MODE OF OPERATION:-
1 MANUAL MODE
2 AUTO MODE
3 TEST MODE
4 SETTING MODE
AUTO MODE :-
Pressing AUTO KEY at any time one can enter in AUTO mode ,press AUTO KEY untile LCD display
(AUTO MOD) . In Auto Mode Relay start and stop D.G. Set Automatically,if the mains either fail or
exceed operating limit , the Main CB is opened and Generator Starting procedure begain
Mains Voltage of 1 phases are monitored continuously .
if the voltage of any phase falls below a safe lower limit or exceed a safe limit then relay takes
following action.
It gives audio of small tone on and off three time warning and visual warning on LCD
(CRANCKING) for 3 sec and after 3 sec ,start relay is activated for predetermined period
(CRANCKING) and then system wait for the engine to start and pick up threshold speed within another
predetermined time (WARMING)time ,If the engine doesnot start within WARMING time ,then another
attempt is made ,if the engine fails to start within set (1- 9)attempts,then lcd display “START FAILURE”
and start failure, audio alarms of long tone . Delayed supervision of oil pressure is provided at the time
of starting .This ensure that sufficient time is available for oil pressure to build .If subsequiently oil
pressure is found to be low, then annunciation is given.
When the mains restored, the Gen CB is opened and mains CB is closed after set time, lcd message
(MAINS RESTORED1,2,3,4). Then after a preset re-cooling time,lcd message (RECOOLING), the Gen-set
is shutdown.
The mains restoration time ensures that the mains supply is stable before it is made available to
consumer
While the Gen-set is in operation ,it is comprehensively protected against over-speeding.overvoltage
under voltage,over current,low lube oil pressure ,high water temperature, air sucking due to low fuel.
MANUAL MODE :-
Pressing MANUAL KEY at any time one can enter in manual mode ,press MANUAL KEY untile LCD
display (MANUAL MOD) . In Manual Mode Relay does not start the D.G.Set. But if
DG. Start manually then it takes over the complete control over the DG Set and
Takcare all safety of dg set but doesnot transfer the load on DG SET automatically
TEST MODE :-
Pressing SETUP KEY before switching dc power any time one can enter in test mode ,press SETUP
KEY untile LCD display (TEST MODE) . In Test Mode Relay inter in Man- Machine Interface mode and in
this mode relay sense all inputs available to it like fuel level, water temp sensor status lub oil level
pressure switch status dg contactor, mains contactor, puller /solenoid wiring status, operating mode.
These checks are performed sequently and message displayed on LCD.It check all driver outputs for its
healthiness. It closes and open dg CB and and give message (DG CONT ON)’It closes MAIN CB and give
message (MAINS CONT ON), like wise it switch on and off puller serion, cooling fan and display
corresponding message.
This is very help full for fault analysis in field ,help in analyzing the wrong wiring during installation
,faulty wiring ,faulty sensors etc , because whatever is connected to it and sensed by the relay is
displayed on LCD and also does operate practically all the driver .one can analyze if any fault in the
system.
Suppose if DG is off and GCU sensed that lub oil pressure is ok then it means the wiring is reversed or
sensor is faulty because in off condition lub oil pressure supposed to be low and if relay is Sensing high
then it will not function correctly. This mode provide very useful information, and display each sensor
status on LCD, it also checks all driver (wiring, sensor wiring and all wiring fault sensor status,
SETTING MODE: -
In this Mode Relay setting can be made as per customer choice
This mode is Opend only in starting, WHEN dc power is just on and GCU Display lcd message
“WELCOME GCU 101” it gives only 10 sec to inter in this mode. If within 10 sec time Setup key is
pressed then unit come in setting mode.and ask the option of factory setting and user stting . Press the
required key as per lcd message to select the option of choice.Following setting are possible in this
mode
Default Setting :-
This setting sets all the parameters of relay as per factory
Standard setting. default setting are
(A) UNDER VOLT TRIP= 200 VOLT
(B) OVER VOLT TRIP= 260 VOLT
(C) OVER FREQ. TRIP =55 HZ
(D) LOW FUEL CUT=10% OF TANK CAPACITY
(E) LOW FUEL AUDIO AND VISUAL WARNINFG=30 % OF TANK CAPACITY
(F) NO OF CRANK ATTEMPT BEFORE START FAILURE WARNING =3
(G) CRANCK TIE =3 SEC
(H) WARMUP TIME AFTER START =10 SEC
(I) RECOOLING TIME AFTER CHANGER =30 SEC
(J) MAINS RESTORATION STABLE TIME = 12 SEC
(K) PULLER ON TIME =20 SEC
(L) NO OF STOP ATTEMPT , BEFORE DG FAIL TO STOP WARNING COMES =3
(M) ALL TRIP TIME DELAY =5 SEC
(N) CT RATIO =1
(O) DG TO MAINS CB CHANGER OVER TIME =5 SEC
(P) PULL TO OFF SETTING
USER CHOICE SETTING RANGE:-
1 Follow the guidelines Written on LCD.
2 For Increasing any value press “INC key” and for decreasing, press “DEC Key”
3 Value display on LCD will be the choice and for storing in memory press “ENTER KEY”
OPTIONS:-
1 Pull to on /pull to off selection , press INC KEY select choice =1/0. 1 for pull to on and 0 for pull to off
2 Crank time :- From (1 – 9 sec)
3. No. of crank attempt: If DG Fail to start :- (1 to 9 attempt), Set as per the choice
4. Under Volt Setting per Phase :- From (80 volt to 410 volt)
5. High Volt Setting per Phase :- From (120 volt to 500volt)
6. High Frequency setting :- 45 Hz TO 65 HZ
7. Warm up time: - From (10 sec to 250 sec), time delay after start ,before closing contactors.
8. Engine Cut off Time :- From (10 sec to 40 sec),and max 3 attempt if dg fail to stop
9. Low Fuel AUDIO Warning Setting :- 30 % of tank Capacity Fix, not adjustable
10. Engine Cut off due to Low fuel Level :- 5% Fix, not adjustable
11. Recooling Time :- From (10 sec to 250 sec)
12. High Water temperature Cut Off :- As per sensor setting of DG
13. Low Lube Oil Pressure Cut Off :- As per sensor Setting of DG
14. Engine Cutting Choice setting :- By pull to On and pull to Off
15. Temperature Sensor Choice :- Temperature sensor can be enabled and disabled
16. HIGH Frequency trip can be enabled or disabled by pressing inc key if choice=1 then setting is
enable ,if choice =0 then it is disable. Llop, also can be enabled or disabled with the same procedure
17. Low Lube Oil Pressure Sensor Choice :- LLOP can be enabled and disabled.
18. Mains Power Restoration Delay :- 10 sec Fix,
19. Over Load Limit :- Any limit as per choice of customer UPTO 1200 AMPS
20 SET CT FACTOR 10 for 50/5=10 ct ratio ,set 20 for 100/5=20 and same way set 200 for
1000/5=200
IN BUILT MEASUREMENT:-
1 1 Phase Voltmeter for mains
1. 1 Phase Volt Meter for DG
2. 1 phase ammeter for load
3. Frequency Meter for DG Power
4. Fuel Level Meter
5. RPM meter
6. Total Hours Run Since Installation
7. Sift Run Hours Meter
Inbuilt safety:-
1. Over Volt Trip
2. Under Volt Trip
3. Over Load Trip
4. Low Lub Oil Pressure Trip
5. High Water Temperature Trip
6. Low Fuel trip at 5%
7. Over Speed Trip
8. Low Fuel Warning At 30%
9. Start Failure Warning If Attempt Increase More Then Set Attempt
10. Stop Failure Warning If Stop Attempt Increase More Then 45 Sec
11. short ckt trip
User Choice Setting
No. of Crank attempt Choice (1-9)
Crank time Choice (1-9 sec)
Power on delay (5-75 sec)
Ideal run time after change over to grid (10-120 sec)
Puller on time (10-40 sec)
Under voltage setting per phase 160-230 volt
Over voltage setting per phase 240-280 volt
Over Load setting up to 9999Amp.
CT ratio up to 1250/5
Cyclic Timer Four Hours On Two Hours Off
Working voltage 12V DC
Deminsion –L*W*D* 138*138*138 mm
RELAY OUTPUTS
1) Start Relay
2) Stop relay
3) Hooter
4) Mains Contactor
5) Gen Contactor
6)EXTRA1
7)EXTRA2
8)EXTRA3
9)EXTRA4
5) Oerating Temperature 0 c to 70 c
6) Dim :190x90x70 mm.
FAULT INPUTS:
Low oil pressure,
High engine temperature,
Low Fuel level,
Overload,
Spare-1,
Spare-2,
Spare-3
Remote
Bat +ve for measurement
RELAY OUTPUTS
MAINS AND GENERATOR INPUTS:
R, MN: mains phases and neutral,
L-,GN: generator phases and neutral,
RELAY OUTPUTS:
STOP: Positive output relay used to control the fuel solenoid.
May also be programmed for activate to stop
START: Positive output relay used to control the engine starter
Solenoid.
HORN: Positive output relay activated by any alarm
condition.
GCON: Outputs the alternator phase
voltage to energise the generator contactor
MCON: Outputs the mains phase voltage to
energise the mains contactor.
MODES OF OPERATION
OFF: Mains contactor will be energised if AC mains are
present.
MANUAL: Used to start the generator and transfer the load
manually.
AUTOMATIC: The unit monitors the 1/3 phases of the mains and
will start the generator and control the changeover of mains
and generator contactors if a mains failure on any phase is
detected.
TEST: The unit will start the generator without a mains failure,
the load will not be transferred until a mains failure occurs.
PROGRAM: Used to program timers and operational limits.
Program modifications may be disabled
TECHNICAL SPECIFICATIONS
Mains voltage: 277V-AC max.
Mains frequency: 50/60Hz.
Alternator voltage: 277V-AC max.
Alternator frequency: 0-100Hz.
Measurement Category: CAT II
DC Supply Range: 9 to 33 V-DC.
4 to 33 V-DC while cranking
Current consumption:
100 mA-DC typical (AUTO mode, mains OK)
250 mA-DC max. (Relay outputs open)
Total DC Current Output Rating: 10A-DC.
Total AC Current Output Rating: 1A-AC.
Max. Current for each Terminal: 1A-RMS.
Operating temp.: -10oC (14oF) to 60oC (140oF).
Storage temp.: -20oC (-4oF) to 80oC (176oF).
Maximum humidity: 95% non-condensing.
Panel cutout dimensions: 190x90mm minimum.
Weight: 800 g (approx.)
Accuracy:
Phase voltages: 2% + 1v
Battery voltage: 2% + 0.2V
Generator frequency: ±0.5 Hz
A1 (+) DG BATT B1 MAINS LINE C1 NO CONNECTION
A2 (-) DG BATT B2 NO CONNECTION C2 NO CONNECTION
A3 NEG OFF START/CRANCK B3 MAINS NEUTRAL C3 NO CONNECTION
A4 NEG OFF STOP/PULLER B4 NO CONNECTION C4 LOW LUBCRICANT OIL PRESSURE
A5 NEG OFF HORN/BUZZER B5 DG NEUTRAL C5 WATER TEMP
A6 NEG OFF DG CONTT/CB B6 NO CONNECTION C6 LOW FUEL LEVEL
A7 NEG OFF MAINS CONT/CB B7 DG LINE C7 NO CONNECTION
A8 NO CONNECTION B8 NO CONNECTION C8 NO CONNECTION
A9 NO CONNECTION B9 CT S1 OF ANY PHAE C9 NO CONNECTION
A10 NO CONNECTION B10 CT S2 OF ANY PHAE C10 NO CONNECTION
A11 NO CONNECTION C11 NO CONNECTION
A12 NO CONNECTION C12 NO CONNECTION
NOTE:- IN CASE OF GENSET STOP LLOP SENSOR WILL BE CONNECT WITH THE GENERATOR
BODY OR BATTERRY NEGATIVE OR IF GENERATOR IN RUNING CONDITION THEN
LLOP SENSEOR WILL BE OPEN WITH THE GENERATOR BODY
NOTE:- IN CASE OF WATER TEMP HIGH THEN WT SENSOR WILL BE CONNECT WITH THE
GENERATOT BODY OR BATTERRY NEGATIVE ANOTHER ALWAYS OPEN WITH THE
GENERATOR BODY OR BATTERY NEGATIVE
