed and then if the breaker is not in the correct position, it will trip a GCB Fault alarm if enabled.

In addition, because of the feedback monitoring, if the breaker state should change without being commanded by the GNS, then a GCB Fault will be triggered if enabled.

In the table below, some alternate control of the GCB are identified and which iput and outputs should be used.


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Mode

GCB Control

GCB Config

GCB Control Outputs

GCB Feedback

Inputs User

Inputs Notes

AUTO None Not Needed

None None Ignored

AUTO GNS Single/Multi Required Optional Ignored

AUTO External Not Needed

None None Ignored Should used Common Unload/Alarm to affect GCB trip on GNS detected conditions

MAN None Not Needed

None None Ignored

MAN GNS Single/Multi Required Optional Required

MAN External Not Needed

None None Ignored Should used Common Unload/Alarm to affect GCB trip on GNS detected conditions

Notes:

1. Not needed – Common unload can be used to trip open an externally controlled breaker and still use the internal protection features.

2. Single/multi Line – Should have output to GCB, optionally feedback from GCB, and GCB request from operator for manual mode.

3. Auto mode – It is expected that in Auto mode, the GCB will be controlled directly by the controller, therefore there should be outputs defined to control the breaker, and optionally input for feedback.

3.29.5 GCB Feedback Behavior

GCB Output GCB Feedback Input Assigned GCB Feedback Input Not Assigned

Single Line or Multi-Line

GNS asserts GCB close signal(s) GNS Waits for time specified by GCB FEEDBACK DELAY If no GCB feedback is detected, the GNS generates an alarm

Default, Not Assigned GNS asserts GCB close signal(s) GNS Waits for time specified by GCB FEEDBACK DELAY GNS assumes GCB is closed

Not Assigned GNS Assumes GCB is controlled manually and takes no action . States and trips of GCB are monitored.

GNS Assumes GCB is controlled manually and takes no action

Requirements:

To Enable Single-Line Breaker Control:

Assign a Binary Output to function GCB Open/Close and select Single-Line for Breaker Control. Set GCB FEEDBACK DELAY to the time the breaker requires to change state. If feedback is desired, check the GCB F/B MONITORING, and assign a Binary Input to the function GCB Feedback Open/Close.

To Enable Multi-Line Breaker Control:


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Assign Binary Outputs to functions GCB Open, GCB Close, and GCB Trip and select Multi-Line for Breaker Control. Set GCB FEEDBACK DELAY to the time the breaker requires to change state. If feedback is desired, check the GCB F/B MONITORING, and assign Binary Inputs to the functions GCB Feedback Open, GCB Feedback Close, and GCB Feedback Trip.

To Disable Breaker Control:

Set GCB Control to Not Needed.

To Enable Breaker Protections:

Follow above steps to enable single or multi line breaker control. Enable GCB Fault protections in SmartVU. This protection will trigger if the GCB is not following a commanded state change. Enable External GCB Trip protections in SmartVU. This protection will trigger if the GCB state is changed when it has not been commanded to.

To Disable Breaker Protections:

Disable protections for GCB Fault and External GCB Trip in SmartVU.

To Enable User Requests for Breaker State Change:

Follow above steps to enable single or multi line breaker control. Assign Binary Inputs to functions GCB Open Request and GCB Close Request.

To Disable User Requests for Breaker State Change:

Change any Binary Inputs assigned to GCB Open Request or GCB Close Request to function Not Assigned



Meters:

Display – On the GNS display the Supplying Load LED indicates the state of the breaker.

SmartVU – In SmartVU, the following meter shows current breaker state and has buttons to control the breaker.

Setpoints:

GCB CONTROL – Defines the type of GCB installed. This also determines the level of control available

GCB DELAY GCB DELAY – Time in seconds to wait after GCB able to be closed, before actually commanding breaker to close.


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GCB F/B MONITORING – Defines whether the GCB will be providing feedback signals indicating the position of the breaker

GCB FEEDBACK DELAY FEEDBACK DELAY - Time, in seconds, the GNS waits from issuing the close/open of the breaker until it assumes the breaker is closed/open. If feedback protection is enabled and feedback is enabled, the user would receive an alarm should the GCB not close/open.


These protections are only active when the engine has reached Nominal speed and voltage configuration has been determined by the configured method (Fixed, Binary Select, or Auto Detect).

External GCB Trip Warning– This protection is activated when the GNS detects an external GCB trip. To use this protection, GCB Trip function must be assigned to a binary input and externally triggered from the GCB

GCB Fault Warning - Activated when the GCB does not reflect the command from the GNS (e.g., GCB is commanded to close and the GCB does not close).


GCB CLOSE REQUEST GCB C REQ – Requests that the GNS closes the GCB. Operational in Manual Mode only.


GCB FEEDBACK CLOSE GCB FB C – Indicates that the GCB is in the closed position. Multi-line breaker control only.


GCB FEEDBACK OPEN GCB FB O – Indicates that the GCB is in the open position. Multi-line breaker control only.


GCB FEEDBACK OPEN/CLOSE GCB FB – Indicates the position the GCB is in. Single line breaker control only.


GCB FEEDBACK TRIP GCB FBT – Indicates that the GCB is in the tripped position. Multi-line breaker control only.


GCB OPEN REQUEST GCB O REQ – Requests that the GNS opens the GCB. Operational in Manual Mode only.

Note: Must not be assigned to more than one input


GCB CLOSE GCB CLOSE – Generator Circuit Breaker control signal – activated when GCB should be closed, deactivated when GCB Feedback Close signal received. For multi-line breaker control only.


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GCB OPEN GCB OPEN – Generator Circuit Breaker control signal – activated when GCB should be opened, deactivated when GCB Feedback Open signal received. For multi-line breaker control only.

GCB OPEN/CLOSE GCB O/C – Generator Circuit Breaker control signal – activated when GCB should be closed, deactivated when GCB should be open. For single wire breaker control only.

GCB TRIP GCB TRIP – Generator Circuit Breaker control signal – activated when GCB should be tripped opened (typically requiring a manual breaker reset), deactivated when GCB FEEDBACK TRIP signal received. For multi-line breaker control only.

GCB WARNING GCB WN - Active when protection GCB Warning or GCB Fault is active.


REQUEST GCB CLOSE GCB CLOSE REQ – The GCB has been requested to close.

REQUEST GCB OPEN GCB OPEN REQ – The GCB has been requested to open.

REQUEST GCB TRIP GCB TRIP REQ - The GCB has been requested to trip open.


3.30 CONFIGURING THE GNS FOR ALARM, WARNING, AND STATUS ANNUNCIATION AND CONTROL

The GNS provides several general purpose inputs and outputs to indicate the state of the generator set. These functions can be used to qualify any of the conditions or control external equipment as needed. Some of the functionality is described below:

Horn - Configuration of the Horn output used to signal an alarm condition, define the length of time the horn sounds and a horn silence function.

Alarm Reset – Fault reset is used to reset the alarm condition.

Note: Once the fault is reset, the set can start at any time without notice.

Alarm Prevention – In addition to the ability to enable and disable each alarm, and configure the setpoints for most alarms, there is also the ability to disable and re-enable certain alarms without reconfiguring the GNS. This is accomplished with the Run All input function.

Alarm Annunciation – Several Output functions are available to signal that any warning alarm, GCB open, or engine stop condition has been triggered.

Set Status - Several operating conditions are available to notify when the generator has reached a desired state.

Requirements:

See the setpoints, Binary Inputs and Outputs listed below to configure functions.


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Meters:

Display – The screens Binary Input States, and Binary Output States shown below, show the current status of the Binary Inputs and Outputs and their assigned functions.

SmartVU – The meters External Discrete Input Levels, and External Discrete Output Levels, shown below, show the current status of the Binary Inputs and Outputs and their assigned functions. The buttons to affect a Fault Reset, Horn Silence, and Run All operations are shown below.

Setpoints:

HORN PERIOD HORN PERIOD - Time, in seconds, the horn will sound. When set to 0 (zero), the horn will sound indefinitely. Horn Silence will turn off Horn output when pressed until the next event occurs.

Protections:

Holdoffs: None

None



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FAULT RESET FLT RST – Clears all non-active faults from alarm list.

HORN SILENCE HORN SLN - Turns off horn output.

RUN ALL RUN ALL - Commands the generator set to run even in the presence of specified alarm conditions. Must be activated before alarm fault triggered.



COMMON ALARM COMMON AL – Activated when any alarm is active or in alarm list. Cleared on Fault Reset.

COMMON SHUTDOWN CMN SD- Activated when hard shutdown protection occurs. Cleared on Fault Reset.

COMMON STOP CMN STOP- Activated when soft shutdown protection occurs. Cleared on Fault Reset.

COMMON UNLOAD CMN UNLD - Activated when a GCB open, or GCB Trip protection occurs. Cleared on Fault Reset.

COMMON WARNING COMMON WN – Activated when any warning is active or in alarm list. Cleared on Fault Reset.

GENERATOR OK GEN OK – Activated when engine is running and all engine and generator levels are within spec.

GENERATOR RUNNING GEN RUN – Activated when engine has successfully started.

HORN HORN – Activated on warnings and alarms for the time configured by setpoint HORN PERIOD. HORN SILENCE function will deactivate horn output immediately

IN AUTO IN AUTO – Active when control is in Auto Mode

NOT IN AUTO NOT IN AUTO – Active when GNS is not in Auto mode

READY TO ACCEPT LOAD RDY2LOAD – Activated when genset’s engine is up to speed with protections enabled and all electric values are with limits.

SUPPLYING LOAD SUP LOAD – Activated when generator set is supplying any load i.e. GCB is closed or engine running with no GCB configured.

WAITING TO RUN WAIT2RUN - Active when the engine is stopped with no warnings or alarms and is able to start.




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3.31 CONFIGURING THE GNS TO WORK WITH ANALOG INPUTS

The analog inputs are highly configurable inputs that can be used to provide signals for system level functions, or can be used for user defined functions. In either case, the analog input must be configured to match the sensor and verified that it is measuring the signal properly before it can be used. The configuration of the analog inputs can only be done in SmartVU and is accomplished by defining a curve that represents the conversion form the voltage being read at the input to the value to be displayed and used by the protection functions. This curve is composed of at least 2 and up to 10 data points which are used to interpolate the input to output conversion. In addition to defining the curve, the type of sensor and the units to be displayed will need to be configured. Based on the type of sensor selected, different ranges of inputs are allowed. The units specified provide a label and range for the converted value. In addition, the units for pressure and temperature have selectable units to display and all values are converted based on these settings. For temperature, SmartVu has a setting to select which units to display all temperatures in. So if the analog input is set to units of temperature, and SmartVU is configured for displaying temperature in oC, then the analog input will be displayed in oC. If the SmartVU setting is changed to oF, then the analog input value will be display in oF. The same is true for units of pressure. Lastly, the analog inputs can have a user-defined name for each input. Care must be taken to define names that will not conflict with the system level names being used by the system. For example, if a temperature sensor is used to measure coolant temperature even though the engine coolant temperature for system level functions is being provided over J1939, it would be best to name is something other than coolant temp, as that is the name used by the system for coolant temperature. An alternative might be Cool Temp, ECT, C Temp Alt, Coolant2, etc.

In addition to allowing flexibility in defining the curve of the sensor, SmartVU also provides many predefined definitions for industry standard sensors. They can be used as is if they match your sensor, or they can be modified if your sensor is close but slightly different than a standard sensor. If the decision is to create one from scratch, then after the definition is complete, it can be saved to a file on the PC for future use.

After definition of the connected sensor is complete and verified, if the signal is not being used as a system level parameter then protections can be enabled to trigger warnings and/or alarms should the input reached defined levels. This allows an analog input that is not be used for a system level parameter to be metered, and protected. This protection function can be used to trigger external equipment if necessary. Protections can be alarms and/or warnings, and be set on high and/or low limits. Warning and Alarm actions are the same for high or low protections, but through the use of independent binary output functions for each protection, different actions can be taken externally based on the fault.

Requirements:

Enabling an analog input:

In order to configure an analog input properly, the following steps must be performed.

Select the input to use from the dropdown list.

(Optional) Define a name for the input. There are length restrictions on the display, so be sure to verify the displayed name. If no name is defined, the analog input is given the name Analog InX on the display and Analog In X Level in SmartVU.

Select the type of sensor being used. SmartVU provides a list of predefined sensors for a number of industry standard sensors. If one of these matches your sensor, load this definition for the file. If it is similar to one of these, the definition can be loaded and then modified. Alternatively, a new definition may be created and then saved to a file for future use.


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Select the units to be displayed. The units are used to set the converted value output range and the label shown with that value.

Add the data points. Each analog can accommodate up to 10 data points. These data points define the conversion from voltage read at the input to value being displayed.

Apply the definition to the GNS. All manipulation of the data is done in SmartVU. Before leaving this entry, be sure to Apply these changes to the GNS.

Disabling an analog input: The analog inputs cannot be disabled, but can be ignored. If the input is no longer needed, the configuration can be left as is or set to display some nominal value. Be sure to disable all analog protections in the User Protection tab of the Configuration Notebook Meter for that input.

Enabling analog protections: The protections on the analog inputs are independent protections from the coolant temperature protection and oil pressure protections that are used at the system level even if that analog input is used for the corresponding input. These protections are typically only used when the analog input is NOT used as the input for the 4 system level parameters Coolant Temperature, Oil Pressure, Fuel Level, and Engine Speed. All analog Input protection features are set in the User Protection tab of the Configuration Notebook Meter in SmartVU. To set the protection,

Select the analog input from the dropdown list.

(Optional) Set the name of the Analog Input. This name for the Analog Input can be set here or on the Analog Input Config tab of the Configuration Notebook Meter.

Select which warning and/or alarm protections are required.

Define the delay. This delay is valid for all warnings and alarms and set the time after the limits have been reached, before the fault is triggered

Select the action to take. This only applies to when an alarm is triggered. Warnings do not take any action to alter the set operating condition, but only record that the warning has happened, and signal the operator.

Set the limits. Each warning and alarm has a different level at which the protection will trip.

Set the active time. There is one set of active times that apply to all warnings and alarms. These active times are when the warnings and alarms will trigger if the level is reached. More than one active time can be enabled, but at least one time must be enabled for the fault to trigger.

Disabling analog protections:

Deselect the warnings and/or alarm protection functions either in the User Protection tab or the Warning/Alarm tab of the Configuration Notebook Meter.


Refer to Analog Input Wiring section for proper wiring of inputs.

Meters:


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Display – The GNS display has a screen dedicated to displaying the measured values seen on the analog inputs. Regardless of whether the inputs are configured or not, the current measured values will be displayed.

SmartVU – SmartVu provides and meter for each analog input as shown below. The meters show the warning and alarm levels if enabled, and show the user-defined name for the input.

All configuration of the analog inputs and their protections is done through SmartVU. The following tabs in the notebook are used to configure the analog inputs and set the protection levels.

Setpoints:

ANALOG INPUT 1 – ACTIVE TIME –



ANALOG INPUT 4 – ACTIVE TIME – The operating states of the system when the protection is active.

ENGINE PRELUBE – This stage is active when a Prelube cycle has been enabled and is running.


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ENGINE PRELUBE PAUSE – This stage is active when a Prelube cycle is enabled but is not running.

ENGINE STOPPED – This stage is active when the engine is at rest with no Prelube cycle enabled.

ENGINE PRESTART – This stage is active when a Prestart cycle is running.

ENGINE CRANKING – This stage is active when the controller is in a crank cycle

CRANK REST – This stage is active when the controller does not detect engine started after crank and is resting until the next crank period.

GAS RPM DELAY – This stage is active when the controller is cranking the engine, the engine has reached the Gas RPM setpoint, and the controller is waiting for the Gas RPM Delay time to elapse.

GAS VENTING – This stage is active when the engine has not started during a crank cycle, and the controller is venting by cranking the engine with the fuel off.

ENGINE IDLE – This stage is active when the engine is idling.

ENGINE IDLE OVERRIDE – This stage is active when the engine is idling during an idle override.

VOLTAGE DETECT DELAY – This stage is active when the engine has finished idling, and is waiting for the controller to detect the voltage configuration and set the protections.

ENGINE RUNNING – This stage is active when the controller has enabled all protections and is running at nominal speed.

ENGINE COOLING – This stage is active when the controller has been requested to perform a soft shutdown and is cooling the engine.

ENGINE STOPPING - This stage is active when the engine is done cooling, has turned off fuel, and is waiting for the engine to stop.

ENGINE AFTER COOLING –This stage is active after the engine has stop and the controller is performing after cool functions.

ANALOG INPUT 1 – ALARM ACTION –



ANALOG INPUT 4 – ALARM ACTION – The action the controller will take when the fault is triggered.

HARD SHUTDOWN – This action will cause the controller to stop the engine immediately and skip all cooling and after cool functions.

SOFT SHUTDOWN – This action will cause the controller to stop the engine by following all configure cooling and after cool periods that are enabled.

GCB OPEN – This action will signal the GCB to open by utilizing the GCB open output.

GCB TRIP – This action will signal the GCB to trip open by utilizing the GCB trip output.

ANALOG INPUT 1 – DATA POINTS –




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ANALOG INPUT 4 – DATA POINTS – The graph points used to map the raw analog input to the defined engineering units.

ANALOG INPUT 1 – DELAY –



ANALOG INPUT 4 – DELAY – The time to wait after the input has reached its high or low limit before triggering fault.

ANALOG INPUT 1 – HIGH LIMIT –



ANALOG INPUT 4 – HIGH LIMIT – The high limit that must be reached for the configured delay time before the fault is triggered.

ANALOG INPUT 1 – TYPE OF SENSOR –



ANALOG INPUT 4 – TYPE OF SENSOR – The type of sensor connected to the input

RESISTIVE 1 WIRE – This type of sensor transmits its signal as a resistance with one wire and uses the sensor housing as a ground path.

RESISTIVE 2 WIRE – This type of sensor transmits its signal as a resistance using two wires.

CURRENT (MICROAMPS) – This type of sensor transmits its signal as a current. Typical sensors are 4-20mA, 0-20mA, etc.

VOLTAGE (MICROVOLTS) – This type of sensor transmits its signal as a voltage in the micovolt range. Typical sensors ar Thermocouple (Type K), etc.

VOLTAGE (MILLIVOLTS) – This type of sensor transmits its signal as a voltage in the millivolt range. Typical sensors are 0-5 VDC, 0-1 VDC, etc.

NONE – This type is used when no sensor is connected.

ANALOG INPUT 1 – UNITS –



ANALOG INPUT 4 – UNITS – The units to use in the conversion of raw analog input (defined by the type of sensor) to engineering units

TEMPERATURE – Use this setting when the sensor is measuring temperature. The units to display (oC, oF) are independently set in SmartVU and the displays.

PRESSURE – Use this setting when the sensor is measuring pressure. The units to display (PSI, Bar) are independently set in SmartVU and the displays.


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OHM – Use this setting when the sensor is measuring Ohms. The units are fixed at Ohms on both SmartVu and the displays.

RPM – Use this setting when the sensor is measuring RPM. The units are fixed at RPM on both SmartVU and the displays.

% - Use this setting when the sensor is measuring %. The units are fixed at % on both SmartVU and the display.

Protections:

Holdoffs: None

Analog Sender Fail Alarm – This protection is activated when the analog sender reading is outside of the programmed limits. Analog sender failure fault will only detect a failure during the active time set in the user protection page.

Analog Sender Fail Warning - This protection is activated when the analog sender reading is outside of the programmed limits. Analog sender failure fault will only detect a failure during the active time set in the user protection page.

Analog Input 1 Over Alarm –



Analog Input 4 Over Alarm – This protection is activated when the analog 1 input reaches the level defined by setpoint ANALOG X HIGH ALARM LIMIT, or ANALOG X HIGH WARNING LIMIT for a period of time defined by setpoint ANALOG X DELAY during stages defined by ANALOG X ACTIVE TIME. If alarm activated the action defined by ANALOG X ALARM ACTION will be executed.

Analog Input 1 Over Warning –



Analog Input 4 Over Warning – This protection is activated when the analog 1 input reaches the level defined by setpoint ANALOG X HIGH ALARM LIMIT, or ANALOG X HIGH WARNING LIMIT for a period of time defined by setpoint ANALOG X DELAY during stages defined by ANALOG X ACTIVE TIME. If alarm activated the action defined by ANALOG X ALARM ACTION will be executed.

Analog Input 1 Under Alarm –



Analog Input 4 Under Alarm – This protection is activated when the analog 1 input reaches the level defined by setpoint ANALOG X LOW ALARM LIMIT, or ANALOG X LOW WARNING LIMIT for a period of time defined by setpoint ANALOG X DELAY during stages defined by ANALOG X ACTIVE TIME. If alarm activated the action defined by ANALOG X ALARM ACTION will be executed.

Analog Input 1 Under Warning –



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Analog Input 4 Under Warning – This protection is activated when the analog 1 input reaches the level defined by setpoint ANALOG X LOW ALARM LIMIT, or ANALOG X LOW WARNING LIMIT for a period of time defined by setpoint ANALOG X DELAY during stages defined by ANALOG X ACTIVE TIME. If alarm activated the action defined by ANALOG X ALARM ACTION will be executed.



ANALOG 1 OVER ALARM ANALOG1ÂL –



ANALOG 4 OVER ALARM ANALOG4ÂL – Active when protection Analog X Over Alarm is active.

ANALOG 1 OVER WARNING ANALOG1^WN –



ANALOG 4 OVER WARNING ANALOG4^WN – Active when protection Analog X Over Warning is active.

ANALOG 1 UNDER ALARM ANALOG1VAL –



ANALOG 4 UNDER ALARM ANALOG4VAL – Active when protection Analog X Under Alarm is active.

ANALOG 1 UNDER WARNING ANALOG1VWN –



ANALOG 4 UNDER WARNING ANALOG4VWN – Active when protection Analog X Under Warning is active.

COMMON SENDER FAILURE SND FAIL - Activated when any sender’s input is outside the range of its graph. Cleared on Fault Reset.




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3.32 CONFIGURING THE GNS FOR USER-DEFINED PROTECTIONS

User-defined protections can be used to signal to the controller that an external event has happened. Once signaled, this event can be used to take controller action or conditioned and used to trigger external equipment. In addition, the user-defined protections can be used to alter pre-defined GNS functionality. Basically by allowing both user-defined inputs and outputs and conditioning the inputs, many standard functions that can be signaled by Binary Outputs can be wrapped back into user-defined Binary Inputs to modify the behavior of the GNS.

The user-defined protections are configured slightly differently than the user-defined analogs. In the case of the analogs, each protection is associated with its corresponding input. With the user-defined protections, they are independent protection functions that are configured, and then assigned to any one of the Binary Inputs or Outputs.

Lastly, the user-defined protections can have a user-defined name for each. Care must be taken to define names that will not conflict with the system level names being used by the system.

An example helps to show the operation. For example, a user would like to monitor a day tank and trigger a warning when the level reaches one point, and an alarm should the level drop further to a lower point. The warning should trigger external equipment to begin refilling the tank. In the User Protection tab, a unused protection would be selected, we will use Digital 6. The name we will give it is “Day Tank”. It will be active all of the time, and we need both a warning and an alarm function. We want to prevent any nuisance tripping and because the day tank level changes very slowly, we will wait for 10 seconds before triggering an alarm or warning. On the alarm condition, we want to open the GCB and perform a soft shutdown. The configuration of the protection would be as shown below:

This configures the protection function, now we must assign it to the Binary Inputs and Outputs. Let’s say we have Binary Input 7, and 8 available, and Binary Output 9 available. In the Binary Input tab, we would select “Day Tank Warning” function for Binary Input 7 and wire the warning level switch to Binary Input 7. Next we would select “Day Tank Alarm” function for Binary Input 8 and wire the alarm level switch to Binary Input 8. Notice a couple of things. First we are using Digital 6, and assigning it to Binary Input 7. As stated earlier, it doesn’t matter which user defined is assigned to which Binary Input or Output. Second, the name we supplied “Day Tank” is the name that shows up in the function list with the “Warning” and “Alarm” applied to it. Even if we do not enable the warning or the alarm, the functions are available but cannot be triggered. The configuration of the Binary Inputs 7, 8 would be as shown below:


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Lastly, we need to signal the external pump to run. This is done, by assigning the function “Day Tank Warning” to Binary Output 9 and wiring Binary Output 9 to the pump control. The configuration of Binary Output 9 would be as shown below:

Note: No provisions have been made in this example to control how long the pump should operate. That can be controlled by a timer, or by a High level switch or some other mechanism.

Requirements:

To enable a user-defined protection:

To enable a user-defined protection, the following steps must be performed.


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Configure Protection – All or the configuration of the user-defined protection is done on the User Protection tab of the Configuration Notebook Meter

Select the protection – The protections are identified by Digital 1 – Digital 8 in the drop down list.

(Optional) Set the name of the protection. This will be the name shown on the Binary Input and Output screens and in the logs. The identification of warning or alarm will be automatically be added to the user-defined name.

Select which warning and/or alarm protections are required. – At least one of these must be enabled for the user-defined protections to work.

Define the delay. This delay is valid for both the warning and alarm for this protection and sets the time after the input is active, before the fault is triggered

Select the action to take. This only applies to when an alarm is triggered. Warnings do not take any action to alter the set operating condition, but only record that the warning has happened, and signal the operator.

Set the active time. There is one set of active times that apply to the warning and alarm. These active times are when the warning and alarm will trigger. More than one active time can be enabled, but at least one time must be enabled for the fault to trigger.

Assign Protection to Binary Input – On the Binary Input tab of the Configuration Notebook Meter, select the user-defined function from the drop-down list associated with the Binary Input to trigger this function. The User-Defined protections functions have names that match their user-defined names. In the list are warning and alarm functions associated with the user-defined name even if the warning or alarm is not enabled.

Optionally assign protection to Binary Output - On the Binary Output tab of the Configuration Notebook Meter, select the user-defined function from the drop-down list associated with the Binary Output to annunciate this condition. In the list are warning and alarm functions associated with the user-defined name even if the warning or alarm is not enabled.

To disable a user-defined protection: To disable a user-defined protection, disable the alarm or warning protection in the User Protection tab or Alarms/Warnings tab of the Configuration Notebook Meter. Remember, in the Alarm/Warning tab, that the protection is listed by it defined name. In addition, because the protection is disabled and will never trigger, you can reassign any Binary Inputs and Outputs assigned to User-Defined Protections to new functions.



Meters:

Display – The screens Binary Input States, and Binary Output States shown below, show the current status of any of the user-defined protections.


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SmartVU – The meters External Discrete Input Levels, and External Discrete Output Levels, shown below, show the current status of any user-defined protections.

The User Protection tab of the Configuration Notebook Meter is shown below. This age is used to define the operation of the user-defined protection. In addition to defining its operation, it needs to be assigned to a Binary Input so that it can be triggered, and optionally assigned to a Binary Output to affect external equipment if necessary.


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Setpoints:

ALARM IC ACTION – The action to take once the Alarm Di input has been activated for ALARM IC DELAY.

ALARM IC DELAY – The time to wait after the Alarm DI input has been activated before triggering a fault and taking the action defined by ALARM IC ACTION.

WARNING IC DELAY – The time to wait after the Warning DI input has been activated before triggering a fault

User Defined – Digital 1 Active Time –







User Defined – Digital 8 Active Time – The operating states of the system when the protection is active.

ENGINE PRELUBE – This stage is active when a Prelube cycle has been enabled and is running.

ENGINE PRELUBE PAUSE – This stage is active when a Prelube cycle is enabled but is not running.

ENGINE STOPPED – This stage is active when the engine is at rest with no Prelube cycle enabled.

ENGINE PRESTART – This stage is active when a Prestart cycle is running.

ENGINE CRANKING – This stage is active when the controller is in a crank cycle

CRANK REST – This stage is active when the controller does not detect engine started after crank and is resting until the next crank period.

GAS RPM DELAY – This stage is active when the controller is cranking the engine, the engine has reached the Gas RPM setpoint, and the controller is waiting for the Gas RPM Delay time to elapse.

GAS VENTING – This stage is active when the engine has not started during a crank cycle, and the controller is venting by cranking the engine with the fuel off.

ENGINE IDLE – This stage is active when the engine is idling.

ENGINE IDLE OVERRIDE – This stage is active when the engine is idling during an idle override.

VOLTAGE DETECT DELAY – This stage is active when the engine has finished idling, and is waiting for the controller to detect the voltage configuration and set the protections.

ENGINE RUNNING – This stage is active when the controller has enabled all protections and is running at nominal speed.


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ENGINE COOLING – This stage is active when the controller has been requested to perform a soft shutdown and is cooling the engine.

ENGINE STOPPING - This stage is active when the engine is done cooling, has turned off fuel, and is waiting for the engine to stop.

ENGINE AFTER COOLING –This stage is active after the engine has stop and the controller is performing after cool functions.

User Defined – Digital 1 Alarm Action –







User Defined – Digital 8 Alarm Action – The action the controller will take when the fault is trigger. This is only valid if the alarm function is assigned to the input.

HARD SHUTDOWN – This action will cause the controller to stop the engine immediately and skip all cooling and after cool functions.

SOFT SHUTDOWN – This action will cause the controller to stop the engine by following all configure cooling and after cool periods that are enabled.

GCB OPEN – This action will signal the GCB to open by utilizing the GCB open output.

GCB TRIP – This action will signal the GCB to trip open by utilizing the GCB trip output.

User Defined – Digital 1 Delay –







User Defined – Digital 8 Delay – The time to wait after the input has been activated before triggering fault.

Protections

Holdoffs: None

DI Fault Alarm - This is a user assignable alarm or warning level protection. To use this protection, the corresponding function (Alarm DI, Warning DI) must be assigned to a binary input


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and externally triggered. When the alarm protection is triggered, the GNS will use the generator shutdown method specified by ALARM IC ACTION. The alarm and the warning each have their own delay (ALARM IC DELAY, WARNING IC DELAY) to determine when protection should trigger.

DI Fault Warning – This is a user assignable alarm or warning level protection. To use this protection, the corresponding function (Alarm DI, Warning DI) must be assigned to a binary input and externally triggered. When the alarm protection is triggered, the GNS will use the generator shutdown method specified by ALARM IC ACTION. The alarm and the warning each have their own delay (ALARM IC DELAY, WARNING IC DELAY) to determine when protection should trigger.

User Defined 1 Alarm -







User Defined 8 Alarm - This protection is activated when a binary input assigned function User Defined X is activated for a period of time defined by setpoint USER DEFINED X DELAY during stages defined by USER DEFINED X ACTIVE TIME. If alarm activated the action defined by USER DEFINED X ALARM ACTION will be executed.

User Defined 1 Warning -







User Defined 8 Warning – This protection is activated when a binary input assigned function User Defined X is activated for a period of time defined by setpoint USER DEFINED X DELAY during stages defined by USER DEFINED X ACTIVE TIME. If alarm activated the action defined by USER DEFINED X ALARM ACTION will be executed.


ALARM DI ALARM DI – Generic user alarm input – User can assign soft shutdown or hard shutdown. Fault Reset needed to clear condition.

~USER DEFINED 1 ALARM USRDEF1AL –




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~USER DEFINED 8 ALARM USRDEF8AL – User defined alarm input. Can be configured for delay, active generator states, alarm action, and user-defined name. Fault Reset needed to clear condition.

Note: The number represents the user defined number and not the binary input number. Any user defined can be assigned to any binary input or output.

~USER DEFINED 1 WARNING USRDEF1WN –







~USER DEFINED 8 WARNING USRDEF8WN – User defined warning input. Can be configured for delay, active generator states, and user-defined name.

Note: The number represents the user defined number and not the binary input number. Any user defined can be assigned to any binary input or output.

WARNING DI WARN DI – Generic user warning input.









~USER DEFINED 8 ALARM USRDEF8AL – Active when protection User Defined X Alarm is active.



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~USER DEFINED 8 WARNING USRDEF8WN – Active when protection User Defined X Warning is active.



Alternate Uses:

Even though User-Defined protections are typically used to signal the controller that external events have happened, they can also be used to condition and control internal events. An example of this is using a low engine temperature switch to extend the idle time. Typically the idle stage of operation has a fixed amount of time it will run regardless of whether the engine is hot or cold. By using a low coolant switch and wiring it to a user-defined protection function, this input can be conditioned by the user-defined protection function to give a delay, operate only during certain active times, and then be output as a new signal that can then be used to override the idle time until the engine temperature reached proper temp.

Many of the alternate uses of the GNS functions use a user-defined protection to alter the typical operation of the GNS and adapt it to a variety of external equipment. Refer to the sections for alternate uses involving user-defined protections.

3.33 CONFIGURING THE GNS FOR SECURITY

The security functions of the GNS allow each service level to have a designated access and select what access can be used by lower levels. The controller has 6 levels available, Service Level 0 is the lowest level and does not have a password. Levels 1 – 5 have passwords assigned to them that can be changed. Each level can change the password for that level and the levels below it. In addition, each level can set the access for levels below its own.

Setting passwords and the access rights to the different levels are a topic outside of this manual. Contact the factory for further information.

In addition to access restrictions to the internal data, the controller provides a panel lock function that can restrict the display from controlling the generator set, but can be used to view the screens.

Requirements:

To set security level access:

To set security levels and access restrictions contact the factory for further information.

To enable the panel lock:


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Set a Binary Input to the Panel Lock function and wire the input to a key switch or directly to ground inside a locked or restricted panel.

To disable the panel lock:

Make sure no Binary Inputs are assigned the Panel Lock function.


Refer to Binary Input Wiring section for proper wiring of binary inputs.

Meters:

Display – The screen Binary Input States, shown below, show the current status of any of the panel lock functions.

SmartVU – The meter External Discrete Input Levels, shown below, show the current status of any panel lock functions.

Setpoints:

PASSWORD PASSWORD LOGIN – The user can enter any level password and unlock associated set points from the front panel. The password is a number and there are five protected levels available.

SET PASSWORD CHANGE PASSWORD – On the display, this setpoint will allow a user to change the password at that level. In SmartVu, the password for the current level and any level below can be changed.

Protections:

Holdoffs: None

None


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PANEL LOCK PNL LOCK - Disables control of generator set from front panel. Set points can be viewed but not modified.




3.34 CONFIGURING THE GNS TO TRANSMIT J1939 DATA

Description:

The GNS is feature rich controller that is tightly integrated with J1939. The controller provides several features that allow it to work in cooperation with J1939 devices. It not only allows monitoring of those devices, it also can use some of the standard J1939 data. This data can be used as system level parameters instead of dedicated sensors in the GNS’s control and protection functions. This functionality is converted in other sections of this manual.

In addition to handling the J1939 data on the bus, the GNS is capable of transmitting much of its own measured and computed data on the J1939 bus. This data can then be used by other monitoring equipment so that it does not need dedicated equipment to monitor all of the generator related data. Data such as voltages, currents, frequencies, and power are all transmitted on the J1939 bus if desired. It can also be used to extend the functionality of the GNS by adding peripherals, such as RA20, CRM20, and JDRs to a system to expand the capabilities. See section on Connectivity for more information.

Requirements:

To enable transmission of J1939 data:

Note: In order for this function to work, the CAN Bus must be configured properly. Refer to the Section Configuring the GNS for Powering and Communicating with an J1939 ECU before proceeding.

To enable the J1939 data transmission, select the data group to be transmitted on the J1939 Config tab of the Configuration Notebook Meter. The data is defined in three groups of related data. Engine, Generator, and Status. Each group can be enabled or disabled individually.

Engine Data - consists of data related to engine operation. Oil pressure, engine speed, coolant temperature to name a few. Any data that is being used by the controller for system level parameters, regardless of their source (J1939, analog inputs, etc), will be transmitted.

Generator Data – This data consists of the parameters measured from the voltage and current inputs as well as the calculated data such as frequency and power.

Status Data – This data consists of warning and alarm conditions, Binary Input and Output statuses, etc.


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To disable transmission of J1939 data:

To disable the J1939 data transmission, deselect the data group on the J1939 Config tab of the Configuration Notebook Meter. The data is defined in three groups of related data. Engine, Generator, and Status. Each group can be enabled or disabled individually.


See section on CAN/J1939 wiring.

Meters:

Display – The data being transmitted by the GNS is shown on the metering screens.

SmartVU – The J1939 Config tab of the Configuration Notebook Meter, shown below, configures the GNS to transmit data.

Setpoints:

CAN1 J1939 GNS ADDRESS – This setpoint defines the address that the GNS will use to transmit data on the J1939 bus.

Note: Each transmitting device on the J1939 bus, must have a unique address.

J1939 TRAFFIC ENABLE – ENGINE DATA – This setpoint enables or disables the transmission of engine related data onto the J1939 bus from the GNS.

J1939 TRAFFIC ENABLE – GENERATOR DATA – This setpoint enables or disables the transmission of generator related data onto the J1939 bus from the GNS.

J1939 TRAFFIC ENABLE – STATUS DATA – This setpoint enables or disables the transmission of status related data onto the J1939 bus from the GNS.

Protections:

Holdoffs: None

None


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4.0 Reference Information

4.1 SECURITY

The GNS supports 6 user defined security levels (0-5). Each set point can be assigned a level to view the parameter, and a level to adjust the parameter.

The default passwords for each of the levels are as follows:

Level Password

0 0

1 17

2 34

3 51

4 68

5 85

The passwords for each security levels can be changed using GAC’s SmartVU software. SmartVU can also be used to change the security level for each of the set points.

Should you forget the password, please contact your dealer or GAC.

4.2 BINARY INPUT FUNCTIONS

Configuring the GNS requires assigning “functions” to the physical inputs. When the physical input is triggered, the functions tell the GNS what action to take. Below is the table of input functions available within the GNS.

Function Type Definition

Alarm DI Maintained Generic user alarm input – User can assign soft shutdown or hard shutdown. Fault Reset needed to clear condition.

Auto Mode Momentary Puts controller in Auto Mode. After release, controller operation follows Auto Mode operation until new mode requested

E Stop Maintained Immediately shuts down engine, cuts fuel, and displays alarm. Fault Reset needed to clear condition.

Fault Reset Momentary Clears all non-active faults from alarm list.

GCB Close Request Momentary Requests that the GNS closes the GCB. Operational in Manual Mode only. Note: Must not be assigned to more than one input.

GCB Feedback Close Maintained Indicates that the GCB is in the closed position. Multi-line breaker control only. Note: Must not be assigned to more than one input.


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GCB Feedback Open Maintained Indicates that the GCB is in the open position. Multi-line breaker control only. Note: Must not be assigned to more than one input.

GCB Feedback Open/Close Maintained Indicates the position the GCB is in. Single line breaker control only. Note: Must not be assigned to more than one input.

GCB Feedback Trip Maintained Indicates that the GCB is in the tripped position. Multi-line breaker control only. Note: Must not be assigned to more than one input.

GCB Open Request Momentary Requests that the GNS opens the GCB. Operational in Manual Mode only. Note: Must not be assigned to more than one input.

Horn Silence Momentary Turns off horn output.

Idle Override Maintained Extends idle operation until signal released

Manual Mode Momentary Put controller in Manual Mode. After release, controller operation follows Manual Mode operation until new mode requested

Not Assigned N/A Input not used, no action taken.

Off Mode Momentary Put controller in Off Mode. After release, controller operation follows Off Mode operation until new mode requested

Panel Lock Maintained Disables control of generator set from front panel. Set points can be viewed but not modified.

Prestart Override 1 Prestart Override 2 Prestart Override 3 Prestart Override 4

Maintained Extends Prestart operation until signal released. Note: Each Prestart has a corresponding period, output, and override input.

Remote Start Momentary Start request for manual mode

Remote Start/Stop Maintained Allows user to start and stop the engine while in auto mode. Note: Must not be assigned to more than one input.

Remote Stop Momentary Stop request for manual mode

Run All Maintained Commands the generator set to run even in the presence of specified alarm conditions. Must be activated before alarm fault triggered. Note: Must not be assigned to more than one input.

~User Defined 1 Alarm ~User Defined 2 Alarm ~User Defined 3 Alarm ~User Defined 4 Alarm ~User Defined 5 Alarm ~User Defined 6 Alarm ~User Defined 7 Alarm ~User Defined 8 Alarm

Maintained User defined alarm input. Can be configured for delay, active generator states, alarm action, and user-defined name. Fault Reset needed to clear condition. Note: The number represents the user defined number and not the binary input number. Any user defined can be assigned to any binary input or output.

~User Defined 1 Warning ~User Defined 2 Warning ~User Defined 3 Warning ~User Defined 4 Warning ~User Defined 5 Warning ~User Defined 6 Warning ~User Defined 7 Warning ~User Defined 8 Warning

Maintained User defined warning input. Can be configured for delay, active generator states, and user-defined name. Note: The number represents the user defined number and not the binary input number. Any user defined can be assigned to any binary input or output.


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Voltage Select 1 V Sel 1 Voltage Select 2 V Sel 2 (Not Supported in GNS2500)

Maintained Used to select entry from Voltage Selection Table when using Binary Voltage Select method. When both Voltage Select 1, 2 assigned

Voltage Select 1

Voltage Select 2

Voltage Selection Table

Entry 0 0 1 1 0 2 0 1 3 1 1 4

When only Voltage Select 1 assigned

Voltage Select 1

Voltage Selection Table Entry

0 1 1 2

When only Voltage Select 2 assigned

Voltage Select 2

Voltage Selection Table Entry

0 1 1 3

Note: Voltage Select 1 and Voltage Select 2 must not be assigned to more than one input.

Warning DI Warn DI Maintained Generic user warning input.

THE FOLLOWING INPUTS APPLY TO THE GNS2500 ONLY

Test Mode Maintained Put controller in Test Mode

MCB Feedback Open Momentary Signal indicating MCB is open.

MCB Feedback Close Momentary Signal indicating MCB is closed.

MCB Feedback Trip Maintained Signal indicating MCB is in trip state. NOTE: When this function is activated, this is considered a genset shutdown condition. This could be a condition where there is a short in the load, so the genset must not generate power into the load (i.e., close GCB).

MCB Open / Close Maintained Toggles state of MCB from open to closed, or, closed to open

MCB Feedback Open/Close Maintained Single line feedback to indicate state of MCB.

Notes: Input functions and polarities can only be assigned to binary inputs using GAC’s SmartVU software.


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4.3 BINARY OUTPUT FUNCTIONS

As with Input Functions, the GNS requires assigning “functions” to the physical outputs. When the GNS triggers one of the functions, the corresponding physical output will be triggered. Below is the table of output functions available within the GNS.

Output Function Definition

After Cool Active during After Cool stage.

Analog 1 Over Alarm Analog 2 Over Alarm Analog 3 Over Alarm Analog 4 Over Alarm

Active when protection Analog X Over Alarm is active.

Analog 1 Over Warning Analog 2 Over Warning Analog 3 Over Warning Analog 4 Over Warning

Active when protection Analog X Over Warning is active.

Analog 1 Under Alarm Analog 2 Under Alarm Analog 3 Under Alarm Analog 4 Under Alarm

Active when protection Analog X Under Alarm is active.

Analog 1 Under Warning Analog 2 Under Warning Analog 3 Under Warning Analog 4 Under Warning

Active when protection Analog X Under Warning is active.

Battery Over Voltage Warning Active when protection Battery Over Voltage Warning is active.

Battery Under Voltage Warning Active when protection Battery Under Voltage Warning is active.

Charger Fail Active when protection Charger Failure is active.

Common Alarm Activated when any alarm is active or in alarm list. Cleared on Fault Reset.

Common Sender Failure Activated when any sender’s input is outside the range of it’s graph. Cleared on Fault Reset.

Common Shutdown Activated when hard shutdown protection occurs. Cleared on Fault Reset.

Common Stop Activated when soft shutdown protection occurs. Cleared on Fault Reset.

Common Unload Activated when a GCB open, or GCB Trip protection occurs. Cleared on Fault Reset.

Common Warning Activated when any warning is active or in alarm list. Cleared on Fault Reset.

Crank Failed Active when protection Crank Fail is active.

Fuel Activated when engine is required to run. Used to control fuel solenoid.

GCB Close Generator Circuit Breaker control signal – activated when GCB should be closed, deactivated when GCB Feedback Close signal received. For multi-line breaker control only.


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GCB Open Generator Circuit Breaker control signal – activated when GCB should be opened, deactivated when GCB Feedback Open signal received. For multi-line breaker control only.

GCB Open/Close Generator Circuit Breaker control signal – activated when GCB should be closed, deactivated when GCB should be open. For single wire breaker control only.

GCB Trip Generator Circuit Breaker control signal – activated when GCB should be tripped opened (typically requiring a manual breaker reset), deactivated when GCB Feedback Trip signal received. For multi-line breaker control only.

GCB Warning Active when protection GCB Warning or GCB Fault is active.

Generator OK Activated when engine is running and all engine and generator levels are within spec.

Generator Over Frequency Alarm Active when protection Generator Over Frequency Alarm is active.

Generator Over Frequency Warning Active when protection Generator Over Frequency Warning is active.

Generator Over Voltage Alarm Active when protection Generator Over Voltage Alarm is active.

Generator Over Voltage Warning Active when protection Generator Over Voltage Warning is active.

Generator Running Activated when engine has successfully started.

Gen Unbalanced Voltage Alarm Active when protection Generator Unbalanced Voltage Alarm is active.

Generator Under Frequency Alarm Active when protection Generator Under Frequency Alarm is active.

Generator Under Frequency Warning Active when protection Generator Under Frequency Warning is active.

Generator Under Vltg Alarm Active when protection Generator Under Voltage Alarm is active.

Generator Under Vltg Warning Active when protection Generator Under Voltage Warning is active.

High Cool Temp Alarm Active when protection High Coolant Temperature Alarm is latched.

High Cool Temp Warning Active when protection High Coolant Temperature Warning is active.

Horn Activated on warnings and alarms for the time configured by setpoint Horn Period. Horn Silence function will deactivate horn output immediately

Idle Activated when GNS is in idle state or cooling state if cooling at idle is enabled. Used to signal engine to go to idle speed.

In Auto Active when control is in Auto Mode

Low Coolant Temperature Alarm Active when protection Low Coolant Temperature Alarm is active.

Low Cool Temp Warning Active when protection Low Coolant Temperature Warning is active.

Low Fuel Level Alarm Active when protection Low Fuel Level Alarm is active.

Low Fuel Level Warning Active when protection Low Fuel Level Warning is active.

Low Oil Pressure Alarm Active when protection Low Oil Pressure Alarm is active.

Low Oil Pressure Warning Active when protection Low Oil Pressure Warning is active.

Not Assigned Output not used.

Not in Auto Active when GNS is not in Auto mode

Overload Alarm Active when protection Generator Overload Alarm is active.


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Over Crank Active when protection Over Crank is active..

Over Current Active when protection Over Current is active.

Over Speed Active when protection Over Speed is active.

Prelube Activated during Prelube stage. Used to periodically signal external components while the engine is off i.e. Oil lubing systems.

Prestart 1 Prestart 2 Prestart 3 Prestart 4

Activated during Prestart state before cranking. Used to signal external engine Prestart equipment. Note: Prestarts are timed to all END at the same time, not start. Any Prestart output can be extended by activating the cooresponding Prestart override input. Note: Each Prestart has a corresponding period, output, and override input.

Ready to Accept Load Activated when genset’s engine is up to speed with protections enabled and all electric values are with limits.

Service Required Active when protection Service Required is active.

Starter Activated during engine cranking state to control starter motor.

Stop Fail Active when protection Stop Fail is active.

Stop Solenoid Activated to stop the engine, deactivated when engine is stopped.

Supplying Load Activated when generator set is supplying any load i.e. GCB is closed or engine running with no GCB configured.

Unbalanced Current Alarm Active when protection Generator Unbalanced Current Alarm is active.

Under Speed Active when protection Under Speed is active.

~User Defined 1 Alarm ~User Defined 2 Alarm ~User Defined 3 Alarm ~User Defined 4 Alarm

Active when protection User Defined X Alarm is active.

~User Defined 1 Warning ~User Defined 2 Warning ~User Defined 3 Warning ~User Defined 4 Warning ~User Defined 5 Warning ~User Defined 6 Warning ~User Defined 7 Warning ~User Defined 8 Warning

Active when protection User Defined X Warning is active. Note: The number represents the user defined number and not the binary output number. Any user defined can be assigned to any binary input or output.

Waiting to Run Active when the engine is stopped with no warnings or alarms and is able to start.

THE FOLLOWING OUTPUT FUNCTIONS APPLY TO THE GNS2500 ONLY

MCB Close Mains Circuit Breaker control signal – activated when MCB should be closed, deactivated when MCB Feedback Close signal received. For multi-line breaker control only.

MCB Open Mains Circuit Breaker control signal – activated when MCB should be opened, deactivated when MCB Feedback Open signal received. For multi-line breaker control only.

MCB Open/Close Mains Circuit Breaker control signal – activated when MCB should be closed, deactivated when MCB should be open. For single wire breaker control only.


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MCB Trip Mains Circuit Breaker control signal – activated when MCB should be tripped opened (typically requiring a manual breaker reset), deactivated when MCB Feedback Trip signal received. For multi-line breaker control only.

Mains OK Enabled whenever the Mains is within specification

Mains Over Frequency Warning Enabled when Mains Over Frequency Warning has been activated.

Mains Over Frequency Alarm Enabled when Mains Over Frequency Alarm has been activated.

Mains Over Voltage Warning Enabled when Mains Over Voltage Warning has been activated.

Mains Over Voltage Alarm Enabled when Mains Over Voltage Alarm has been activated.

Mains Unbalanced Voltage Alarm Enabled when Mains Unbalanced Voltage Alarm has been activated.

Mains Under Frequency Warning Enabled when Mains Under Frequency Warning has been activated.

Mains Under Frequency Alarm Enabled when Mains Under Frequency Alarm has been activated.

Mains Under Voltage Warning Enabled when Mains Under Voltage Warning has been activated.

Mains Under Voltage Alarm Enabled when Mains Under Voltage Alarm has been activated.

Notes: Input functions and their polarity can only be assigned to physical inputs using GAC’s SmartVU software.


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4.3.1 Binary Output Function Categories

The Binary Output Functions can be categorized as protections, control, and status. The following tables list the assignable functions.

Protections – These output functions indicate that the specified protection function is active or has been active. They typically are used to signal external annunciation devices, control auxiliary equipment or can be wrapped back into an input to perform logic and fault conditioning functions. Warnings typically deactivate when the protection deactivates, alarms are typically latched until the Fault Reset has been pressed.

Input Protections Engine Protections Generator Protections Main Protections

Analog 1 Over Alarm Analog 1 Over Warning Analog 1 Under Alarm Analog 1 Under Warning Analog 2 Over Alarm Analog 2 Over Warning Analog 2 Under Alarm Analog 2 Under Warning Analog 3 Over Alarm Analog 3 Over Warning Analog 3 Under Alarm Analog 3 Under Warning Analog 4 Over Alarm Analog 4 Over Warning Analog 4 Under Alarm Analog 4 Under Warning User Defined 1 Alarm User Defined 1 Warning User Defined 2 Alarm User Defined 2 Warning User Defined 3 Alarm User Defined 3 Warning User Defined 4 Alarm User Defined 4 Warning User Defined 5 Alarm User Defined 5 Warning User Defined 6 Alarm User Defined 6 Warning User Defined 7 Alarm User Defined 7 Warning User Defined 8 Alarm User Defined 8 Warning

Battery Over Voltage Warning

Battery Under Voltage Warning

Charger Fail Crank Failed High Cool Temp Alarm High Cool Temp Warning Low Coolant Temperature

Alarm Low Cool Temp Warning Low Fuel Level Alarm Low Fuel Level Warning Low Oil Pressure Alarm Over Speed Over Crank Low Oil Pressure Warning Stop Fail Under Speed Common Protections Common Alarm Common Sender Failure Common Shutdown Common Stop Common Unload Common Warning

GCB Warning Generator Over Frequency

Alarm Generator Over Frequency

Warning Generator Over Voltage

Alarm Generator Over Voltage

Warning Gen Unbalanced Voltage

Alarm Generator Under

Frequency Alarm Generator Under

Frequency Warning Generator Under Vltg

Alarm Generator Under Vltg

Warning Over Current Overload Alarm Service Required Unbalanced Current Alarm

MCB Warning Mains Over Frequency

Alarm Mains Over Frequency

Warning Mains Over Voltage Alarm Mains Over Voltage

Warning Mains Unbalanced Voltage

Alarm Mains Under Frequency

Alarm Mains Under Frequency

Warning Mains Under Vltg Alarm Mains Under Vltg Warning


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Control – Control output functions are typically used to signal external equipment.

Status – Status output functions indicate set status and are typically used to activate remote annunciation devices.

Control Status After Cool Fuel GCB Close GCB Open GCB Open/Close GCB Trip Idle Horn Prestart X Prelube Starter Stop Solenoid

Generator OK Generator Running In Auto Not in Auto Ready to Accept Load Supplying Load Waiting to Run Not Assigned

The status and currently assigned function for the binary outputs can be found on the Binary Output Status screen on the display

The status and currently assigned function for the binary outputs can be found on the Binary Output Status screen in the SmartVU software


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4.4 STATUS MESSAGES

The GNS has the ability to record changes in status in its event log for troubleshooting purposes. The following is the list of status changes available:

Status Description

After Cool The engine has reached the after cool stage

Cool Down The engine has reached the cool down stage

Engine Started The engine has completed its cranking stage and is proceeding to idle or rated speed.

Gas RPM Reached The engine has reached the RPM specified by the Gas RPM set point

Gas Venting Recorded when a gaseous engine fails to start and enters the gas venting cycle.

Idle Speed Override The idle override input function has been triggered.

Nominal Speed Reached

The engine has reached the nominal operating speed.

Prelube The controller has entered the Prelube stage

Prestart Override A Prestart override input has been activated when the controller was in a Prestart stage.

Request GCB Close The GCB has been requested to close.

Request GCB Open The GCB has been requested to open.

Request GCB Trip The GCB has been requested to trip open.

Start Command The controller has received a request to start the engine either from the input or remote command

Stop Command Recorded when the controller has commanded a stop of the generator set.

Note: The user has the ability to enable or disable the recording of each type of status change message only through SmartVU software.

4.5 PROTECTIONS (WARNINGS, ALARMS/SHUTDOWNS)

Virtually all protections can individually be enabled or disabled using SmartVU. The table below lists the protection, the set points that affect the protection and the behavior during a shutdown (note, when a protection triggers a hard shutdown, the engine is immediately stopped, with a soft shutdown, the engine goes through the cool down cycle):


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Protection Description Warning Alarm Shutdown

DI Fault This is a user assignable alarm or warning level protection. To use this protection, the corresponding function (Alarm DI, Warning DI) must be assigned to a binary input and externally triggered. When the alarm protection is triggered, the GNS will use the generator shutdown method specified by Alarm IC Action. The alarm and the warning each have their own delay (Alarm IC Delay, Warning IC Delay) to determine when protection should trigger.

X User Defined (Hard or Soft)

Alternator GNS is no longer receiving a voltage on the D+ input.

X

Analog Sender Fail This protection is activated when the analog sender reading is outside of the programmed limits

X Soft

Analog Input 1 Over Analog Input 2 Over Analog Input 3 Over Analog Input 4 Over

This protection is activated when the analog 1 input reaches the level defined by setpoint Analog X High Alarm Limit, or Analog X High Warning Limit for a period of time defined by setpoint Analog X Delay during stages defined by Analog X Active Time. If alarm activated the action defined by Analog X Alarm Action will be executed.


Analog Input 1 Under Analog Input 2 Under Analog Input 3 Under Analog Input 4 Under

This protection is activated when the analog 1 input reaches the level defined by setpoint Analog X Low Alarm Limit, or Analog X Low Warning Limit for a period of time defined by setpoint Analog X Delay during stages defined by Analog X Active Time. If alarm activated the action defined by Analog X Alarm Action will be executed.


Auto Volt Detect This protection is activated when setpoint Voltage Detection is enabled and the GNS cannot determine the configuration of the wiring or operating voltages after Voltage Detection Time has elapsed.

X Soft**

Battery Over Voltage Activated when the battery voltage reaches the Battery Over Voltage set point for time specified by the Battery Delay set point.

X

Battery Under Voltage Activated when the battery voltage reaches the Battery Under Voltage set point for time specified by the Battery Delay set point.

X

CAN Bus Error This protection is activated when any of the configured ECU data (Oil Pressure, Engine Temperature, Fuel Level, Engine Speed) is not being received properly for the time specified by CAN Error Delay from the address configured by ECU Addr.

X** Soft

Communication Fail This protection is activated when the communication through the serial port has failed

X**

Configuration Error This protection is activated when the controller detects an issue with the saved configuration.

X** Soft

Crank Fail This protection is activated when the GNS detects no RPM after 3 seconds of cranking.

Hard**


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Engine Service This protection is activated when the number of hours specified by the Next Service Time reaches zero.

X

ECU Offline This protection is activated when the GNS stops receiving any data from the address configured by setpoint ECU addr for an extended period of time

X Soft

High Coolant Temperature

Activated when the coolant temperature reaches the value set by the High Coolant Temp set point for the amount of time specified by the Coolant Temp Delay set point.

X Hard

Low Coolant Temperature

Activated when the coolant temperature reaches the value set by the Low Coolant Temp set point for the amount of time specified by the Coolant Temp Delay set point.

X Hard

Low Fuel Level Activated when the fuel level reaches the level specified by the Low Fuel Level set point for the amount of time specified by the Low Fuel Delay set point.

X Hard

Low Oil Pressure This protection is activated when the oil pressure reaches the value specified by the Low Oil Pressure set point for the amount of time specified by the Oil Pressure Delay set point.

X Hard

Speed Sensor Fail This protection is activated when the GNS detects no activity on the magnetic pickup for one second (note: this protection should only be activated if the magnetic pickup is assigned).

X** Hard

Over Crank Activated when the GNS exhausts the number of cranking cycles configured. This means the GNS has cranked the engine specified by the Crank Attempts set point, each crank has been attempted for the amount of time specified by the Crank Period set point, and the GNS has waited in between each crank for the amount of time specified by the Crank Pause set point.

Hard**

Over Speed This protection is activated when the engine reaches the speed specified by the Over Speed set point for the amount time specified by the Engine Protect Delay set point.

Hard**

Stop Fail This protection is activated when the engine is reading RPM after the engine should have stopped. There are no set points.

X Hard

Under Speed This protection is activated when a running engine dips to the speed specified by the RPM Disconnect set point for the amount of time specified by Engine Protect Delay set point.

Hard

External GCB Trip This protection is activated when the GNS detects an external GCB trip. To use this protection, GCB Trip function must be assigned to a binary input and externally triggered from the GCB.

X


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Generator Over Current Activated when the current reaches the percentage of nominal current specified by the Generator Over Current Alarm set point for the time specified by the Generator Over Current Delay set point.

Hard

Generator Over Frequency

This protection is activated when the frequency on any of the phases reaches the values specified by the Generator Over Frequency Alarm or Generator Over Frequency Warning set points for the amount of time specified by the Generator Frequency Delay set point.

X Soft

Generator Over Voltage This protection is activated when the generator voltage reaches the values specified by the Generator Over Voltage Alarm or Generator Over Voltage Warning set points for the time specified by the Generator Under/Over Voltage Delay set point.

X Hard

Generator Unbalanced Current

This protection is activated when the GNS detects an unbalance in the generator current that reaches Generator Current Unbalance Alarm for the time specified by the Generator Current Unbalance Delay set point.

Hard

Generator Unbalanced Voltage

This protection is activated when the GNS detects an unbalance in the generator voltage that reaches Generator Voltage Unbalance Alarm for the time specified by the Generator Voltage Unbalance Delay set point.

Hard

Generator Under Frequency

This protection is activated when the frequency on any of the phases reaches the values specified by the Generator Under Frequency Alarm or Generator Under Frequency Warning set points for the amount of time specified by the Generator Frequency Delay set point.

X Soft

Generator Under Voltage

This protection is activated when the generator voltage reaches the values specified by the Generator Under Voltage Alarm or Generator Under Voltage Warning set points for the time specified by the Generator Voltage Delay set point.

X Hard

Over Current IDMT The GNS is equipped with an Inverse Definite Minimum Time Over Current (IDMT) algorithm. The response time of this protection is based on the amount of current the GNS is detecting. The higher the current the faster the over current response. The lower the current the slower the response. The current v. response times can be found in the “IDMT Response Table” section of this manual.

X Hard

Over Load Activated when the power reaches the values specified by the Overload Alarm or Overload Warning set points for the amount of time specified by the Overload Delay set point.

X Soft

Short Circuit Activated when the GNS detects a short circuit in the wiring to the load.

X Hard**

GCB Fault Activated when the GCB does not reflect the command from the GNS (e.g., GCB is commanded to close and the GCB does not close).

X**


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Phase Wiring Error – Voltage

Activated when the GNS detects an improper phase relationship between the generator voltage inputs.

X Soft**

Phase Wiring Error – Current

Activated when the GNS detects an improper phase relationship between the generator current inputs.

X Soft**

User Defined 1 User Defined 2 User Defined 3 User Defined 4 User Defined 5 User Defined 6 User Defined 7 User Defined 8

This protection is activated when a binary input assigned function User Defined X is activated for a period of time defined by setpoint User Defined X Delay during stages defined by User Defined X Active Time. If alarm activated the action defined by User Defined X Alarm Action will be executed.


GNS2500 PROTECTIONS ONLY

External MCB Trip This protection is activated when the GNS detects an external MCB trip. To use this protection, MCB Trip function must be assigned to a binary input and externally triggered from the MCB.

X

Mains Over Frequency This protection is activated when the frequency on any of the phases reaches the values specified by the Mains Over Frequency Alarm or Mains Over Frequency Warning set points for the amount of time specified by the Mains Frequency Delay set point.

X Starts Generator

Mains Over Voltage This protection is activated when the mains voltage reaches the values specified by the Mains Over Voltage Alarm or Mains Over Voltage Warning set points for the time specified by the Mains Under/Over Voltage Delay set point.

X Starts Generator

Mains Unbalanced Voltage

This protection is activated when the GNS detects an unbalance in the mains voltage that reaches Mains Voltage Unbalance Alarm for the time specified by the Mains Voltage Unbalance Delay set point.

Starts Generator

Mains Under Frequency This protection is activated when the frequency on any of the phases reaches the values specified by the Mains Under Frequency Alarm or Mains Under Frequency Warning set points for the amount of time specified by the Mains Frequency Delay set point.

X Starts Generator

Mains Under Voltage This protection is activated when the mains voltage reaches the values specified by the Mains Under Voltage Alarm or Mains Under Voltage Warning set points for the time specified by the Mains Voltage Delay set point.

X Starts Generator

MCB Fault Activated when the MCB does not reflect the command from the GNS (e.g., MCB is commanded to close and the MCB does not close).

X**

Note: ** These protections should always be enabled unless instructed otherwise by qualified personnel. They allow detection and notification

Note: All protections, except E-Stop, Engine Over Speed, and Short circuit are disabled when the “Run All” input function is active !!


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Note: To help troubleshoot, keep in mind, during pre-commissioning testing, each protection can enabled or disabled. Please be sure to re-enable any protections disabled during the testing process. !!

4.6 SET POINTS

The defaults shown are for the GNS2000 and GNS2500. Configuration differences may appear in the E-Series and other models.

Set Point Description Group Valid Range Default

After Cool Period

Time, in seconds, the after cool output will be active after the engine is stopped.

Engine Parameter

0-3600 Sec. 0 Sec.

Alarm IC Action The action to take once the Alarm DI input has been activated for Alarm IC Delay.

Generator Protection

Soft w/GCB Open (32787)

Soft w/GCB Trip (32803)

Hard w/GCB Open

(32789) Hard w/GCB

Trip (32805)

Soft w/GCB Open

(32787)

Alarm IC Delay The time to wait after the Alarm DI input has been activated before triggering a fault and taking the action defined by Alarm IC Action


0 – 600 Sec. 0 Sec.

Alternator Fail Delay

Time, in seconds, D+ signal from alternator can be 0V, before GNS will report a failure.

Engine Protection

0 – 600 Sec. 2 Sec.

Analog Input 1 – Active Time




The operating states of the system when the protection is active.

User Protection Engine Stopped Engine Cranking

Crank Rest Gas Venting

Gas RPM Delay Engine Idle

Voltage Detect Delay

Engine Running Engine Cooling

Engine Pre-Lube Engine PreLube

Pause Engine Pre-Start

Engine After-Cooling

Engine Idle Override

Engine Stopping

Active during all stages


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Analog Input 1 – Alarm Action




The action the controller will take when the fault is trigger.

User Protection Soft w/GCB Open Soft

w/GCB Trip Hard w/GCB

Open Hard w/GCB

Trip

Hard w/GCB Open

Analog Input 1 – Data Points




The graph points used to map the raw analog input to the defined engineering units.

Analog Input Config

Depends on Analog sensor configuration

Analog 1 – 4-20mA

(0-145 PSI) Analog 2 –

10- 250 ohms (-40-

250 oF) Analog 3 –

10–300 ohms (0-100%)

Analog Input 1 – Delay




The time to wait after the input has reached its high or low limit before triggering fault.

User Protection 0 – 6553 Sec. 1 Sec.

Analog Input 1 – High Limit




The high limit that must be reached for the configured delay time before the fault is triggered.

User Protection Depends on Analog sensor configuration

Protection not enabled

Analog Input 1 – Low Limit




The low limit that must be reached for the configured delay time before the fault is triggered.

User Protection Depends on Analog sensor configuration

Protection not enabled

Analog Input 1 – Type of Sensor Analog Input 2 – Type of Sensor

Analog Input 3 – Type of Sensor

Analog Input 4 – Type of Sensor

The type of sensor connected to the input Analog Input Config

None Voltage

(Millivolts) Voltage

(Microvolts) Current

(Microamps) Resistive 1Wire Resistive 2Wire

Analog 1 – Current

Analog 2 - Resistive

2Wire Analog 3 – Resistive

2Wire Analog 4 –

None


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Analog Input 1 – Units




The units to use in the conversion of raw analog input (defined by the type of sensor) to engineering units

Analog Input Config

None Temperature

Pressure Ohm RPM

%

Analog 1 – Pressure

Analog 2 – Temperatur

e Analog 3 -

% Analog 4 –

None

Battery Delay Battery Delay

Time, in seconds, the battery voltage will have to exceed the set points for the Batter under/over warnings to activate.

Engine Protection

0 – 600 Sec. 20 Sec.

Battery Over Voltage Warning

Threshold for the battery over voltage warning.

Engine Protection

8 – 40 V 30 V

Battery Under Voltage Warning

Threshold for the battery under voltage warning.

Engine Protection

8 – 40 V 9 V

CAN Error Delay The amount of time to wait after losing CAN data before triggering a fault

J1939 Config 0 – 600 Sec. 2 Sec.

CAN1 J1939 ECU Address

The source address the GNS looks for when attempting to read data from the ECU

J1939 Config 0 – 250, 255 0

CAN1 J1939 GNS Address

The source address the GNS uses when transmitting data

J1939 Config 0 – 250 200

Coolant Temperature

The source of the system coolant temperature. This temperature is used by the coolant temperature protection.

Engine Protection

Not Assigned Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4

CAN J1939

Analog Input 2

Cooling Period Cooling Period

Time, in seconds, engine will run, unloaded, to cool the engine. This can be linked to the Idle if it is desired to run at idle speed for cooling. See Idle Cooling.

Engine Parameter

0 – 3600 Sec. 0 Sec.

Crank Attempts Crank Attempts

Number of times the controller will go through the Crank – Pause cycle.

Engine Parameter

1 – 10 3

Crank Pause Crank Pause

Time, in seconds, the controller will wait before issuing another crank cycle.

Engine Parameter

5 – 60 Sec. 5 Sec.

Crank Period Crank Period

Time, in seconds, the controller will try to start the engine before pausing.

Engine Parameter

1 – 60 Sec. 10 Sec.

CT Ratio Gen Primary CT Ratio-Primary

The primary rating of the Current Transformer.

System Setting 1 – 65535 5


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CT Ratio Gen Secondary

CT Ratio – Secondary

The secondary rating of the Current Transformer.


D+ Function This is the configuration of the D+ terminal. When Enabled the terminal is use as an engine running detection and belt break detection. Once the terminal has detected engine running, the belt break / charger failure detection begins. Belt Break Detection uses this terminal as a charger failure only. When disabled, the terminal does nothing.

System Setting Enabled, Belt Break Detection, Disabled

Disabled

Engine Protect Delay

The amount of time give to detect Over Speed and Under Speed conditions.

Engine Protection

0.0 – 1.0 Sec. 1 Sec.

Engine Run Time Set Run Hrs

Used to set the number of hours on the engine.

Engine Protection

0 – 1193046 Hrs 0 Hrs

Engine Speed The rated speed of the application. This parameter is typically set to 1800 for 60Hz applications and 1500 for 50Hz applications. It is used by overspeed and underspeed protections, and engine speed computation from generator frequency. Other setpoints are % of this speed

System Setting 100 – 4000 RPM 1800 RPM

Engine Type Indicates type of fuel used by the engine.

If Diesel is chosen the Fuel Solenoid output will activate during Crank Period and deactivated during a Crank Pause. It will also be deactivated when an emergency stop is issued or if the engine is to be stopped. It will also deactivate if the engine fails to start.

If Gas is chosen the fuel solenoid output will be activated during Crank Period but only after the engine has exceeded the Gas RPM for Gas RPM Delay. The Fuel Solenoid output will deactivate during Crank Pause. It will also be deactivated when an emergency stop is issued or if the engine is to be stopped. It will also deactivate if the engine fails to start. After a failed crank, the engine will be ventilated for Vent Period by running the starter with Fuel Solenoid off.

Engine Parameter

Diesel, Gas

Diesel

Fuel Level The source of the system fuel level. This level is used by the fuel level protection.

Engine Protection


CAN J1939

Analog Input 3


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Gas RPM Delay Time, in seconds, that the engine must exceed the Gas RPM before the Fuel solenoid is activated when Gas is selected in Engine Type

Engine Parameter

0 – 600 Sec. 0 Sec.

Gas RPM RPM the engine must exceed for the fuel solenoid output to activate when Gas is selected in Engine Type

Engine Parameter

0 – 100 % of Engine Speed

1 %

GCB Control Defines the type of GCB installed. This also determines the level of control available

System Setting Not Needed Single-Line Multi-Line

Single-Line

GCB Delay Time in seconds to wait after GCB able to be closed, before actually commanding breaker to close.

System Setting 0 – 300 Sec. 1 Sec.

GCB F/B Monitoring

Defines whether the GCB will be providing feedback signals indicating the position of the breaker

System Setting Enable Disable

Disable

GCB Feedback Delay

Time, in seconds, the GNS waits from issuing the close/open of the breaker until it assumes the breaker is closed/open. If feedback protection is enabled and feedback is enabled, the user would receive an alarm should the GCB not close/open.


Generator Configuration

This setpoint defines the wiring of the generator in Fixed detection method.

System Setting Delta, Wye, Zig-Zag,

High Leg Delta.

Wye

Generator Overload Alarm

The percentage of Nominal Power where the generator is considered in an overload condition and is shutdown. When the kW reaches this level the controller will open the GCB, cool the engine, and stop.


0 – 200 % of Nominal

Power

110 %

Generator Current Unbalance

The maximum allowable percent difference in current between any two active legs.



Current

10 %

Generator Current Unbalance

Time, in seconds, the current must be in the unbalance condition before the alarm is activated.


0 – 60 Sec. 2 Sec.

Generator Frequency Delay

Time, in seconds, that the generator will have to exceed the above limits in order for the corresponding warning or alarm to activate.


0 – 60 Sec. 2 Sec.

Generator Minimum Voltage

The percentage of the nominal voltage at which all voltages detected beneath this value will be considered 0 volts.



Voltage

10 %

Generator Nominal Current

This setpoint is the nominal phase current for Fixed detection method. Other setpoints are % of this current when using Fixed Detection method.

System Setting 0 – 5000 A 0 A


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Generator Nominal Frequency

The nominal frequency of the application. Used for under/over frequency protections and to compute speed of engine from generator frequency.

System Setting 30 – 440 Hz 60 Hz

Generator Nominal Power Single Phase

This is the nominal power for the system when a single phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.

System Setting 1 – 4000 kW 1 kW

Generator Nominal Power

This is the nominal power for the system when a three phase configuration is selected or detected by the configured voltage detection method. Other setpoints are % of this power.

System Setting 1 – 4000 kW 1 kW

Generator Nominal Voltage

This setpoint is the L-N voltage for Fixed Voltage detection method. Other setpoints are % of this voltage when using Fixed Detection method

System Setting 0 – 30000 V 120 V

Generator Over Current Alarm

The over current protection, as soon as this level is exceeded for the Generator Over Current Delay time the genset shutdowns.



Current

100 %

Generator Over Current Delay

Time, in seconds, the current must be in the over current state before the alarm is activated.


0 – 15 Sec. 2 Sec.


The percent of nominal frequency limit for the generator to go into an over frequency alarm condition.


100 – 200 % of Nominal Frequency

110 %


The percent of nominal frequency Limit for the generator to go into an over Frequency warning condition.



105 %

Generator Over Voltage Alarm

The percent of nominal voltage to trigger the over voltage alarm.


100 – 200 % 120 %

Generator Over Voltage

The percent of nominal voltage to trigger the over voltage warning.



Voltage

110 %

Generator Overload Delay

Time, in seconds, the generator will have to be in the overload condition before the warning or alarm will be activated.


0 – 3600 Sec. 2 Sec.

Generator Overload Warning

The percentage of Nominal Power where a overload warning will be triggered.



Power

100 %

Generator Under Frequency Alarm

The percent of nominal frequency Limit for the generator to go into an under Frequency alarm condition.



90 %

Generator Under Frequency Warning

The percent of nominal frequency limit for the generator to go into an under Frequency warning condition.



95 %


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Generator Under Voltage Alarm

The percent of nominal voltage to trigger the under voltage alarm.



Voltage

80 %

Generator Under Voltage Warning

The percent of nominal voltage to trigger the under voltage warning.



Voltage

90 %

Generator Under/Over Voltage Delay

Time, in seconds, that the generator will have to exceed the over/under voltage limits in order for the corresponding warning or alarm to activate.


0 – 600 Sec. 2 Sec.

Generator Voltage Unbalance Alarm

The maximum allowable percent difference in voltage between any two active legs.



Voltage

10 %

Generator Voltage Unbalance Delay

Time, in seconds, the voltage must be in the unbalance condition before the alarm is activated.


0 – 60 Sec. 2 Sec.

High Cool Temp Alarm

Coolant temperature at which the High Temp Alarm is triggered.

Engine Protection

-40 to 680 oF 190 oF

High Cool Temp Delay

Time, in seconds, the High Coolant Temperature Warning or Alarm condition must be present before the GNS will report the failure.

Engine Protection

0 – 600 Sec. 10 Sec.

High Cool Temp Warning

Coolant temperature at which the High Temp Warning is triggered.

Engine Protection

-40 to 680 oF 180 oF

High Leg Delta This is to denote which leg will be used as the high leg (wild leg) when high leg delta configuration is selected or detected.

System Setting A / L1, B / L2, C / L3

B / L2

Horn Period Time, in seconds, the horn will sound. When set to 0 (zero), the horn will sound indefinitely. Horn Silence will turn off Horn output when pressed until the next event occurs.

System Setting 0 – 600 Sec. 4 Sec,

Idle Cooling Enables or disables the idle output during the cooling period (this cools the engine at idle speed).

Engine Parameter

Enabled (1) / Disabled (0)

Disabled (0)

Idle Period Time the Idle output will be active to keep the engine at an idle rpm. The time does not begin until the start criteria is satisfied

Engine Parameter

0 – 600 Sec. 0 Sec.

Inverse Definite Min Time IDMT

Time dependent curve for over current protection.


1 – 15 Sec. 1 Sec.

J1939 Traffic Enable - Engine Data

Enables the GNS to transmit Engine related data over J1939

J1939 Config Enable Disable

Disable


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J1939 Traffic Enable -

Generator Data

Enables the GNS to transmit Generator related data over J1939


Disable

J1939 Traffic Enable - Status Data

Enables the GNS to transmit Status related data over J1939


Disable

Low Cool Temp Alarm

Coolant temperature at which the Low Temp Alarm is triggered.

Engine Protection

-40 to 680 oF 32 oF

Low Cool Temp Delay

Time, in seconds, the Low Coolant Temperature Warning or Alarm condition must be present before the GNS will report the failure.

Engine Protection

0 – 600 Sec. 10 Sec.

Low Cool Temp Warning

Coolant temperature at which the Low Temp Warning is triggered.

Engine Protection

-40 to 680 oF 50 oF

Low Fuel Level Alarm

Percent of fuel at which GNS will report a Low Fuel Alarm.

Engine Protection

1 – 100 % 1 %

Low Fuel Level Delay

Time, in seconds, the Low Fuel Warning or Alarm condition must be present before the GNS will report the failure.

Engine Protection

0 – 600 Sec. 30 Sec.

Low Fuel Level Percent of fuel at which GNS will report a Low Fuel Warning.

Engine Protection

0 – 100 % 10 %

Low Oil Pressure Alarm

Pressure level at which the Low Oil Pressure Alarm is triggered.

Engine Protection

0 – 145 PSI (0 – 10 Bar)

15 PSI

Low Oil Pressure Delay

Time, in seconds, the Low Oil Pressure Warning or Alarm condition must be present before the GNS will report the failure.

Engine Protection

0 – 600 Sec. 2 Sec.

Low Oil Pressure Warning

Pressure level at which the Low Oil Pressure Warning is triggered.

Engine Protection

0 – 145 PSI (0 – 10 Bar)

30 PSI

Number of Starts The number of times the unit has been successfully started since the last time the counter was set to zero


Oil Disconnect The Oil Pressure that will have to be exceeded before the starter is disengaged. NOTE: When one of following parameters (Start RPM, D+, or Start Oil Pressure, generator parameters) are exceeded the engine is considered running and the starter is disengaged

Engine Parameter

0 – 145 PSI (0 – 10 Bars)

30 PSI

Oil Pressure The source of the system oil pressure. This pressure is used by the oil pressure protection, and start detection

Engine Protection


CAN J1939

Analog Input 1


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Overspeed Over Speed

Speed threshold, expressed in percent, of Engine Speed. When reached, engine is in an over speed condition.

Engine Protection

100 – 200 %. of Engine Speed

110 %

Password The user can enter any level password and unlock associated set points from the front panel. The password is a number and there are five levels.

System Setting 0 – 999999 Dependent on Security

Level

Prelube Pause The time the engine will pause, in minutes, between Prelubes. When set point is set to 0 (zero), function is disabled.

Engine Parameter

0 – 44640 min. 0 min.

Prelube Period Time, in seconds, the engine will perform Prelube. When Prelube time is set to zero, the function is disabled.

Engine Parameter

0 – 600 Sec. 0 Sec.

Prestart Period 1

Prestart Period 2 Prestart Period 3 Prestart Period 4

Time, in seconds, the output will be enabled before cranking the engine. Note: these are used for engine heaters, glow plugs, etc. The GNS calculates the start time for each Prestart so the all end at the same time.

Engine Parameter

0 – 600 Sec. 0 Sec. 0 Sec. 0 Sec. 0 Sec.

PT Ratio Gen Primary

The primary rating of the Potential Transformer


PT Ratio Gen Secondary

The secondary rating of the Potential Transformer


RPM Disconnect The percent of Engine Speed at which the engine will have to exceed before the starter is disengaged. This is also the set point for under speed. NOTE: When one of following parameters (Start RPM, D+, or Start Oil Pressure, generator parameters) are exceeded the engine is considered running and the starter is disengaged

Engine Parameter

5 – 50 % of Engine Speed

25 %

Service Hours Serv. Hrs

Time, in hours to next required service. Once this counter expires a warning will be displayed. This set point counts down to zero. A persistent warning will be displayed until a new value is loaded for next service time.

Engine Protection

0 – 1193046 Hrs 0 Hrs

Set Password This setpoint will allow a user to change the password at that level

System Setting 0 – 999999 N/A

Single Phase Zero Leg

Indicates leg to use when measuring zero volts when single phase is selected or is being detected.

System Setting A / L1, B / L2, C / L3

B / L2

Speed Input : Master

Primary input to use for determining speed.

System Setting Mag Pick Up, Generator, ECM,

None

Mag Pick Up

Speed Input : Second

Secondary input to use for determining speed. The secondary input is used only when the primary speed selection is unavailable or fails.


None

Generator


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Speed Input: Third

Tertiary input to use for determining speed. The tertiary input used only when the primary and secondary speed selections are unavailable or fail.


None

None

SPN Fault Conversion

The method the GNS uses to convert fault data from the ECU

J1939 Config / Setup/Test

0 – 65535 4

Stop Period Time, in seconds, engine is given to come to a complete stop. If this time is exceeded, the Stop Fail protection is triggered.

Engine Parameter

0 – 180 Sec. 20 Sec.

Teeth Number of teeth on the flywheel of the engine. Used to compute RPM from mag pickup signal.


User Defined – Digital 1 Active Time








The operating states of the system when the protection is active.

User Protection Engine Stopped Engine Cranking

Crank Rest Gas Venting

Gas RPM Delay Engine Idle

Voltage Detect Delay

Engine Running Engine Cooling

Engine Pre-Lube Engine PreLube

Pause Engine Pre-Start

Engine After-Cooling

Engine Idle Override

Engine Stopping

Active during all stages


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User Defined – Digital 1 Alarm Action








The action the controller will take when the fault is trigger. This is only valid if the alarm function is assigned to the input.

User Protection Soft w/GCB Open Soft

w/GCB Trip Hard w/GCB

Open Hard w/GCB

Trip

Hard w/GCB Open

User Defined – Digital 1 Delay








The time to wait after the input has been activated before triggering fault.

User Protection 0 – 6553 Sec. 1 Sec.

Vent Period Extra time, in seconds the Starter will be activated if the engine fails to start after fuel deactivates when Gas is selected in Engine Type. This is used for venting excess gas.

Engine Parameter

0 – 600 Sec. 0 Sec.

Voltage Detection

This setpoint will activate the controller for Auto Voltage Detection method.

System Setting Enabled Auto/ Disabled Man

Disabled Man


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Voltage Detection Delay Time

Time, in seconds, the controller will wait before determining the Voltage and Connection of the system in Auto Voltage Detection and Binary Voltage Selection methods. Voltage Detect Time does not begin countdown until the engine has reached nominal speed and idle period has elapsed.


Voltage Select 1 - Nom. Volt




The Nominal Voltage for the generator for each of the four entries in the Voltage Selection Table

Voltage Select 0 - 999 V 120 V

Voltage Select 1 – Wiring




The wiring configuration of the generator for each of the four entries in the Voltage Selection Table.

Voltage Select Delta Wye

Zig-Zag High Leg Delta

Wye

Warning IC Delay

The time to wait after the Warning DI input has been activated before triggering a fault


0 – 600 Sec. 0 Sec.

THE FOLLOWING SETPOINTS APPLY TO THE GNS2500 ONLY

MCB Open Event

With this set point the user can determine when they would like the MCB to open, at mains fail, or, at genset ready to accept load.

System Setting Mains Fail, Ready to Accept Load

MCB Feedback Delay

Time, in seconds, the GNS2500 is to wait from issuing the close of the breaker until it assumes the MCB is closed. If feedback protection is enabled and feedback is enabled, the user would receive an alarm should the MCB not close

System Setting 0 – 2 Sec.

Mains Over Voltage Alarm

Limit for the utility to go into an over voltage alarm state.

Mains Protection 100 – 200%.

Mains Over Voltage Warning

The limit for the utility to go into an over voltage warning state.

Mains Protection 100 - 200%

Mains Under Voltage Warning

The limit for the utility to go into an under voltage warning state.


Mains Under Voltage Alarm

The limit for the utility to go into an under voltage alarm state.


Mains Voltage Delay

Time, in seconds, that the utility will have to exceed the above limits in order for the corresponding warning or alarm to activate.

Mains Protection 0 – 600 sec.


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Mains Voltage Unbalance

The maximum percentage difference in voltage between the worst two legs of the utility.

Mains Protection 1 – 100%.

Mains Voltage Unbalance Delay

Time, in seconds, that the voltage must be in the unbalance state before the alarm is activated.

Mains Protection 0 – 60 sec

Mains Over Frequency Alarm

The limit for the utility to go into an over frequency alarm state.

Mains Protection 100 – 200%

Mains Over Frequency Warning

The limit for the utility to go into an over Frequency warning state.


Mains Under Frequency Warning

The limit for the utility to go into an under Frequency warning state.


Mains Under Frequency Alarm

The limit for the utility to go into an under Frequency alarm state.


Mains Frequency Delay

Time, in seconds, the utility will have to exceed the above limits in order for the corresponding warning or alarm to activate.

Mains Protection 0 – 600 sec.

Mains Return Delay

Time, in seconds, the Mains must be within spec before the generator can be unloaded and the Mains put back on line.

Mains Protection 0 – 3600 sec

Note: Parameters in shaded area are only available through SmartVU software/

The table below sorts the setpoints by functional group (e.g., System Setting, Engine Protection, Generator Protection, etc.). For the description, valid range, and default values, refer to the previous table.

Group Set Point

Analog Input Config Analog Input 1 – Data Points Analog Input 2 – Data Points Analog Input 3 – Data Points Analog Input 4 – Data Points

Analog Input Config Analog Input 1 – Type of Sensor Analog Input 2 – Type of Sensor Analog Input 3 – Type of Sensor Analog Input 4 – Type of Sensor

Analog Input Config Analog Input 1 – Units Analog Input 2 – Units Analog Input 3 – Units Analog Input 4 – Units

Engine Parameter After Cool Period

Engine Parameter Cooling Period Cooling Period


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Group Set Point

Engine Parameter Crank Attempts Crank Attempts

Engine Parameter Crank Pause Crank Pause

Engine Parameter Crank Period Crank Period

Engine Parameter Engine Type

Engine Parameter Gas RPM

Engine Parameter Gas RPM Delay

Engine Parameter Idle Cooling

Engine Parameter Idle Period

Engine Parameter Oil Disconnect

Engine Parameter Prelube Pause

Engine Parameter Prelube Period

Engine Parameter Prestart Period 1 Prestart Period 2 Prestart Period 3 Prestart Period 4

Engine Parameter RPM Disconnect

Engine Parameter Stop Period

Engine Parameter Vent Period

Engine Protection Alternator Fail Delay

Engine Protection Battery Delay Battery Delay

Engine Protection Battery Over Voltage Warning

Engine Protection Battery Under Voltage Warning

Engine Protection Coolant Temperature

Engine Protection Engine Protect Delay

Engine Protection Engine Run Time Set Run Hrs

Engine Protection Fuel Level

Engine Protection High Cool Temp Alarm

Engine Protection High Cool Temp Delay

Engine Protection High Cool Temp Warning

Engine Protection Low Cool Temp Alarm

Engine Protection Low Cool Temp Delay


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Group Set Point

Engine Protection Low Cool Temp Warning

Engine Protection Low Fuel Level

Engine Protection Low Fuel Level Alarm

Engine Protection Low Fuel Level Delay

Engine Protection Low Oil Pressure Alarm

Engine Protection Low Oil Pressure Delay

Engine Protection Low Oil Pressure Warning

Engine Protection Oil Pressure

Engine Protection Overspeed Over Speed

Engine Protection Service Hours Serv. Hrs

Generator Protection Alarm IC Action

Generator Protection Alarm IC Delay

Generator Protection Generator Overload Alarm

Generator Protection Generator Current Unbalance

Generator Protection Generator Current Unbalance

Generator Protection Generator Frequency Delay

Generator Protection Generator Minimum Voltage

Generator Protection Generator Over Current Alarm

Generator Protection Generator Over Current Delay

Generator Protection Generator Over Frequency

Generator Protection Generator Over Frequency

Generator Protection Generator Over Voltage

Generator Protection Generator Over Voltage Alarm

Generator Protection Generator Overload Delay

Generator Protection Generator Overload Warning

Generator Protection Generator Under Frequency Alarm

Generator Protection Generator Under Frequency Warning

Generator Protection Generator Under Voltage Alarm

Generator Protection Generator Under Voltage Warning


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Group Set Point

Generator Protection Generator Under/Over Voltage Delay

Generator Protection Generator Voltage Unbalance Alarm

Generator Protection Generator Voltage Unbalance Delay

Generator Protection Inverse Definite Min Time IDMT

Generator Protection Warning IC Delay

J1939 Config CAN Error Delay

J1939 Config CAN1 J1939 ECU Address

J1939 Config CAN1 J1939 GNS Address

J1939 Config J1939 Traffic Enable - Generator Data

J1939 Config J1939 Traffic Enable - Engine Data

J1939 Config J1939 Traffic Enable - Status Data

J1939 Config / Setup/Test

SPN Fault Conversion

System Setting CT Ratio Gen Primary CT Ratio-Primary

System Setting CT Ratio Gen Secondary CT Ratio – Secondary

System Setting D+ Function

System Setting Engine Speed

System Setting GCB Control

System Setting GCB Delay

System Setting GCB F/B Monitoring

System Setting GCB Feedback Delay

System Setting Generator Nominal Power Single Phase

System Setting Generator Configuration

System Setting Generator Nominal Current

System Setting Generator Nominal Frequency

System Setting Generator Nominal Power

System Setting Generator Nominal Voltage

System Setting High Leg Delta


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Group Set Point

System Setting Horn Period

System Setting Number of Starts

System Setting Password

System Setting PT Ratio Gen Primary

System Setting PT Ratio Gen Secondary

System Setting Set Password

System Setting Single Phase Zero Leg

System Setting Speed Input :Third

System Setting Speed Input : Master

System Setting Speed Input : Second

System Setting Teeth

System Setting Voltage Detection

System Setting Voltage Detection Delay Time

User Protection Analog Input 1 – Active Time Analog Input 2 – Active Time Analog Input 3 – Active Time Analog Input 4 – Active Time

User Protection Analog Input 1 – Alarm Action Analog Input 2 – Alarm Action Analog Input 3 – Alarm Action Analog Input 4 – Alarm Action

User Protection Analog Input 1 – Delay Analog Input 2 – Delay Analog Input 3 – Delay Analog Input 4 – Delay

User Protection Analog Input 1 – High Limit Analog Input 2 – High Limit Analog Input 3 – High Limit Analog Input 4 – High Limit

User Protection Analog Input 1 – Low Limit Analog Input 2 – Low Limit Analog Input 3 – Low Limit Analog Input 4 – Low Limit

User Protection User Defined – Digital Active Time (one per user protection)

User Protection User Defined – Digital Alarm Action (one per user protection)

User Protection User Defined – Digital Delay (one per user protection)


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Group Set Point

Voltage Select Voltage Select 1 - Nom. Volt Voltage Select 2 - Nom. Volt Voltage Select 3 - Nom. Volt Voltage Select 4 - Nom. Volt

Voltage Select Voltage Select 1 – Wiring Voltage Select 2 – Wiring Voltage Select 3 – Wiring Voltage Select 4 – Wiring

Access to the setpoints is done by pressing the right arrow from any of the metering screens. A setpoints menu will be presented to allow sub-menu selection of the different groups of setpoints. The Sub-Menu selection screen is shown below.

Access to all parameters is done via SmartVU through the configuration meter shown below.


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5.0 User Interface

5.1 DISPLAY FEATURES/DESCRIPTION

The GNS series of products are available with or without an integrated display. Either configuration also allows the addition of a remote display that can be used to operate the unit from a remote location just as if your were standing right next to the generator. The only difference is the integrated display is attached to the controller, and the remote display is connected to the controller by a serial cable and has a separate battery connection.

5.2 STANDARD GNS2000 DISPLAY

The standard GNS2000 (non “E Series) front display for both the integrated unit and the remote display look and operate the same. The display is shown below and its features are described in the following sections.

GNS2002/GNS2004 System Display and GNS2002D/GNS2004D Remote Display


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5.2.1 Status LED Definitions (Standard GNS2000)

Status LED Definition

Ready/Auto GNS is in “Auto Mode”

Running Generator is running

Supplying Load Generator is generating power, GCB is closed

Not in Auto GNS is in “Manual Mode” or “Off Mode”

Warning A warning protection has been triggered

Shutdown/Alarm A alarm protection has been triggered

(G) OFF-Engine not running Yellow- Engine started but not at nominal speed Green – Engine at nominal speed Red – Generator alarm

5.2.2 Button Definitions (Standard GNS2000)

Button Definition

Start Start engine, “Manual Mode” only

Stop Stop engine (when pressed twice immediate stop engine), “Manual Mode” only

Horn Silence If sounding, turns off horn until next new warning or alarm occurs

Fault Reset Clear stored alarms. Resets system to allow normal operation. Caution, resetting faults when in Auto mode and remote start/stop signal active, will cause controller to initiate start sequence immediately.

Enter Primarily used to select and accept changed data.

Left Arrow Depending on the screen: change mode, change screen, escape

Right Arrow Depending on the screen: change mode, change screen, next page

Up Arrow Depending on screen, change screen, move cursor up, increase value.

Down Arrow Depending on screen, change screen, move cursor down, decrease value.


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5.3 GNS2000E SERIES DISPLAY

The GNS2000E Series is similar to the GNS2000 series displays with the exception of the addition of two buttons and one LED. The E series provides a “back” button for the menu system and a GCB Open / Close button.

5.3.1 GNS2000E Series Additional Status LED Definitions


GCB Open Off - GCB Open Green – GCB Closed

5.3.2 GNS2000E Series Additional Button Definitions

Button Definition

Back Escape, go up one menu level

GCB Open / Close Manual control of the GCB


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5.4 GNS2500 DISPLAY (INCLUDES GNS2500E SERIES)

The GNS2500 Series is similar to the GNS2000 series displays with the exception of the addition of three buttons and three LEDs. The GNS2500 includes a back button, mains breaker and generator breaker control buttons.

5.4.1 GNS2500 Additional Status LEDs Definitions


GCB Open/Close Off - GCB Open Green – GCB Closed Red – GCB Trip or Fail

MCB Open/Close Off - MCB Open Green – MCB Closed Red – MCB Trip or Fail

Mains Status Green – Mains OK Red – Mains failed Yellow – Mains in “warning” state Blinking Green – Mains good, or returning


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5.4.2 GNS2500 Additional Button Definitions

Button Definition

Back Escape, go up one menu level

GCB Open / Close Manual control of the GCB

MCB Open / Close Manual control of the MCB

5.5 SPECIAL DISPLAY FUNCTIONS

Function Key Sequence / Notes

Change Language Hold “Horn Silence” and press ENTER. Display will cycle to next language available. This can be done at any point in the display system and will remain in effect until it is changed again. Some screen are only displayed in English. These are J1939 Monitoring, and CAN DTC List


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5.6 MENU STRUCTURE/NAVIGATING THE MENUS

Most GNS set points are accessible via the display. The following chart shows the locations of set points accessible via the display. Keep in mind, if security is enabled on a set point, the user must log into the display at that level or above to be able to modify the set point. To log in at a different user level, navigate to Set Points -> System Settings -> Password Login.

The menu system is navigated both vertically and horizontally. Pressing the up and down arrows navigates from the Main Screen to the Generation Metering screen (ECM1 and ECM 2 may not appear if the ECM is not configured). When the end of the list is reached, the restart in the direction

Main Screen

Set Points

System Settings

Eng. Protections

Eng. Parameters

Gen. Protections

Main Protections

Setup/Test

CAN DTCs

Event Log

Alarm/ Warnings

Binary Outs Set Point Menus

Binary Ins

Analog Ins

Analog Meters

Mains Protection

(GNS2500 Only)

Over Volt Alm

Over Volt Wrn

Under Volt Wrn

Under Volt Alm

U/OP Volt Dly

Volt Unbal Alm

Volt Unbal Dly

Over Freq Alm

Over Freq Wrn

Und Freq Wrn

Und Freq Alm

Freq Delay

ECM 1

Eng Parameters

RPM Disconnect

Oil Disconn Prelube Period Prelube Pause

Idle/Cooling Aft Coll Per

Prestart Per1 Prestart Per2 Prestart Per3 Prestart Per4 Crank Period Crank Pause

Crank Attempts

Engine Type Gas RPM

Gas RPM Delay

Vent Period Idle Period Stop Period

Cooling Period

Eng Protections

Over Speed Lo Fuel Delay Low Fuel Warn

Lo Fuel Alarm Lo Oil P Delay Low Oil P Warn

Lo Oil P Alarm Lo Temp Delay

Lo Temp Warn Lo Temp Alarm

Hi Temp Delay Hi Temp Warn Hi Temp Alarm

Batt Over Volt Batt Under Volt

Battery Delay Eng Prot Dly

Serv. Hrs Run Hrs

System Settings

Password Login Change Password

Volt Detect Nom Pwr 3Ph Nom Pwr 1 Ph Nominal Volt

Nominal Amps Nominal Power Phase Select Gen Config

V Detect Delay Zero Leg High Leg CT Ratio PT Ratio

Nominal Freq Gear Teeth GCB Delay

D+ Horn Period Speed Inputs Engine Speed

Gen Protections

Overload Alm Overload Wrn Overload Dly

Over Curr Alm Over Curr Dly

Curr Unbal Curr Unbal Dly

IDMT Over Volt Alm Over Volt Wrn

Under Volt Warn

Under Volt Alm

U/OP Volt Dly Volt Unbal Alm Volt Unbal Dly Over Freq Alm

Over Freq Warn

Under Freq Wrn

Under Freq Alm

Freq Delay

ECM 2

Power

Generator Meter


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5.7 REVIEWING SETPOINT VALUES

The current value of any authorized parameter can be viewed by navigating to the desire parameter by moving through the menu system as instructed in the menu diagram. The display will show the current value for that parameter.

5.8 CHANGING SETPOINT VALUES

When authorized, you can change the value of a setpoint. To change a setpoint value, navigate to the desired parameter by moving through the menu system as instructed in the diagram. Once the desired parameter is selected, press enter to enable edit mode. When edit mode is enabled, the display will change to full screen mode for that parameter. In full screen mode, the parameter, its current value, a more detailed description of the parameter, and the range of values will be shown for the parameter. At that point you can use the up or down arrows to change the parameter value. For numeric values, holding the up or down key will automatically increment or decrement the value. The incrementing will start with incrementing by 1, after 10 increments, the increment value will increase by a factor of 10, this will continue until the key is released. For example, when incrementing from 0 the increment sequence would be 1,2,3,4,5,6,7,8,9,10,20,30,40,50,60,70,80,90,100,200,300, etc… Once the desired value is set, the change can be saved by pressing enter. At that point edit mode will be exited, and the screen will exit full screen mode and revert back to the parameter list screen. If you do not want to save the change, press the left arrow key (or back key if available). This will exit the edit mode, close the full screen mode, revert back to the parameter list, and the change will not be saved.

Full screen mode is available for all setpoints except the Display Setup parameters.

5.9 CHANGING OPERATING MODES

The operating mode of the unit can be changed using any one of three methods; SmartVU configuration software, display selection, or Binary Inputs. When changing the operating mode using the display, the Main Screen must be shown. From the Main screen, press enter to enable edit mode. While in edit mode, the left and right arrow keys will change the mode. Once the desired mode is selected, press enter to save the change. Additionally, while in edit mode, the main screen can be changed to display either total power, or RPM. These change is made by pressing the up or down arrows. After the proper parameter is displayed, press enter to save the changes and exit edit mode.

5.10 METERING SCREENS

5.10.1 Main Screen

5.10.2 Binary Output Screen

This screen shows the functions assigned to the binary output and the current value of the output. Values shown are inverted pin states (0 = open or high voltage, 1 = ground).


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5.10.3 Binary Input Screen

This screen shows the function assigned to each binary input and the current value of the input. Values shown are inverted pin states (0 = open or high voltage, 1 = ground).

5.10.4 Analog Input Screen

This screen shows the values for the analog inputs regardless of whether they are used by the controller for the system protection function of oil pressure, coolant temperature, or fuel level.

5.10.5 Analog Metering Screen

This screen shows two different types or information. First it shows the current values the control is using for Oil Pressure, Coolant Temperature, Fuel Level, and Battery Voltage metering and protections, regardless of the source of the data (analog input , or J1939). These are the values compared against the protection setpoints, and are considered the system values for these parameters. Second, the service parameters are shown.


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5.10.6 J1939 Monitoring Screen(s)

This screen will show any of the configured parameters from the engine ECU if connected and enabled. If the unit is not configured for monitoring, then the screen will flash “Not Configured”. Configuration of these screens can only be done through SmartVU configuration software. If there are more than five configured parameters, they will be broken up into multiple screens. The configured ECU is shown on the top line of the screens. The data shown on these screens is only monitored from the CAN/J1939 bus and is not used in anyway by the control. There is only an English translation for this screen.

5.10.7 Power Screens

This screen automatically scrolls between Reactive Power, and Power Factor screens, showing the reactive power per phase and total, power factor per phase and average, and apparent power.

5.10.8 Generator Metering Screens

These screens automatically scroll between Generator Current, and Generator Voltage screens, showing the Line-Line, Line –Neutral voltages, and Line currents, total current, and frequency.


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5.11 SETPOINT SCREENS

Note, on the GNS2500, “MAINS PROTECTION” also appears.

5.12 SETUP/TEST SCREEN

The GNS display can be configured to do the following:

Function Description Default Value

Screen Test Tests all of the screen pixels. n/a

LED Test Tests all of the on-board LEDs n/a

Keyboard Test Tests all of the keys on the display n/a

Comm. Test Tests the communications with the controller n/a

Comm. Mode Allows user to select whether display is to operate using RS232 or RS485 mode. Once switched, the unit will no longer communicate with the controller until the controller or the display is switched to so they both match. Note: This mode should always be RS232 on the GNS2002, GNS2004 units.

RS232

LCD Contrast Allows the user to adjust the contrast of the LCD. 95%

LED Brightness Allows the user to adjust the brightness of all of the LEDs on the display 90%

Backlight Allows the user to adjust the brightness of the backlight. 90%

Screen Alert Indicates if the GNS should highlight the particular parameter when it is in either a warning or alarm condition.

OFF

Scroll Rate The rate at which to scroll between screens when displaying live parameters. 5 Seconds

Key Delay The key repeat rate. 375 msec

Temp Scale The units of measure to use when displaying temperature. °F

Oil P Scale The units of measure to use when displaying oil pressure. PSI


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Function Description Default Value

Auto Logout Function to automatically log the current user out after an idle time. Disabled

DTC Operation This option is used to setup the J1939 DTC operation. The FMI parameter indicates whether the code is to be displayed as a number or an alphanumeric text. The DM1 alert parameter commands the GNS to jump to the DTC Active Alarms when an active alarm condition occurs. The Conversion method tells the GNS the data conversion method used by the engine ECU.

FMI Type=Alpha,

DM1 Alert=ON, Conversion Method=V3

5.13 CAN/J1939 DTC LOG SCREEN

This screen will show any diagnostic messages coming from the engine ECU (if connected via J1939). The controller will monitor the ECU for any messages, if they are found; they will be displayed on the screen. The default is to show the DM1 messages which are the conditions that are still active. Pressing the enter screen, allows viewing of any DM2 or previously active conditions. From this screen, pressing the fault reset will cause the controller to send a DM3 message to the ECU in an attempt to clear any DM2 messages in the ECU. Note: Some ECU manufacturers do not allow clearing of DM2 messages and therefore pressing the fault reset on this screen will have no affect on the ECUs DM2 messages.

For each message, the following information will be shown,

SPN – Parameter causing the problem

OC – How many time this fault has occurred.

FMI – What the fault is

In addition to the codes, an English translation of the parameter and fault will be displayed if known.

5.14 EVENT LOG SCREEN

A sample of the Event Log screen is shown below. The screen lists any event that has happened in chronological order. The log will list all alarms, warnings, and status messages. The screen shows three columns of data for each event in the log.

# - Event number

WN – Warning condition

AL – Alarm condition

ACT – Active condition

LAT – Latched condition


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<Condition> - Refer to Warning/Alarm section for complete list of conditions and their meaning.

The log is 30 entries deep and will automatically overwrite the oldest with the newest event when the log is full. Therefore the log will always show the last 30 events that have occurred.

To review the timestamp associated with a given event, select the event with the up and down arrow keys. Once selected, the time stamp associated with the event is shown on the top line of the screen.

5.15 ALARM/WARNING SCREEN

A sample of the Alarm/Warning screen is shown below. The screen lists any active or latched alarms/warning. Active alarm/warnings are conditions that are still present. Latched warnings/alarms are conditions that were once active, but have now gone inactive (e.g. Low Temp in the sample screen below). The screen shows three columns of data separated by “:” for each active or latched condition.

WN – Warning condition

AL – Alarm condition

ACT – Active condition

LAT – Latched condition

<Condition> - Refer to Warning/Alarm section for complete list of conditions and their meaning.

To clear an alarm/warning, press fault reset. Any conditions still listed are still active.


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6.0 GNS Configuration Software – SmartVU

6.1 GETTING TO KNOW SMARTVU

SmartVU is a powerful, easy to use, PC tool that not only allows you to configure the GNS2000, 2500, or E-Series controls. Note, configuring the E-Series is identical to configuring the non-E-Series controls.

The examples in this section of the manual demonstrate configuring a GNS200. Configuring a GNS2500 is almost identical with the exception of selecting the GNS2500, setting up the mains protections, and mains circuit breaker (MCB).

SmartVU is a Monitoring tool that can display the current operating conditions for the generator provide a remote or local interface to the generator set. When the set is not operating correctly, the software can be used as a diagnostic tool to help trouble shoot the situation.

SmartVU’s functionality is based on the concepts of screens, meters and connections. Screens are similar to windows in the Windows™ Operating System. You can have multiple screens, each displaying different or the same meters. At any time you can switch between the screens to get access to the different meters, view the data differently, etc. Each screen is made up of various meters. A predefined set of screens is installed with the SmartVU installation. Others can be created but that is outside the scope of this document. Contact GAC for further information. Meters can be very simple used to display only one parameter, or they can be complex used to display multiple parameters, have multiple control buttons, or configurable parameters. Meters are predefined in the system. Connections are used to connect a physical product with the virtual meters defined in the screens. The connection identifies what unit is being accessed, and how SmartVU will talk to the unit, and what hardware on the PC will be used.

All of the information regarding the connection, the defined screens, and the meters on each screen is saved in a Screen Layout File. By default, two screen layout files are installed with SmartVU. These screen layouts are described later in this chapter. Starting SmartVU can be done by selecting SmartVU from the Start Menu, or double-clicking the shortcut. Once started, the screen layout file can be selected which will automatically open the connection manager with the preset connection information. After entering the access level and password, all of the screens will be created. Alternatively, double-clicking on the screen layout file will automatically start SmartVU, and open the layout file and get you to the connection manager waiting for the access level and password. All this with just a double-click of the icon.

Screens – Screens are predefined collections of meters that are related. In the default screens, there is a screen for generator operation showing all of the standard metering information on the generator and allowing the user to start and stop the set. There are other screens used to configure the GNS. A couple of screens are dedicated to diagnostics and troubleshooting by providing access to alarms and warnings, monitoring the physical inputs and outputs, etc. Then there is the J1939 screen used with a J1939-based ECU to help configure and monitor the ECU.

Meters – Meters are discrete components that are used to meter parameters that are measured by the GNS such as voltages, currents, engine speed etc. In addition, some meters are used to configure the GNS. There is one Configuration Notebook Meter that has almost all configurable parameters in it. Simply stepping through each of the tabs allows the user to verify the configuration of the unit. Other meters are more complex and are used to display logs and internal information for troubleshooting. Then there are meters which provide a button or checkbox to cause the GNS to take action. Meters with a Start button, stop button, etc are provided.

GNS Configurations – GNS configurations are files that are saved to the PC by SmartVU that contain all of the configuration information from the connected GNS. This is not the screen layout, but the configuration


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stored in the GNS that instructs the GNS how to operate. Information such as Nominal Engine Speed, Set rated Power, Nominal Voltages, Binary Input assignments, etc are stored in the configuration file. These files are created by SmartVU from the attached unit. The files can then be used later on to load another unit with the same configuration. By creating a configuration file, the state of the GNS can be saved for archive purposes, and also be used to load into additional unit ensuring similar operation.

Screen Layouts – Screen Layouts are a collection of all of the defined screens, meters, and connections, used to communicate with the GNS. They do not contain and of the configured parameter values. The layouts are saved to a file for easy reloading the next time SmartVU is needed to configure , monitor and diagnose a GNS. The screen layouts provide the look and feel of the SmartVU software regardless of which GNS it is connected to. Custom layouts can be created to provide a different look and feel to SmartVU. Some users may want to see all of the voltages, and currents together, or J1393 monitoring meter with the analog meters. The possibilities are endless. Even two GNSs can be viewed together on the same screen, allowing the voltages of two or more units to be displayed on the same screen. Please contact GAC for more information.

Connections – Connections control which type of device is being communicated to, what protocol to use, and what hardware on the PC to use. It is mainly controlled through the connection Manager which displays a dialog box with all of the options. Once a connection is established, the connection information can be saved in the screen layout file so that it is available new time that file is opened. The default Screen Layout files have the default connection information in them. If upon opening these files, the connection information needs to be changed, it can be done before trying to establish the connection. Once the connection is established the screen layout including the new connection information can be saved to a new file so that it will be correct when that file is opened.

Units – Units allow the user to view pressures and temperatures in the units that are most familiar to them. The selection of units is only effective for the data viewed in SmartVU and does not affect the operation of the GNS or how the pressures and temperatures are displayed on the GNS display. This allows the SmartVU to display parameters in units that are different than the GNS display units. In fact each display and SmartVU connected to the GNS can independently define which units are used to display pressure and temperatures.

Grids – The Grid is used when creating custom screens by allowing the user easy alignment and resizing of the meters.

6.2 ESTABLISHING A CONNECTION TO THE GNS

Connecting to the GNS involves three steps. Step one is connecting the hardware of the GNS and the PC together properly. Step two is starting the SmartVU software and configuring it to match the GNS configuration. And Step three is entering the access information and establishing the connection.

Step 1 – Connecting the GNS to the PC

The connection between the GNS and the PC is done with a standard 3 wire null modem cable. This cable is available through many different sources, or can be purchased from GAC. The cable should only have 3 wires , DB9F connectors on both ends, and be wired as shown in the following table.

GNS PC 2 3 3 2 5 5

In addition to the communication cable, the GNS will need to be powered for SmartVU to communicate successfully. The GNS is not required to have any other connections in order to configure the unit, just the communications cable and power. Refer to the wiring section on what the battery terminals wiring requirements are.


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Once the communication cable is attached between the PC and the GNS and the GNS is powered up, you can then proceed to the next step.

Step 2 – Starting SmartVU and configuring the connection

If you have not installed SmartVU yet, do so now. Refer to the section Installing SmartVU on the PC for further information.

Once installed, SmartVU can be started by selecting it from the Start Menu, or double-clicking the icon created during installation. After SmartVU starts, selecting File/Open Screen Layout… option from the File menu allows you to select one of the default screen layout files installed with SmartVU.

Select File “GNS Default Setup.SFG”


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When the file is opened the connection manager will open with the default connection information already setup. Alternatively this can be done in one step but just double-clicking the screen layout file. This will automatically open SmartVU, and the screen layout file and present the connection manager with just a double-click. How easy!

At this point all connection information should default to what is required to connect to the GNS. The only option that may need to be changes is which COM port to use. That is determined by which COM port the communication cable was connected to on the PC. If it is different than the default one, just select the correct port.


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Step 3 – Entering Access information and connecting to the GNS

At this point, select the access level to connect at and the corresponding password for the level then press Connect button. After a few seconds, screens should automatically be created with their corresponding meters. Wait for all of them to be created.

At this point you should be communicating and viewing the status of the GNS. Congratulations!

After the first connection to the GNS, it will be easier as any issues should have been worked out to make the first connection. The next time it is as simple and connecting the unit to the PC, powering the GNS, double-clicking on the screen layout file, and entering the access information.

If there is a problem connecting to the GNS the following message appears.

This message indicates that no communication between the PC is occurring. Possible problems are:

Wrong/Bad cable (USB to serial adapters are very problematic)

Wrong COM port


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Wrong PC port settings – Settings are automatically set for the default settings. Unless changed they should work.

If the communication between the units is working but you have the wrong password you may get this message. Retype the password and try again.

6.3 MONITORING AND CONTROLLING THE GENERATOR

Monitoring and controlling the generator is typically done through one screen within SmartVU. This screen, called “Generator” shows the important operating conditions found on the generator as well as giving the user the ability to control certain functions of the generator.

Generator Screen – This screen shows several meters that display the current operating conditions of the generator, statistical information, and buttons to control the starting and stopping of the engine (only when in Manual Mode), fault reset, and horn silence. The ability to monitor and control the GCB, if configured, is provided. The following meters are available:

Generator Voltage Phase A – This meter shows the voltage measured on generator phase A. In addition it will show any enabled warning or alarms configured for under and over voltage protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Generator Frequency (A) – This meter shows the frequency measured on generator phase A. In addition it will show any enabled warning or alarms configured for under and over frequency protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Generator KW Total – This meter shows the total KW power being provided by the generator. It is the sum of the power calculated for each phase of the generator.

Generator Current Phase A – This meter shows the current measured on generator phase A. In addition it will show any enabled warning or alarms configured for over current protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Generator Current Phase B – This meter shows the current measured on generator phase B. In addition it will show any enabled warning or alarms configured for over current protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Generator Current Phase C – This meter shows the current measured on generator phase C. In addition it will show any enabled warning or alarms configured for over current protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Engine Oil Pressure – This meter shows the Engine Oil Pressure measured from the analog inputs, or received from a J1939 based ECU. In addition it will show any enabled warning or alarms configured for low oil pressure protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.


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Fuel Level – This meter shows the Fuel Level measured from the analog inputs, or received from a J1939 based ECU. In addition it will show any enabled warning or alarms configured for low fuel protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Coolant Temp – This meter shows the Engine Coolant Temperature measured from the analog inputs, or received from a J1939 based ECU. In addition it will show any enabled warning or alarms configured for low or high coolant temperature protection functions. The warnings will be shown as a yellow bar, and the alarms will be shown as a red bar as shown in the screenshot below.

Battery Voltage – This meter shows the Battery Voltage measured from the battery terminals on the GNS. In addition it will show any enabled warnings configured for low or high battery protection functions. The warnings will be shown as a yellow bar as shown in the screenshot below.

Operating Mode Status – This meter shows the status of various systems in the GNS

Start Mode – This status shows if the GNS is in OFF, MAN, or AUTO mode.

Status – This status shows if a start is pending during a Prelube cycle. If blank, no start is pending.

ESTOP Status – This indicator shows the status of any ESTOP configured binary input. If an ESTOP is active it will be shown in RED.

Operating Mode – This group of statuses shows the operating state of the major system components

Generator – This indicator shows whether the generator is UNLOADED, or SUPPLYING LOAD.

Engine – This indicator shows the status of the engine and any associated timer

STOPPING – The engine has been commanded to stop but the RPM has not reached zero yet. The timer will show the seconds remaining in the configured stop period before a Stop Fail fault will occur, if enabled

STOPPED – The engine has been commanded to stop and the RPM has reached zero.

PRELUBE – A Prelube period is configured and is currently running. The seconds left in the period is shown on the timer. If the Start button is pressed during this time, the start will be queued until the period completes. A queued start will be shown in the status indicator above as START PENDING.

PRELUBE PAUSE – A Prelube period is configured and is currently waiting to run. The number of minutes until the next Prelube run is shown on the timer.

PRESTART – A Prestart period is configured and a start requested has been issued to activate the Prestart period. The seconds remaining in the Prestart period is shown on the timer. The Prestart period can be aborted prior to this time, assuming there are no overrides active, by issuing a start request again.

CRANKING – A start request has been issued and all Prestart periods have completed. The controller is now cranking the engine. The seconds of cranking remaining in this crank period is shown on the timer.

CRANK REST – A crank period has been completed and the engine has not met its configured start criteria. Therefore a crank rest period is running. The seconds remaining in the rest period is shown on the timer.


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VENTING - A crank period of a GAS engine has been completed and the engine has not met its configured start criteria. Therefore a vent period is running where the fuel has been turned off but the starter continues to run to exhaust any unburned fuel. The seconds remaining in the vent period is shown on the timer.

GAS RPM DELAY – The cranking speed of the engine has reached the GAS RPM value, but the time configured by GAS RPM DELAY has not elapsed yet. The seconds remaining before the time elapses is shown on the timer. After the time elapses, the fuel will be turned on.

IDLE – The engine has reached the start criteria while cranking. The idle period is now running and the seconds remaining is shown on the timer. The idle period can be aborted, assuming there are no overrides active, by issuing a start request again.

IDLE OVERRIDE – An idle cycle is running and an idle override is active. The engine will remain in the idle stage until the override is removed. The normal idle period will still count down to 0, and remain at zero during the override.

VOLTAGE DETECT DELAY – The engine has started and completed its idle period. It is now waiting for the engine to reach nominal engine speed and the voltage detect delay to elapse (if configured for Auto Voltage Detection, or Binary Voltage Selection) before determining generator configuration and setting generator protections. The seconds remaining before the voltage detect delay elapses is shown on the time.

RUNNING – The engine has reached nominal engine speed and the Voltage Detect Delay has elapsed. All generator protections are enabled.

COOLING – A slow stop request has been issued and the cooling period is running. The seconds remaining in the cooling period is shown on the timer. The cooling period can be aborted and the engine brought back to rated speed by issuing a start request.

AFTERCOOL – A slow stop request has been issued, and the engine commanded to stop. The aftercool period is running and the seconds remaining in the aftercool period is shown on the timer.

Auto Sequencer – This indicator shows the status of the Auto Sequencer in the GNS. The Auto Sequencer is set to be INACTIVE in the GNS.

The following statistics are available of meters:

Engine Run Time – This meter shows the number of running hours on the generator. This time is used as a time stamp for the event log.

Number of Starts – This meter shows the number of successful starts the generator has made.

The following buttons are available to control the GNS:

Start – This button functions identically to the button on the front display of the controller. It is used to request the engine to start in Manual Mode.

Stop – This button functions identically to the button on the front display of the controller. It is used to request a slow stop of the engine in Manual Mode.

Fault Reset – This button functions identically to the button on the front display of the controller. It is used to reset the faults in the controller.

Warning: Clearing faults while in Auto mode may cause the generator to restart immediately.


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Horn Silence – This button functions identically to the button on the front display of the controller. It is used to silence the horn on the controller.

The GCB Meter contains buttons to control the GCB and also displays the status of the GCB.

Buttons – The following buttons are used to control the GCB in Manual mode only

Open GCB – When the breaker is closed and the controller is in manual mode, this button will request the GCB to open.

Close GCB – When the breaker is open and the controller is in manual mode, this button will request the GCB to close.

Status – The following status messages are displayed by the meter.

GCB Open (Green) – The GCB is considered to be in the open state. This status is derived from the GCB Feedback (if configured), or assumed after the configure feedback delay has expired after requesting GCB to open.

GCB Closed (Red) – The GCB is considered to be in the closed state. This status is derived from the GCB Feedback (if configured), or assumed after the configure feedback delay has expired after requesting GCB to close.

GCB Tripped (Yellow) – The GCB is considered to be in the tripped state. This status is derived from the GCB Feedback (if configured), or assumed after requesting GCB to trip..

GCB Opening (Green) – The GCB is attempting to open. This status is derived from the GCB Feedback (if configured) not being in the open state after being commanded to open, or waiting for the configured feedback delay to expired after requesting GCB to open.

GCB Closing (Red) – The GCB is attempting to close. This status is derived from the GCB Feedback (if configured) not being in the closed state after being commanded to close, or waiting for the configured feedback delay to expired after requesting GCB to close.

GCB Unknown (Blue) – The state of the GCB is not known. This can be due to the feedback signals indicating no or more than one state of the breaker or the feedback indicating a state that is different than commanded after the configure feedback Delay time has elapsed.

GCB Tripping (Yellow) – GCB is attempting to trip. This status is derived from the GCB Feedback (if configured) not being in the tripped state after being commanded to trip, or waiting for the configured feedback delay to expired after requesting GCB to trip.


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6.4 CONFIGURING THE GNS WITH SMARTVU

Almost all configurable parameters can be found in the configuration Meter shown in the Configuration Screen. Any parameter not shown in this meter should not be adjusted unless instructed by authorized personnel. Most changes take effect immediately. Once configuration is complete, a complete power-down then power-up cycle should be performed on the GNS to ensure that all changes work as desired.

Configuration Screen – This screen shows the configuration meter which is used to configure almost all parameters. The meter is based on a notebook tab scheme and closely mimics the screens on the GNS. After changing an entry Press ENTER to ensure that the change was recognized by the GNS. The following notebook tabs are available.

The following tabs are used to configure the GNS functions that can be configured through SmartVU or the GNS display.

System Settings – This tab is used to configure the system parameters. Typically these are the parameters found on the System Settings Set Points screens of the Display.

Engine Parameters – This tab is used to configure the engine parameters. Typically these are the parameters found on the Engine Parameters Set Points screens of the Display.

Engine Protection – This tab is used to configure the engine protection parameters. Typically these are the parameters found on the Engine Protection Set Points screens of the Display.

Generator Protection – This tab is used to configure the generator protection parameters. Typically these are the parameters found on the Generator Protection Set Points screens of the Display.

The following tabs are used to configure the GNS functions that can only be configured through SmartVU.

Binary Input – This tab is used to configure the Binary Input function assignments and polarity.

Binary Output – This tab is used to configure the Binary Output function assignments and polarity.


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Gen Circuit Breaker – This tab is used to configure the GNS to work with the GCB. In this tab the type of circuit breaker; None, Single-Line, or Multi-Line can be configured. The feedback delay, assignment of Binary Outputs and polarity can be configured. In addition, if feedback monitoring is desired, the Binary Inputs and their polarities can be assigned as well.

Warnings/Alarms – This tab is used to enable or disable any warning or alarm.

Status – This tab is used to enable or disable any status message.

J1939 Config – This tab is used to configure the basic J1939 functionality. This functionality must be configured properly before any of the J1939 functions can be used. The J1939 functions are configure on the CAN Configuration Screen. See section Using SmartVU with a J1939 Based ECU for additional details.

User Protection – This tab is used to configure user-defined protections for the analog inputs, and binary inputs.

Voltage Select – This tab is used to configure the voltage selection Table that is used by the Binary Voltage Selection Logic.

Analog Input Config – This tab is used to configure the Analog Inputs for sensor type, data points, name, and units.


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6.5 USING SMARTVU WITH A J1939 BASED ENGINE

The GNS has direct support for J1939 based ECUs as a standard feature. In order to utilize the functions of the J1939 sub-system, the GNS must be configured using SmartVU. The J1939 sub-system consists of the following components:

J1939 Setup – This component is used to configure the J1939 sub-system so that any communication can occur. It is configured in the configuration notebook meter under the J1939 Config tab.

J1939 Diagnostics – This component is used to view any J1939 based diagnostic messages. In J1939 terminology, there are DM1, DM2, and DM3 messages. Both DM1 (active DTCs), and DM2 (previously active DTCs) are viewable in SmartVU using the GNS2000 DM1 Active Diagnostics Meter. This meter is always running and will display DM1 messages as they are received by the GNS. To view DM2 messages, select STORED option in the meter. When stored messages are being displayed, pressing CLEAR STORED button will send the DM3 command to clear the ECU of DM2 messages. As an option, either list may be saved to a file by pressing the Save to File… button. This meter is similar to the DTC screen on the GNS display.

J1939 Monitoring – This component is used to view any of the available parameters on the J1939 bus. Up to 10 parameters may be selected based on the ECU defined. The current available value for those 10 parameters will be displayed on the GNS2000 Meter continuously. There is also the option to save the current values to a file. Configuration of the 10 parameters and selection of the ECU is done through the J1939 Monitoring Meter where the ECU can be selected from the list of known ECUs. Once an ECU is selected, a list of available parameters is displayed. Up to 10 of those parameters can be selected. Those 10 parameters are then displayed continuously in the J1939 Monitoring Meter, and also shown on the J1939 Monitoring Screen of the GNS Display.

J1939 Sensor Selection – This component is used to select the J1939 parameters as the source for key system parameters in the GNS. The system parameters that can be sourced from J1939 data are the Engine Speed, Coolant Temperature, Oil Pressure, and Fuel Level. This component allows the selection of J1939 data as any one or more of these system level parameters. The selection is done in the configuration notebook meter under the System Settings tab for Engine Speed source and under the Engine Protection tab for Oil Pressure, Coolant Temperature, and Fuel Level source.

CAN Configuration Screen – This screen has several meters monitor J193 traffic and configure different J1939 sub-systems.

J1939 Diagnostics Meter - Shows the current DM1, and DM2 DTCs being transmitted by the ECU.

J1939 Monitoring Configuration Meter – Allows the configuration of up to 10 parameters to be monitored from the J1939 traffic.

J1939 Monitoring Meter – Show the current value of up to 10 J1939 parameters and allows the current value to be saved to a file.


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6.6 TROUBLE SHOOTING WITH SMARTVU

Event Log Screen – This screen shows the event log meter which displays the event log contained within the GNS. Each event is numbered, timestamped with engine running hours, identified as an (A) Alarm, (W) Warning, or (S) Status event, described by event name, and identifies any supporting data. Refer to the Event Log Supplemental Information section for a description of the supplemental data. From this meter, several control options are available.

Start – Pressing this button, starts the logging function on the PC. By default the PC display of the GNS event log is stopped. Pressing this button starts the reading and displaying of the GNS log. Once started, the logging will automatically show any new entries and will continue to do so until SmartVU is closed, or the STOP button is pressed.

Stop – Pressing this button, stops the logging function on the PC. Events are still log on the GNS. The GNS can only hold a limited amount of entries in the log. Once the maximum entries are saved, the newest will automatically overwrite the oldest. If the Event Log on the PC is stopped for a long enough time, some entries may be lost.

Clear – Pressing this button will clear the log on the PC only. It does not affect the log on the GNS. If the Event Log meter is already started, it will continue to display new entries as they are added to the log on the GNS.

Save to File… - Pressing this button will allow selecting a filename and location and saving of the event log to a file. It does not clear the event log. If the Event Log meter is already started, it will continue to display new entries as they are added to the log on the GNS.


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Reset – Pressing this button clears the log on the PC, and in the GNS. If the Event Log meter is already started, it will continue to display new entries as they are added to the log on the GNS.

Note: The logging function on the GNS cannot be started nor stopped manually. The GNS control is always logging.

Diagnostic Screen – This screen shows several meters that can be used to diagnose problems with the generator set. There are three meters:

External Discrete Input Levels Meter – This meter shows the current state of the Binary Inputs. It is similar in function to the Binary Input State Screen found on the GNS display.

External Discrete Output Levels Meter – This meter shows the current state of the Binary Outputs. It is similar to the Binary Output State Screen found on the GNS display.

Alarm Warning Status Meter – This meter shows the currently active and latched warnings and alarms. This meters is similar to the Alarm/Warning Screen on the GNS display.


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7.0 Alarms/Warnings/Statuses

The GNS has two systems for identifying issues that have happened on the generator set. The Event Log and the Alarm/Warning List. The Event Log is a chronological list of faults and statuses that have been triggered. Mutilple triggers of the same type of event will be logged multiple times. This log will continuously overwrite old entries with newer ones. The Alarm/Warning Lists is a list of all active or previously active faults that have occurred. Each fault can have only one entry. The list is used to identify what alarms or warnings have been triggered since the last fault reset.

Both the Event Log and the Alarm/Warning List present alarms, warnings, but only the Event Log presents statuses as well. Alarm, Warnings, and Statuses are all triggered by different conditions, and take different actions.

7.1 ALARM BEHAVIOR

Alarms are used to cause the controller to take action to protect some part of the system. These can be used to protect the engine, generator, or another part of the system from damage. All alarms trigger some action. The action taken is dependent on the alarm triggered. See the corresponding sections for more information on the alarms, and the actions taken. All alarms take action and follow the behavior defined below.

An alarm, if enabled and the GNS is not in RUN ALL mode, will perform the following behavior:

1. Log the condition in the Event Log

2. Add the alarm to the Alarm/Warning List

3. Assert the specific alarm output function specific if available (to signal an external device, the output function must be mapped to a binary output)

4. Assert Common Alarm

5. Open the breaker and assert Common Unload.

6. Command a “stop”. Whether this is a hard stop or soft stop is dependent on the alarm. On a hard stop, the GNS will assert Common Shutdown and shutdown the set immediately. On a soft stop, the GNS will assert Common Stop and shutdown the set using the defined cooling sequence.

7. Illuminate the Shutdown/Alarm LED on the GNS display.

Once the alarm goes inactive, the active indication in the Alarm/Warning List will disappear.

To clear the alarm condition and resume operation, press the fault reset. The entry will be removed from the Alarm/Warning List, the Common Alarm, Common Unload, Common Shutdown, and Common Stop outputs will be deactivated, the Shutdown/Alarm LED on the GNS display will turn off, and any alarm specific output functions will be deactivated.

7.2 WARNING BEHAVIOR

Warnings are used to signal the user that a condition exists that is approaching the point where damage may occur to some part of the system. These warnings are typically used as pre-alarm conditions to notify the user that if the condition gets worse, an alarm, if enabled, will trip. This allows the user to take action to correct the condition before it reaches the point at which the controller will take action. No warnings trigger action. All warnings follow the behavior defined below.

A warning, if enabled, will perform the following behavior:


2. Add the Warning to the Alarm/Warning List


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3. Assert the specific warning output function if available (to signal an external device, the output

function must be mapped to a binary output)

4. Assert the Common Warning output function

5. Illuminate the Warning LED on the GNS display

Once the warning goes inactive, the active indication in the Alarm/Warning List will disappear and the specific warning output will deactivate.

To clear the warning condition and resume operation, press the fault reset. The entry will be removed from the Alarm/Warning List, the Common Warning output will be deactivated, the Warning LED on the GNS display will turn off.

Note, when an alarm level is tripped, the corresponding warning level may not trip. This is dependent on the time to transition through warning area.

7.3 STATUS

Statuses are used to signal the user that a expected condition occurred. These statuses can be used in troubleshooting the system by chronologically identifying when certain actions occurred. The statuses do not take any action. All statuses follow the behavior defined below.

A status, if enabled, will perform the following behavior:


Statuses are only logged in the Event Log and therefore no action is required by the user in response to a status being logged.

7.4 ALARM/WARNING LIST

The Alarm/Warning List shows all of the currently active and previously active alarms and warnings that have not been acknowledged. The list contains only one entry for each different alarm or warning no matter how many times it has been triggered. Once the alarm has gone inactive, it can be cleared with a fault reset. This signals the GNS that the user has acknowledged the alarm or warning and has addressed the cause. At that point the generator is ready to be restarted. In AUTO mode, if the conditions for generator start are present, the controller may immediately issue a start request. If the fault condition is no longer active, then the fault will be removed from the Alarm/Warning List. The Fault Reset should not be pressed until the condition causing the condition has been identified. Statuses are not entered in the Alarm / Warning List. Each entry in the Alarm / Warning List shows whether it is an alarm or warning, whether it is active or not, and the fault condition.

Display

SmartVU – The Warning/Alarm list meter is shown below


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7.5 EVENT LOGS

The Event Log is a chronological list of events that have been detected in the generator set. These events can be Alarms, Warnings, or Statuses. Only enabled alarms, warnings, or statuses will be logged in the event log. Each entry in the log contains a timestamp, message and supporting data. The supporting data can only be viewed using SmartVU software. Each trigger of the event will cause a new entry to be logged even if the previous condition hasn’t been acknowledged. Any warning or alarm condition that is displayed in the Alarm/Warning List is also logged in the Event Log. In addition, enabled statuses that are triggered are logged in the Event Log. The Event Log is 30 entries deep and will continuously overwrite the oldest entry each time a new entry is added regardless of whether the earlier events have been acknowledged.

Triggers can be setup to allow notification that entries are being added to the Event Log for generators that are installed remotely. These notifications are in the form of SMS text messages sent through a cellular modem. Refer to the section on Cellular Modem Configuration for more details.

Display –

SmartVU –

AL – Active Still L – No longer active


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7.6 EVENT LOG SUPPLEMENTAL INFORMATION

The GNS is equipped with an event log. This log contains any status changes (that are enabled) and protections. Besides the event itself, some event log entries contain supplemental information. This supplemental data can only be viewed from SmartVU software. Below is a table of entries and a description of the supplemental information:

Entry Description of Supplemental Data

SPEED SENSOR FAIL Numeric 1 – 3, indicating primary, secondary, or tertiary speed sensor fail

ANALOG SENSOR FAIL Numeric 1 – 4, indicating analog channel

SHORT CIRCUIT Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

CAN1 ERROR Bit mapped reading error: 1 = oil pressure, 2 = Coolant temp, 4 = Fuel level, 8 = speed

OVER CURRENT Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

OVER CURRENT IDMT Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

PHASE WIRING CURRENT Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

GENERATOR UNDER VOLTAGE Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

GENERATOR OVER VOLTAGE Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

GEN UNBAL VOLTAGE Bit mapped phase: 3 = AB, 5 = BC, 6 = AC

UNBAL CURRENT Bit mapped phase: 3 = AB, 5 = BC, 6 = AC

OVER LOAD Total RMS Power (A+B+C)

GENERATOR UNDER FREQUENCY

Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

Engine run hours when event occurred

S = Status W = Warning A = Alarm


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Entry Description of Supplemental Data

GENERATOR OVER FREQUENCY Bit mapped phase: 1 = A, 2 = B, 4 = C (e.g., 1=A, 3=AB, 6=BC)

UNDER SPEED Engine RPM

OVER SPEED Engine RPM

BATTERY UNDER VOLTAGE Battery Voltage (milli-volts)

BATTERY OVER VOLTAGE Battery Voltage (milli-volts)

CONFIGURATION ERROR


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8.0 Connectivity

8.1 GNS2X00 CONNECTIVITY

The GNS family of products is available with several communication ports to expand the connectivity options of the product. Connections to the GNS can be done through standard serial ports, CAN ports, and analog telephone lines. Much of the same information is available through any of the ports. Which port to use largely depends on what the GNS is being connected to the intended purpose of that connection. The following table shows the available ports on the standard units.

Model RS-232 Only

RS-232 / RS-485 CAN

GNS2X02, Integrated control and display 0 1 1

GNS2X04, Integrated control and display (Extended Temp Version) 0 1 1

GNS2X04B, Control only, no display 1 1 1

GNS2X02D, Display only, no control 0 1 0

GNS2X04D, Display only, no control (Extended Temp Version) 0 1 0

Note: Factory installed modem shares the same port as RS-232/RS-485 port. When modem is in use, external connector is not usable.

Every GNS is equipped with a serial port that can be configured as RS-232/485. The “B” version is equipped with a second serial port that supports RS-232. These ports use standard DB9 male connectors and support the industry standard Modbus protocol. The pin out for the ports is as follows:

Pin COM1 – RS232 COM1 – RS485 COM2 – RS232 (Only)

1 CD NC NC

2 RX TX+/RX+ RX

3 TX TX-/RX- TX

4 DTR NC NC

5 GND GND (SHLD) GND

6 DSR NC NC

7 RTS NC NC

8 CTS NC NC

9 RI NC NC

8.2 RS-232 ONLY PORT

The RS-232 only port is only available on the GNS2004B product. Typically it is used to connect to a local display or PC. External convertors can be used to convert this port into a RS-485 port. Configuration of this port consists of proper wiring, and software configuration of baud rate, parity bits, and stop bits. As shipped from the factory, the port is configured to operate with the remote displays, and SmartVU software without any changes. Simply connect a NULL modem cable between the units. All changes to the communication parameters for this port is done using the GNS Configuration Software, SmartVU.


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Below is the COM Port Configuration meter used to configure the COM ports. Shown is the configuration options for the RS-232 only port. Notice that all RS-485 options are grey out and not available.

8.3 RS-232/RS-485 PORT

All units have at least one RS-232/RS-485 switchable port. This port can be used in RS-232 or RS-485 mode without any external convertors. All necessary convertors are built into the products. Typically these ports should be used in RS-232 mode for distances up to 25 feet. If longer distances are required,, the ports can be switched to run in RS-485 mode. In RS-485 mode, the units can operate up to 1km away from each other provided the baud rate is low enough. This port also has modem handshaking signals and is shared with the optional factory-installed modem. All changes to the communication parameters for this port including switch modes, is done using the GNS Configuration Software, SmartVU

Configuration of this port for RS-232 operation consists of proper wiring (Null Modem Cable), disabling of termination resistor, configuration of mode (RS-232), selection of baud rate, parity bits, and stop bits. As shipped from the factory, the port is configured to operate in RS-232 mode with remote displays and SmartVU software without any changes. Simply connect a NULL modem cable between the units.

Configuration of this port for RS-485 operation consists of proper wiring (Straight Through Cable), disabling or enabling of the termination resistor, configuration of mode (RS-485), selection of baud rate, parity bit, and stop bits.

Below is the COM Port Configuration meter used to configure the COM ports. Shown is the configuration options for the RS-232/RS-485 port. Notice that in addition to RS-232 and RS-485 options, internal and external modem options are available as well.


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8.4 CAN PORT

All control units have CAN bus built-in. This port can be used by accessories and also for connecting to third part units such as engine ECUs. Configuration of the CAN port consists on defining addresses to use, proper wiring of the CAN port, and enabling or disabling of the CAN bus termination resistor. Once proper communication is established, any of the available features can be used. But if one or more of the features are not working properly, the first step is to always verify that proper CAN port configuration has been done.

CAN Bus wiring must be a twisted pair enclosed in a shield. The shield must be tied to ground at one end (not both). The pin out for the CAN connector is as follows:

Pin Definition

L CAN Low

S Shield

H CAN High

8.5 ISOLATION

Both the RS-485 and the CAN Ports can be used to communicate with units that are a considerable distance apart. Typically, any time that devices are connected by a communication port, care must be taken to ensure that the ground potential difference between the units is kept below the requirements. Requirements for RS-232, RS-485, and CAN are just a few volts. Any voltage beyond this will begin to introduce communications errors and if high enough will lead to hardware failures. A general rule to follow is that if the units are powered from different sources, they should be isolated from each other. Third-party communication isolators are available, as well as a factory-installed isolation option. Contact factory for more information.


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All configuration of the ports is performed using the GAC SmartVU software.

!! Care must be used when connecting to the RS-232 / RS-485 connector. Static discharge can destroy the serial port. When connecting to the port first touch the outside of the serial connectors of the cable and the GNS !!

8.6 CONFIGURING THE GNS200XD REMOTE DISPLAY FOR RS-232/RS-485 OPERATION

Out of the box, the GNS2002D and GNS2004D remote displays are configured for RS232 operation and can be connected directly to either GNS RS-232 ports with a Null Modem cable. The remote displays can be connected to either or both RS-232 ports. For distances longer than 25 feet, the GNS and the remote display need to be switched to RS-485 mode and a Straight Through cable used. Switching modes is done through SmartVU software on the GNS controller, and through a configurable parameter in the Setup/Test menu on the display. The preferred way is to configure the display to use RS-485 mode first, then use SmartVu to change the GNS controller port to RS-485 mode. Switching back to RS-232 mode should be done in the same order, first the display, then the controller.


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GNS2X02 or GNS2X04 with one remote display


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GNS2X04B with Two Remote Displays


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8.7 CRM/RA CONFIGURATION

The RA/CRM family of peripherals can be used to extend the output capabilities of the GNS. They are also used to remain NFPA 110, and CSA 282 compliant. The RA20 is a remote Annunciator consisting of 20 tri-colored LEDs. Each of the LEDs can be configured to illuminate based on a user-configured condition, and each LED can be configured for Red, Yellow, or Green. The RA communicates with the main controller through, CAN bus or either one of two RS-232/RS-485 ports. All data is received over these communication ports, and becomes the source of the logic used to decide whether the LED should be on or off. The logic can be configured to light the LED when a specific piece of data is received, or can use any of the math, logic, or comparison operators to establish the condition. In that way, it acts like a mini PLC. Connection of the RA/CRM to the GNS is accomplished by either CAN Bus, RS-232, or RS-485 ports.

The CRM is identical to the RA except that has a form C relay associated with each LED. When the LED illuminates, the relay is energized. All other features are identical.

CAN bus wiring is done using twisted shielded pairs. Terminating resistors can be enabled on the GNS, the RA/CRM, or both as necessary. The RA/CRM would then configured by the user to look at the J1939 port data for the desired condition.

RS-232 wiring is done with a Null Modem cable between the GNS and the RA/CRM. Terminating resistors on the RS-485 ports on both products must be off. The RA/CRM would then be configured by the user to look at the specified serial port for the desired data.

RS-485 wiring is done with a Straight-Through cable between the GNS and the RA/CRM. Terminating resistors may be used as needed, but two and only two must be used somewhere in the wiring, preferably at the physical ends of the wiring. The RA/CRM would then be configured by the user to look at the specified serial port for the desired data.

8.8 JDR FAMILY CONFIGURATION

The JDR family of products are used to monitor CAN/J1939 bus for diagnostic trouble codes from the ECU, and key engine parameters from the ECU. Because the GNS has the functionality of the JDR built-in, the JDR can be used as a remote display unit, or as a primary display unit when used with the GNS2004B, display-less controller. Connection of the JDR products to the GNS is easily accomplished by connecting the CAN bus wiring between the units with twisted shielded pair wiring. Be sure that there are two and only two termination resistors in the wiring. Refer to the JDR literature for more information on the JDR options, wiring, and operation.

8.9 CELL MODEM CONFIGURATION

The GNS can also work with externally mounted GSM cellular modems. This allows notification of generator events from remote locations. To do this the GNS can be configured to send out SMS text messages under certain circumstances. The GNS can be configured with up to four different triggers conditions. The conditions are:

Alarm – This condition is true when any alarm event is entered into the event log.

Warning – This condition is true when any alarm or warning event is entered into the event log.

Status – This condition is true when any status, warning, or alarm event is entered into the event log.

Log Count – This condition is true when the number of entries in the log reaches the level defined by parameter Message Count Trigger.


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Once any one of the trigger conditions is true, the GNS will send a SMS text message to one or more numbers. The message will can user-defined information of the generator identification as well as the code of the alarm, warning, or status message in the log. This information can be used by service personnel to dispatch the appropriate personnel to the site with the required maintenance parts if necessary.


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9.0 Appendix A - Glossary of Terms

Term

Definition

Alarm A critical engine and/or generator condition that will initiate an engine shutdown (e.g., high

coolant temperature alarm) or open breaker.

Discrete Input a.k.a., Binary Input

A physical digital input connected to the GNS. When configured as active low, ground represents active state and battery voltage represents inactive state. When configured as active high, ground represents inactive state and battery voltage represents active state.

Discrete Output a.k.a., Binary Output

A physical digital output signal generated by the GNS. If configured as active low, when the function is active the output is switched to ground, when function inactive, the output will be open circuit. If configured as active high, when the function is active the output will be open circuit, when the function is inactive, the output will be switched to ground.

Form A Relay Electromechanical relay with normally open contacts only.

Form C Relay Electromechanical relay with two sets of contacts – one normally open, one normally closed.

Hard Shutdown Immediate stopping of engine by commanding breaker to open and engine to stop immediately.

Input Function An internal action taken by the GNS as the result of an external stimulus. Typically, these Input Functions are logically mapped to a discrete input. For example, the Input Function “Horn Silence” can be mapped a discrete input which is then connected externally to a switch. When the button is pressed, the GNS will issue a “Horn Silence” request. Many Input Functions can also be triggered via Modbus.

Local Display User interface attached directly to the GNS through RS-232 only communication port.

Output Function An internal GNS behavior that can be monitored from outside the GNS. Typically, these functions are logically mapped to outputs. For example, the “Starter” output function can be assigned to a discrete output. When the GNS wishes to start the engine, it will trigger the “Starter” function, which will set the output to the active state. The Output Functions can also be monitored via Modbus.

Protection An alarm or warning to notify the operator that the engine and/or generator has a problem.

Remote Display User interface not attached to GNS – attached via a communications cable.

Run All Input to command the GNS to disable protections. a.k.a., “battle short”, “Sprinkler”

Soft Shutdown When engine is commanded to stop it is allowed to run through the cooling cycle.

Status A non-protection change in state of the genset (e.g., “Engine Started”).

Warning A non critical engine and/or generator condition. Warnings do not initiate an engine shutdown only log a warning in history log. A.K.A. pre-alarm (e.g., high coolant temperature warning).


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10.0 Appendix B - Specifications

Category Specification Notes

Certifications UL508 (Pending)

CE

CSA (Pending)

NFPA110

Power 8-32VDC

Reverse polarity protection

0V for 50ms if it was at least 10V before dip and recovers to a minimum of 5V

Environmental -40 to 85°C (-40 to +185°F) (GNS2004, GNS2004B, GNS2004D)

-20 to 85°C (-33 to +185°F) (GNS2002, GNS2002D)

95% non-condensing @ 110°F

Salt spray (ASTM-B117)

Splash and immersion to spray paint

Fungus

IP65 Dust, Sand, & Gravel

Altitude 12,000ft Operational, 40,000ft Storage

20G Mechanical Shock

Inputs/Outputs 3 AC Current Inputs

3 AC Generator Voltage Inputs

3 AC Mains Voltage Inputs (GNS2500)

Magnetic Pickup

9 Discrete inputs

9 Discrete outputs (2 form A relays, 2 form C relays, 5 open drain outputs)

4 Analog inputs

Discrete input and output functions are user configurable.

Analog input functions are user configurable

Connectivity/Networking 1 - RS232/RS485 (GNS2X02, GNS2X04)

1 - RS232, 1 RS232/485 (GNS2X04B)

Modbus

CAN J1939

Internal/External Modem Hayes Compatible

Internal modem is available as a factory installed option.

RS232/485/CAN port isolation is available as a factory installed option.


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11.0 Appendix C - Inputs, Outputs, and Communications

The GNS is equipped with 9 discrete inputs, 9 outputs (4 are relays), 4 analog inputs, a magnetic pickup input, 1 or 2 serial ports (depending on the model), and CAN communications. Factory installed modem, and/or communication port isolation is available. Ethernet communications can be accomplished with an external adapter (GAC part no. EAM1000).

The discrete physical inputs and outputs can be mapped, by the user, to logical control functions. This is accomplished using GAC’s SmartVUTM software.

11.1 CONNECTIONS

All connections are made on the back on the GNS. The connections are detailed in subsequent sections. With the exception of the “Mains” voltage inputs on the GNS2500 the connections are identical for all models of the GNS.

Rear View of GNS2000


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Rear View of GNS2500 (Note the Mains Voltage Connections in Upper Right Corner)

11.2 ANALOG INPUTS

The GNS supports up to 4 analog inputs. Each analog input will accept a resistive, voltage, current or thermocouple device. The profile for the device is user programmable. Using SmartVU, it is possible to assign upper and lower warning and alarm points.

11.3 COMMUNICATIONS PORTS

All models of the controller are equipped with at least one serial port. This port communicates using Modbus protocol over RS-232 or RS-485. The port is configured using the SmartVU software. By default the GNS uses RS-232. See appendices for pinout and wiring diagram.

11.4 CONFIGURING CAN COMMUNICATIONS

By default the GNS is equipped with a CAN port that is intended to communicate with engine ECUs and to transmit J1939 power information. The CAN address is set to 200. . See appendices for pinout and wiring diagram.


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11.5 PHYSICAL INPUTS

Category Input Specification/Default Notes

A Voltage 0-600VAC

B Voltage 0-600VAC

C Voltage 0-600VAC

Generator Voltage Inputs

COM

A Voltage 0-600VAC

B Voltage 0-600VAC

C Voltage 0-600VAC

Mains Voltage (GNS2500 Only)

COM

A Current 5A

B Current 5A

C Current 5A

Generator Current Inputs

COM

Units manufactured before 2009 have a 6 pin connector – each phase has a dedicated common.

Mag P/U Mag P/U 0.5-30 VAC RMS, 10KHz Max

Analog 1 Default Function: Oil Pressure

Analog 2 Default Function: Coolant Temp

Analog 3 Default Function: Fuel Level Analog Inputs

Analog 4 Default Function: Not used

All analog inputs accepts the following signals: 0–5V, 0–10V, 4-20mA,0-20mA,0-100mV, Resistive (0-2.4kO), Thermocouples (type K)

There are four programmable graphs with a minimum of 2 points and a maximum of 10. Note: When connecting a single wire resistive input, make sure the second input to the analog input is connected to ground.

Binary 1 Default: E-Stop

Binary 2 Default: Remote Start/Stop

Binary 3 Default: Auto Mode

Binary 4 Default: Off Mode

Binary 5 Default: Manual Mode

Binary 6 Default: Fault Reset

Binary 7 Default: Remote Start

Binary 8 Default: GCB Open Request

Binary Inputs

Binary 9 Default: GCB Close Request

All binary inputs are closed to ground to activate (Software control whether signal is interpreted as normally open or normally closed).

D+ D+ Belt Break (alternator not functioning)

D+ is an input only terminal. To flash the alternator, connect alternator D+ to one side of one of the normally open relay contacts and the other side to B+; then assign the relay to “Starter”.


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11.6 PHYSICAL OUTPUTS

Category Output Specification/Default Notes

Binary 1 Form C Relay, Default: Fuel

Binary 2 Form C Relay, Default: Starter

Binary 3 Form A Relay, Default: Not Used

Binary 4 Form A Relay, Default: Starter

Form C Relays rated at 12A @ 125VAC, 28VDC Form A Relays rated at 3A @ 250VAC, 30VDC Binary 4 default is used to flash the alternator (B+ on one side of the contract alternator D+ on other side)

Binary 5 Default Function: GCB Open Close

Binary 6 Default Function: Horn

Binary 7 Default Function: Common Alarm

Binary 8 Default Function: Common Warning

Binary Outputs

Binary 9 Default Function: Not Used

Binary Outputs 5-9 are open collector, close to ground, diode protected to battery VDC.


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12.0 Modbus Definition

12.1 MEASURED DATA MODBUS DEFINITION TABLE

Description MB Addr

(Hex) MB Addr (Dec) Data Format

Operating Mode Status 0x0B00 2816 UNSIGNED16

Generator Voltage Phase A 0x0B0D 2829 GNS_VOLT_GEN

Generator Voltage Phase B 0x0B0E 2830 GNS_VOLT_GEN

Generator Voltage Phase C 0x0B0F 2831 GNS_VOLT_GEN

Generator Voltage Line A-C 0x0B10 2832 GNS_VOLT_GEN

Generator Voltage Line A-B 0x0B11 2833 GNS_VOLT_GEN

Generator Voltage Line B-C 0x0B12 2834 GNS_VOLT_GEN

Generator Current Phase A 0x0B13 2835 GNS_CURR_GEN

Generator Current Phase B 0x0B14 2836 GNS_CURR_GEN

Generator Current Phase C 0x0B15 2837 GNS_CURR_GEN

Generator KW Total 0x0B16 2838 GNS_PWR_GEN_2

Generator KW Phase A 0x0B17 2839 GNS_PWR_GEN_2

Generator KW Phase B 0x0B18 2840 GNS_PWR_GEN_2

Generator KW Phase C 0x0B19 2841 GNS_PWR_GEN_2

Generator KVA Total 0x0B1A 2842 GNS_PWR_GEN_1

Generator KVA Phase A 0x0B1B 2843 GNS_PWR_GEN_1

Generator KVA Phase B 0x0B1C 2844 GNS_PWR_GEN_1

Generator KVA Phase C 0x0B1D 2845 GNS_PWR_GEN_1

Generator KVar Total 0x0B1E 2846 GNS_PWR_GEN_3

Generator KVar Phase A 0x0B1F 2847 GNS_PWR_GEN_3

Generator KVar Phase B 0x0B20 2848 GNS_PWR_GEN_3

Generator KVar Phase C 0x0B21 2849 GNS_PWR_GEN_3

Generator Power Factor Total 0x0B22 2850 GNS_PF

Generator Power Factor Phase A 0x0B23 2851 GNS_PF

Generator Power Factor Phase B 0x0B24 2852 GNS_PF

Generator Power Factor Phase C 0x0B25 2853 GNS_PF

Engine Run Time High 0x0B26 2854 GNS_SERVICE_TIME

Engine Run Time Low 0x0B27 2855 GNS_SERVICE_TIME

System Run Time High 0x0B28 2856 GNS_SERVICE_TIME


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Description

MB Addr (Hex) MB Addr (Dec) Data Format

System Run Time Low 0x0B29 2857 GNS_SERVICE_TIME

Generator Frequency A 0x0B2A 2858 GNS_FREQUENCY

Generator Frequency B 0x0B2B 2859 GNS_FREQUENCY

Generator Frequency C 0x0B2C 2860 GNS_FREQUENCY

Engine Oil Pressure 0x0B2E 2862 GNS_OIL_PRESSURE

Coolant Temp 0x0B2F 2863 GNS_TEMPERATURE

Engine Speed 0x0B30 2864 GNS_RPM

Battery Voltage 0x0B32 2866 GNS_VBATT

Fuel Level 0x0B33 2867 GNS_PERCENT

Circuit Breaker Status 0x0B3B 2875 GNS_BIT_FIELD

Next Service Time High 0x0B45 2885 GNS_SERVICE_TIME

Next Service Time Low 0x0B46 2886 GNS_SERVICE_TIME

External Discrete Input Levels 0x0B4D 2893 GNS_BIT_FIELD

External Discrete Output Status 0x0B4E 2894 GNS_BIT_FIELD

Number Of Starts 0x0B4F 2895 UNSIGNED16

Active Warnings 1 0x0B80 2944 GNS_BIT_FIELD




Active Alarms 1 0x0B84 2948 GNS_BIT_FIELD




Latch Warnings 1 0x0B88 2952 GNS_BIT_FIELD

Latch Warnings 2 0x0B89 2953 GNS_BIT_FIELD

Latch Warnings 3 0x0B8A 2954 GNS_BIT_FIELD

Latch Warnings 4 0x0B8B 2955 GNS_BIT_FIELD

Latch Alarms 1 0x0B8C 2956 GNS_BIT_FIELD

Latch Alarms 2 0x0B8D 2957 GNS_BIT_FIELD

Latch Alarms 3 0x0B8E 2958 GNS_BIT_FIELD

Latch Alarms 4 0x0B8F 2959 GNS_BIT_FIELD


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12.2 DATA FORMAT DEFINITIONS

Type ID Units Size (B)

Scale Multiplier

From GNS2000

Scale

Multiplier To GNS2000 Offset

Active Range (Raw)

CMD 0x0000 - 2 - 0-65534 0 0-65534

UNSIGNED8 0x0001 - 1 1 0-255 0 0-255

UNSIGNED16 0x0002 - 2 1 0-65535 0 0-65535

UNSIGNED32 0x0003 - 4 1 0-232 0 0-232

UNSIGNED48 0x0004 - 6 1 0-248 0 0-248

UNSIGNED64 0x0005 - 8 1 0-264 0 0-264

SIGNED8 0x0011 - 1 1 -128-127 0 -128-127

SIGNED16 0x0012 - 2 1 -32768-32767 0 -32768-32767

SIGNED32 0x0013 - 4 1 -231-(231-1) 0 -231-(231-1)

SIGNED48 0x0014 - 6 1 -247-(247-1) 0 -247-(247-1)

SIGNED64 0x0015 - 8 1 -263-(263-1) 0 -263-(263-1)

BINARY8 0x0020 - 1 --- 0-255 0 0-255

BINARY16 0x0021 - 2 --- 0-65535 0 0-65535

STRING 0x0030 ASCII n --- --- ---

GNS_VOLT_GEN 0x0301 V 2 1 1 0

GNS_CURR_GEN 0x0302 A 2 1 1 0

GNS_VOLT_MAIN 0x0303 V 2 1 1 0

GNS_PWR_GEN_1 0x0304 KVA 2 1 1 0

GNS_PWR_GEN_2 0x0305 KW 2 1 1 0

GNS_PWR_GEN_3 0x0306 KVAR 2 1 1 0

GNS_PF 0x0307 - 2 0.001 1000 0 0-0x83E8

GNS_TIMER_1 (not used) 0x0308 Min 2 1 1 0 0-65535

GNS_TIMER_2 0x0309 Sec 2 .10 10 0 0-65535

GNS_FREQUENCY 0x030A Hz 2 .01 100 0

GNS_SERVICE_TIME 0x030B Sec 4 1 1 0

GNS_VBATT 0x030C V 2 0.001 1000 0

GNS_VOLTAGE_CAL 0x0313 V 2 0.1 10 0

GNS_CURRENT_CAL 0x0314 A 2 0.001 1000 0

GNS_J1939_ENGINE_SPEED 0x0315 RPM 2 1/8 8 0

GNS_J1939_OIL_PRESSURE 0x0316 KPA 2 4 ¼ 0

GNS_J1939_COOLANT_TEMP 0x0317 C 2 1 1 -40


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Type ID Units

Size (B)

Scale Multiplier

From GNS2000

Scale

Multiplier To GNS2000 Offset

Active Range (Raw)

GNS_RPM 0x0318 RPM 2 1 1 0

GNS_TIMER_3 0x0319 Sec 2 1 1 0

GNS_OIL_PRESSURE 0x031A KPA 2 4 ¼ 0

GNS_PHASE_ERROR 0x031B % 2 1/1024 - 0

GNS_TIMER_4 (not used) 0x031C Sec 2 0.001 1000 0 0-65535

GNS_BIT_FIELD 0x031D - 2 --- --- --- -

GNS_PERCENT 0x031F % 2 1 1 --- 0-200

GNS_TEMPERATURE 0x0320 C 2 1 1 --- -40-1000


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12.3 PROTECTION BITS (WARNINGS & ALARMS)

Bit Protection Bit Protection

00 GEN_UNDER_FREQ 32 GCB_EXTERNAL_TRIP

01 GEN_OVER_FREQ 33 UCB_EXTERNAL_TRIP

02 MAIN_UNDER_FREQ 34 ANALOG_IN_1_UNDER

03 MAIN_OVER_FREQ 35 ANALOG_IN_1_OVER

04 GEN_UNDER_VOLT 36 ANALOG_IN_2_OVER

05 GEN_OVER_VOLT 37 ANALOG_IN_2_UNDER

06 GEN_UNBAL_VOLT 38 ANALOG_IN_3_UNDER

07 MAIN_UNDER_VOLT 39 ANALOG_IN_3_OVER

08 MAIN_OVER_VOLT 40 ANALOG_IN_4_UNDER

09 MAIN_UNBAL_VOLT 41 ANALOG_IN_4_OVER

10 OVER_CUR 42 COMM_FAIL

11 OVER_CUR_ITD 43 SHORT_CIRCUIT

12 UNBAL_CUR 44 CONFIG_ERROR

13 OVER_LOAD 45 AUTO_VOLT_DETECT

14 UNDER_SPEED 46 PHASE_WIRING_VOLT

15 OVER_SPEED 47 PHASE_WIRING_CUR

16 CRANK_FAIL 48 ANALOG_SENSOR_FAIL

17 ALTERNATOR 49 CAN1_ERROR

18 GCB_FAULT 50 CAN1_ECU_OFFLINE

19 UCB_FAULT 51 USER_DFINED_1

20 DI_FAULT 52 USER_DFINED_2

21 ESTOP 53 USER_DFINED_3

22 ENGINE_SERVICE 54 USER_DFINED_4

23 BATTERY_UNDER_VOLT 55 USER_DFINED_5

24 BATTERY_OVER_VOLT 56 USER_DFINED_6

25 LOW_FUEL_LEVEL 57 USER_DFINED_7

26 LOW_OIL_PRESSURE 58 USER_DFINED_8

27 LOW_COOLANT_TEMP 59 RESERVED

28 HIGH_COOLANT_TEMP 60 RESERVED

29 STOP_FAIL 61 RESERVED

30 OVER_CRANK 62 RESERVED

31 MAG_PICKUP_FAIL 63 RESERVED


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12.4 OPERATING MODE STATUS

0 0 Start Mode Generator Engine Reserved 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Start Mode:

0 - Off – not initialized 1 - Remote Stand-By 2 - Manual 3 - Auto 4 - Test

Generator:

0 - Unloaded 1 - Supplying Load

Engine:

0 - Stopped 1 -Cranking 2 -Crank Rest 3 -Venting 4 -Gas RPM Delay 5 - Idle 6 - Voltage Detect Delay 7 - Running 8 - Cooling 9 – Prelube 10 – Prelube Pause 11 – Prestart 12 - After Cooling 13 - Idle Override 14 – Stopping


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13.0 Appendix D – Troubleshooting

Trouble-shooting issues involve isolating the issue to as small a set of possible causes as possible. In addition, before assuming that there is a major problem, first start by verifying the basic operation of the unit. The following table outlines specific issues, and possible causes of those issues. In addition to these items, the following list of basic troubleshooting steps should be done before calling service personnel.

Check battery voltages going to GNS, sensors, relays, and other electronics.

Verify all terminal blocks are securely seated; connectors have proper strain-relief.

Measure voltage at input terminals, is it what is expected? Do they match what the control is showing?

Have any changes been done to the application recently?

If another unit is available, swap out the unit (making sure the it is configured the same) and see if the problem follows the application or the unit swapped.

Refer back to section of manual explaining requirements for this feature having the issue. Have the requirements been met?

Has this issue been seen before? Was the application working correctly at one time, or has it always been like this?

When contacting service personnel, always have the following information available:

a. Display software version number

b. Controller software version number

c. Model numbers

d. Application Information including configuration information, running hours, etc.

Symptom Possible Cause Possible Corrective Action

Controller trips under voltage but displays proper voltage

Under voltage setpoint set wrong

Nominal Voltage set to L-L voltage instead of L-N

Adjust under voltage setpoint

Enter Nominal voltage as L-N voltage

Controller logs ECU Offline fault

ECU not powered

Wiring swapped or broken

Wrong ECU address configured

ECU is not sending any data

Termination resistors not proper

Correct/Verify wiring, termination resistors, and configuration.

Controller logs CAN Bus fault

ECU not sending configured data (Engine Speed, Oil Pressure, Engine Temperature, Fuel Level)

Verify ECU Offline fault is not tripping (is it enabled?) as the ECU may not be sending anything or not connected properly.

Engine cranks, doesn’t start, but indicates engine running

Oil Disconnect set too low

RPM Disconnect set too low

Set Oil Disconnect higher and monitor during cranking

Set RPM Disconnect higher and monitor during cranking


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Engine cranks, starts, then stops

Crank Fail Shutdown

Engine is not reaching start RPM

Oil pressure not high enough

Mis-configured speed input source

Check magnetic pickup

Check oil pressure sensor

Check start RPM set point

Check start oil pressure

Check speed input configuration (e.g., if engine is using magnetic pickup, make sure it is configured)

Engine cranks and starts, then engine stops but continues to crank

Starter and fuel outputs are mis-wired or mis-configured

Check fuel and starter configuration (typically, fuel is on discrete output 1 and starter is on discrete 2).

Make sure the starter and fuel are wired properly.

Engine cranks, starts, then shuts down on Mag Pickup Fail

Mag pickup is shared with electronic governor and both sides of the pickup are grounded.

Reverse the leads on the magnetic pickup on the GNS.

Engine can be started manually, but not with GNS (engine cranks and never starts)

Mag pickup is shared with electronic governor and both sides of the pickup are grounded.

Reverse the leads on the magnetic pickup on the GNS.

Engine starts and comes up to rated speed, but breaker cannot be closed in MAN mode or will not automatically close in AUTO mode

Running Stage has not been entered

Engine not reaching configured Nominal Speed

Voltage Detect Delay time not elapsed

Check display or SmartVU to determine what stage control is in

Check actual engine speed and Nominal Speed setpoint.

Wait for delay to elapse, remaining time shown on display and SmartVU

Voltage is not properly displayed

Improper PT ratio configured

PT ratio is forced to 1 when using Binary Select and Auto Voltage Detect methods

Minimum Voltage setpoint set too high

Verify PT ratio

Adjust Minimum Voltage Setpoint

Current is not properly displayed

Improper CT ratio

Improper wiring of CT’s

Check CT primary and secondary set points.

CTs have a polarity. Verify the orientation of the CT. The phase of the current being captured by the CT must be in phase with the voltage inputs.

Power is not properly displayed or power factor reads 0.

Mis-wired CTs or voltage inputs

Verify phase wiring of CT

Verify phase wiring of voltage inputs

Check CT primary and secondary set points

Enable the phase wiring voltage protection to verify the phase to phase wiring.

Enable the phase wiring current protection to verify the current inputs are in phase with the voltage inputs – note: if the CT’s are wired to the proper phase, but are installed in reverse polarity the voltage and current will be 180 degrees out of phase.


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Improper oil pressure being displayed

Improperly defined analog curve for sender

Analog input for pressure sender not assigned

Ungrounded unused leg of analog input

Check for accuracy of the sender profile.

Verify the analog input is mapped for use as an oil pressure sender.

Verify the resistance for the sender is correct for the actual oil pressure.

For a single wire resistive sender, verify the unused leg of the analog input is connected to ground.

Improper coolant temperature being displayed

Improperly defined analog curve for sender

Analog input for temperature sender not assigned

Ungrounded unused leg of analog input

Check for accuracy of the sender profile.

Verify the analog input is mapped for use as an oil temperature sender.

Verify the resistance for the sender is correct for the actual temperature of the engine.

For a single wire resistive sender, verify the unused leg of the analog input is connected to ground.

The GNS is shutting down on a high coolant temperature alarm immediately after the engine is started.

Improperly defined analog curve for the sender

Verify the curve of the sender. Some senders do not begin operating until a specific temperature is reached (e.g., 100F). This can be especially problematic if it is a reverse curve, i.e., a low resistance equates to a high temperature. With these senders, the resistance will appear to be low, or close to zero until the “turn on” temperature is reached.

Cannot see set point

Logged in at wrong security level

Log in at security level high enough to view the set point.

Cannot modify set point

Logged in at wrong security level

Log in at security level high enough to modify the set point.

Cannot start generator from front panel

GNS is not in Manual Mode

GNS previously shutdown because of a generator or engine protection.

Emergency stop condition

Starter discrete output is not assigned

Make sure the unit is in Manual Mode (check the display)

Check for shutdown and find cause. If generator condition has been corrected, press Fault Reset.

Make sure emergency stop switch is in proper position and is properly assigned. Typically, the emergency stop is assigned to a normally closed input. If the emergency stop function is assigned to a discrete input, and the input is assigned to be normally open then the input must be energized.

Check the starter wiring and make sure the starter function is properly mapped to the starter function.

RPM disappears from display after the engine is running

This is normal operation. RPM is replaced with power.

Once the generator is up to speed, RPM and frequency (Hz) essentially conveying the same information as one can compute the other by applying a multiplier. The multiplier is derived using the nominal frequency and the engine speed set points.

The fuel and starter are engaged as soon as the connector is plugged into the GNS

The starter or the fuel solenoids are connected to the normally closed pins of the relay.

Verify the connection is to the normally open contact. Discrete outputs 1 and 2 have form C relays, which have both normally open and normally closed contact.


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SmartVU cannot connect to the GNS

GNS is not powered on

Invalid password

High noise from ignition cables (non diesel)

Control is in edit mode

Check make sure GNS is powered on

Insure the password is correct for the level being logged in to.

Verify that you are using the proper cable.

Verify that no setpoint is being edited, and mode is not being changed

Remote display does not consistently communicate to the GNS

If using RS-232, distance between display and GNS is greater than 27 feet (9m).

If using RS-485, terminating resistors not configured.

If using RS-232 and distance is greater than maximum allowed distance, consider using RS-485.

If using RS-485 and GNS is last device on the cable, install jumpers to enable the terminating resistors.

GNS resets during crank

Starter is drawing too much current and voltage is sagging too low and too long.

Check the crank capacity of the battery – the battery may need to be replaced or re-charged.

GNS display resets while cranking or running

High noise from ignition cables is interfering with the GNS.

Replace high noise ignition cables with noise suppression cables.

Overload Protection is Trigger in Single Phase

If set is a true single phase set, and it is configured with Zig-Zag, the set has been de-rated 66% (e.g., 60KW is de-rated to 40KW).

Re-enter the nominal power as 1.5 times to original value (e.g., 60KW * 1.5 = 90KW).

Cannot change mode or mode changes briefly then changes back when using Display or SmartVU

Controller has mode hard wire on Binary Input with switch

Use switch to change mode

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PRODUCT USER GUIDE - governors-america.com€¦ · PRODUCT USER GUIDE GNS2000 GNS2000E GNS2500 & GNS2500E . GNS2000 / GNS2500, Product User Guide PUG4123_A This document is subject