6000 Series Control System

Technical Manual
Document: MAN-6000 Series
Data: 04/99
Part No. 276-947

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 TABLE OF CONTENTS
1. SYSTEM OVERVIEW........................................................................................................................................................................................... 1
1.1. Scope of this Document ............................................................................................................................................................................. 1
1.2. General Description ................................................................................................................................................................................... 1
1.3. Information Displays .................................................................................................................................................................................. 1
2. FUNCTIONAL DESCRIPTION 6000 SERIES CONTROL SYSTEMS................................................................................................................... 3
2.1 System Overview....................................................................................................................................................................................... 3
2.2 Generating set Parameter Displays ........................................................................................................................................................... 3
2.3 Control Features ........................................................................................................................................................................................ 3
2.4 Control Functions....................................................................................................................................................................................... 4
2.5. Protective Features.................................................................................................................................................................................... 5
2.6 Standard Auxilliary Equipment ................................................................................................................................................................... 5
2.7 Standard Options....................................................................................................................................................................................... 5
2.8. Communications Options........................................................................................................................................................................... 6
2.9 Hardware ................................................................................................................................................................................................... 6
3. CONFIGURATION - OUTLINE OF SETPOINTS .................................................................................................................................................. 9
3.1 Configuration Menu ................................................................................................................................................................................... 9
3.2 Shutdowns, Alarms .................................................................................................................................................................................. 10
3.3 Engine Control ......................................................................................................................................................................................... 13
3.4 Synchroscope.......................................................................................................................................................................................... 13
3.5 Real Load Control.................................................................................................................................................................................... 14
3.6 Reactive Load Control ............................................................................................................................................................................. 15
3.7 Process Control ....................................................................................................................................................................................... 16
3.8 Calibration ............................................................................................................................................................................................... 16

4.0 6100 - SINGLE GENERATING SET, AUTOMATIC MAINS FAILURE................................................................................................................ 18

4.1 6200 - MULTIPLE GENERATING SET, NO PARALLEL.................................................................................................................................... 19
4.1 Functional Description ............................................................................................................................................................................. 19
4.2. Prime Power Variant - Normal Switch Positions ....................................................................................................................................... 19
4.3. AMF Variant - Normal Switch Positions.................................................................................................................................................... 20
5. 6300 - AUTOMATIC SYNCHRONISING OF ONE GENERATING SET WITH MAINS ........................................................................................ 21
5.1 Functional Description ............................................................................................................................................................................. 21
5.2. Base Load Operation ............................................................................................................................................................................... 21
5.3. Base Load Variant - Normal Switch Positions .......................................................................................................................................... 21
5.4. Peak Shaving Operation .......................................................................................................................................................................... 22
5.5. Peak Shaving Variant - Normal Switch Positions ..................................................................................................................................... 22
5.6. Soft Transfer Variant - Normal operation:................................................................................................................................................. 23
5.7. Soft Transfer Variant - Normal Switch Positions....................................................................................................................................... 23
6. 6400 - AUTOMATIC SYNCHRONISING OF MULTIPLE GENERATING SETS WITH MAINS............................................................................. 24
6.1. Functional Description ............................................................................................................................................................................. 24
6.2. Base Load Operation ............................................................................................................................................................................... 24
6.3. Base Load Variant - Normal Switch Positions .......................................................................................................................................... 24
6.4 Peak Shaving Operation .......................................................................................................................................................................... 25
6.5 Peak Shaving Variant - Normal Switch Positions ..................................................................................................................................... 25
6.6 Soft Transfer Variant - Normal operation:................................................................................................................................................. 26
6.7 Soft Transfer Variant - Normal Switch Positions....................................................................................................................................... 26
7. ALARM / EVENT INDICATION AND LOGGING ................................................................................................................................................ 27
8. REMOTE CONTROL AND MONITORING VIA A PC: ........................................................................................................................................ 27
8.1 System Outline ......................................................................................................................................................................................... 28
8.2 Functional Description............................................................................................................................................................................... 28
8.3 Hardware Specifications............................................................................................................................................................................ 28
8.4 Equipment Supplied With Each Option: .................................................................................................................................................... 29
9. INITIAL STARTUP AND COMMISSIONING....................................................................................................................................................... 29
9.1 Test Procedure for Single Generating set Systems. .................................................................................................................................. 29
10. TROUBLESHOOTING........................................................................................................................................................................................ 32
10.1 Control Hardware and I/O ......................................................................................................................................................................... 32
10.2 Engine Control / Sensing Parameters ....................................................................................................................................................... 32
10.3 Synchronisation ........................................................................................................................................................................................ 33
10.4 Breaker Close / Open Control ................................................................................................................................................................... 33
10.5 Real Load Control ..................................................................................................................................................................................... 34
10.6 Reactive Load Control............................................................................................................................................................................... 34
10.7 Sequencing............................................................................................................................................................................................... 35
10.8 Mains / Bus Sensing ................................................................................................................................................................................. 35
10.9 Communications ....................................................................................................................................................................................... 35
11. DEFINITION OF TERMS .................................................................................................................................................................................... 36

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1. System Overview

1.1. Scope of this Document

This document is intended for use by any suitably qualified
person wishing to obtain technical information regarding the
configuration and setup of any of FG Wilson’s range of 6000
series control systems. It may also be used reference
document for those in the Sales, Engineering and Product
Support departments within FG Wilson. The information
contained herein is sufficiently detailed as to give the reader
insight into the operating modes of the 6000 Series Control
System and is designed to replace the Woodward GCP-1
manual for any of the FG Wilson range.
1.2. General Description
The 6000 Series Control System employs the 6000 Controller
as its core in addition to some ancillary components to realise
the range of 6000 Series Control Panels offered. Depending
on the requirements of the installation, the 6000 Series
Control System may be configured to operate in one of
several modes: 6100, 6200 or 6300. It may also be
configured to operate in the 6400 mode in conjunction with an
external master control section.
The control panel provides a means of starting and stopping
the generating set, monitoring its operation and output, and Figure 1: Diagram of Typical Control Panels
automatically shutting down the set in the event of a critical 10. “STATUS PAD”:
condition arising such as low oil pressure or high engine
coolant temperature. A pad to move cursor into the status screen.
11. VOLTS RAISE / LOWER SWITCH:
Figure 1 shows typical diagrams of the 6000 Series Control
Panel. Addition of optional equipment will add items to the A switch to manually control the generator voltage
panel so the panel fitted on the generating set may be slightly (optional in 6100 Mode).
different from the one shown. The following descriptions 12. SPEED RAISE / LOWER SWITCH:
explain the function of each item on both the panel and This switch manually controls the engine speed (optional
controller and each display screen menu on the panels: in 6100 Mode).
1. ALARM LAMP: 13. EMERGENCY STOP PUSHBUTTON:
Fault lamp that illuminates to indicate that the protective A red lock-down pushbutton that immediately shuts
circuitry has sensed a fault condition. The lamp flashes down the generating set and will inhibit start until the
on an ALARM condition and lights continuously on a pushbutton has been released by turning it clockwise.
SHUTDOWN condition. The specific nature of the fault
is detailed in the ALARM / EVENT LOG menu on the 14. CONTROL SWITCH:
STATUS screen. A four position switch that provides a means of
2. ALARM RESET: controlling the generating set mode and function.
By pressing this pad the audible alarm is reset. Specific Position "1" - Off
faults are reset by pressing the ALARM RESET pad Generating set is stopped and automatic starting is
when in the ALARM / EVENT LOG menu on the disabled.
STATUS screen. Position "2" - Auto
3. ESC: Press this pad to exit from any menu. This is the normal position for automatic start up.
4. COMMIT: Position “3” - Test
Depending on exact configuration the generating set
Use this pad to enter any menu or amended settings starts and runs off load.
(subject to security clearance).
Position “4” - Run
5. “UP PAD”:
Depending on exact configuration the generating set
A pad to step upwards through the menu items or to starts and runs on load.
increase numerical values of parameters (subject to
15. AUDIBLE ALARM:
security clearance).
Buzzer that sounds on sensing of a fault condition
6. “DOWN PAD”:
depending on fault handling description.
A pad to step downwards through the menu items or to
16. BREAKER / CONTACTOR CLOSED:
decrease numerical values of parameters (subject to
security clearance). Light to indicate generator breaker / contactor closed.
7. “LEFT PAD”: 1.3. Information Displays
A pad to move cursor to the left on numerical
The 6000 Series Control Panel has two 4 line alphanumeric
parameters (subject to security clearance).
LCD displays. The lines of information displayed on these
8. “RIGHT PAD”: screens is split into two sections. All four lines of the upper
A pad to move cursor to the right on numerical display and the top two lines of the lower display make up the
parameters (subject to security clearance). first section, outlined on the front panel in blue. The bottom
two lines of the lower display make up the second section,
9. “TUNEABLE PAD”: outlined on the front panel in white. The white section is the
A pad to move cursor into the tuneable screen. tunables section where all tuning of setpoints is carried out.
The blue section is used to display all status information.
All information on the status of the generating set is
subgrouped into the various display screens listed below:

1
• Control Overview - 3 x Phase kVar

• Engine Overview - 3 x Phase kVA

• Generator Overview #1 Aφ Bφ Cφ
V 221 220 220
• Generator Phases A 250 248 251
• Synchroscope KW 58.2 58.2 58.2

• Alarm/Event Log Kvar 20.0 19.0 22.0

• I/O Status Kva 60.6 60.6 60.6

• Sequencing - Slip Frequency

Control Overview Screen Layout - Phase Angle Difference

- Unit Number - Voltage Differential

- Engine Status - Mains/Bus PT Selection

- Mains/Bus Volts Status - Dead Bus (Yes/No)

- Generator Output Status - Synchroniser Status

- Mode of Operation - Generator Voltage (A: )

- Control Status - Mains/Bus Voltage (U: )

- List of All Available Units SLIP PHASE VOLTS

**** **** ****
- Network Priorities of All Units on the Network MAINS/BUS: MAINS
UNIT 1 ALARMS 0 DEAD BUS: NO
ENGINE: OFF
MAINS ~ GEN - (Synchroniser status) IN SYNC
AUTO OFF A: 381 U: 380
Alarm/Event Log Screen Layout
UNIT NO: 1 2 3
PRTY: 1 2 3 - Number of Unacknowledged Faults

Engine Overview Screen Layout - Listing of up to Eight Most Recent Faults

- Engine Coolant Temperature UNACK FAULTS : 0

Faults Listing:
- Engine Oil Pressure OVERSPEED
- Battery Voltage 26-9 13:01

- Time LOW OIL PRESSURE

28-9 11:59 1.5
- Date
- Engine RPM I/O Status Screen Layout

- Generating set kW-Hrs - Status of Discrete Inputs 1-12 (‘*’ Denotes Active I/P)
- Generating set Run Time - Status of Discrete Output 1-12 (‘*’ Denotes Active O/P)
H2O OIL BATT - Volts Bias Output
67C 4.0B 27.9V
TIME DATE RPM - Speed Bias Output
12:00 26 09 1500
DI: 1 2 3 4 5 6 7 8 9 0 1 2
* * *
KW-HRS RUN TIME
DO: 1 2 3 4 5 6 7 8 9 0 1 2
831 25
* * *
Generator Overview Screen Layout
Volts Bias : 0
- 3 x Phase/Phase Volts Speed Bias : 0
- 3 x Phase Currents Sequencing Screen Layout
- Generator Power Factor
- List of All Available Units
- Generator kW
- List of All Running Units
- Load Status
- Network Priorities of All Units on the Network
#1 Aφ Bφ Cφ
V 381 379 380 - Unit Number of the Designated Master
A 250 248 251 - Address of Next Unit to be Sequenced On
Hz 50.0 kW 174.6
- Address of Next Unit to be Sequenced Off
PF 1.00 LAGGING
Generator Phases Screen Layout
0.96 (Load Control status) UNIT 1 2 3
- 3 x Phase/Neutral Volts OPER X X
PRTY 1 2 3
- 3 x Phase Currents MASTER UNIT 1
- 3 x Phase kW

2
 Remote Starting capability (method employed depends on
NEXT ON: 3 application)
NEXT OFF: 2 Automatic Mains Failure Control (handled externally in 6100
2. Functional Description 6000 Series Control Systems and 6200 Modes)
Alternator Output / Load Control
2.1 System Overview
Import/Export Control (6300 Mode only)
The 6000 Series control system incorporates a
microprocessor based complete load control and engine Automatic Proportional Real and Reactive Load Sharing (6200
management system and carries out all the functions and 6400 Modes)
necessary for engine control, synchronising, real (kW) control,
Automatic Soft Load Ramping Facility (6200, 6300 and 6400
reactive (kVAR) control and automatic generator sequencing.
Modes)
Protection is provided by the control system against various
fault conditions. VAR or Power Factor Load Control in Mains Parallel Operation
(6300 and 6400 Modes)
To simplify the variations in control capability the most
common operating modes have been designated as follows:- Externally Adjustable VAR/PF Reference
6100 - Automatic mains failure (no paralleling). Externally Adjustable Baseload/Process reference
6200 - Automatic synchronising of multiple generating sets (up Soft Load Ramping
to 8 sets).
Soft load Transfer and Re-transfer Control (6300 and 6400
6300 - Automatic synchronising of one generating set with Modes)
mains (baseload, peak lopping and soft transfer).
Manual Voltage Control Facility (depends on configuration)
6400 - Automatic synchronising of multiple generating sets (up
to eight) with the mains (baseload and peak lopping). Manual Frequency Control Capability (depends on
configuration)
2.2 Generating Set Parameter Displays
Synchronising
AC Voltage Phase/Phase and Phase/Neutral
Automatic Phase Match Synchronisation
AC Phase Current
3-Mode operation (Run, Permissive and Check)
Output Frequency
Automatic Voltage Matching
Power Factor (Cos Phi)
Dead Bus Closing
Total and Per Phase kW
Synch Timer
Per Phase kVAr
Reclose Attempt Timer
Total and Per Phase kVA
Manual Synchronisation Capability (depends on configuration)
Total kWh to Date
Mains Sensing
% Voltage Difference between Bus and Generator (Single
Phase/Neutral) Over / Under Voltage

Bus/Generator Phase Angle Difference Over / Under Frequency

Bus/Generator Frequency Slip Load Surge Detection
Generator Run Time Programmable Loss of Mains Detection
Engine Coolant Temperature Loss of Mains Action Delay Timer
Engine Lube Oil Pressure Programmable Mains Stable Delay
DC Voltage Sequencing (6200 and 6400 Modes)
Single Phase/Neutral AC Bus Voltage Each unit in the system has an assigned priority
Generator AC Voltage within limits indication Master (Highest Priority Unit) sequences units on / off line as
Bus AC Voltage within limits indication required

2.3 Control Features Higher priority units are sequenced on in order of priority;
sequenced off in reverse of priority
Engine Control
‘Max System Load’ and ‘Min System Load’ setpoints
OFF/AUTO/TEST/RUN Control Switch determine percentage system load at which units are
sequenced on or off line
Emergency Stop Pushbutton (Latching)
Programmable sequence on and off delays
Multiple Attempt Crank Timer
Separate programmable time delay for overload (> 100%)
Multiple Crank Repeat Setpoint system load levels
Crank Repeat Timer
Crank Fail Alarm/Shutdown
Crank Cutout (RPM based)
Programmable Pre-Glow Timer
Automatic Cooldown Timer

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2.4 Control Functions
Engine Cranking
The GCP-1 Control is designed to automatically control the
cranking functions of the engine generator set. In order to
safely control engine cranking the GCP-1 uses the following
setpoints, as found in the Engine Control tuning menu of the
software:
− Preglow Time
− Crank Time
− Crank Cutout
− Crank Delay
− Crank Repeats
Starting Sequence:
Upon receiving a start command the following events occur:
1. The Preglow Output Energizes for the given preglow
time delay, and remains energized through the crank
cycle.
2. After the preglow time expires, the Fuel Solenoid output
energizes.
3. 200 ms after the Fuel Solenoid output energizes, the
Crank output energizes.
At this point, the engine should be cranking at a certain RPM,
and receiving fuel. Typically a start would occur in these
conditions. To check if a start does occur, the GCP-1 monitors
the magnetic pickup from the engine. If the magnetic pickup
input indicates that the engine is operating above the Crank
Cutout speed, the GCP-1 will remove the Crank and Preglow
outputs, leaving the fuel solenoid energized. The engine state
in the control overview menu changes from “OFF” to “RUN”.
If for some reason the engine does not reach the crank cutout
RPM level, the GCP-1 will crank the engine for the Crank
Time. If the engine fails to rise above the crank cutout level in
this time, the GCP-1 will remove the Crank output signal, wait
for the Crank Delay, and if allowed by the number of Crank
Repeats, will crank the engine again. This sequence will
continue until the number of crank repeats is depleted, or until
the engine speed rises above the crank cutout RPM setting,
whichever comes first. If the number of crank repeats is
depleted, the GCP-1 will activate the Crank Fail Alarm Output
based on this Alarm setpoint’s configuration.
NOTE:
• The preglow output may stay energized between crank
attempts if the preglow time is greater than the sum of the
Crank Time and Crank Delay timers.
WARNING:
! Set Crank Repeats to zero when starting the engine
for the first time with the GCP-1. This will prevent
starter and ring gear damage to the engine if the MPU
input to the control should be faulty. Monitor Engine
Overview Status menu on the first start and confirm
the RPM readout during cranking. After a successful
start is made, the crank repeats may be set to the
appropriate value for the application.
4
Generator Voltage Control
The GCP-1 has the ability to control the voltage of the
generator set. This ability is used to control four separate
operations which require generator voltage adjustment :
1. Manual voltage adjustment
2. Voltage Matching during Synchronization across the
generator or mains breaker Reactive load sharing between
multiple units on an isolated bus
3. Reactive load control while in parallel with the mains.
The generator voltage, or reactive load (depending on the
operation) is adjusted by injecting a voltage bias signal to the
Automatic Voltage Regulator. The GCP-1 can be set for +/- 1
VDC, +/- 3 VDC, and +/- 9VDC outputs. The span of the
output is selected by a dip switch located on the back of the
GCP-1, as SW-2, which is near the J5 connector. Here is a
table showing the dip switch settings, and resulting voltage
bias output ranges for those settings:
Dip Switches Voltage Bias Output Range
ON
SW2-5 +/- 1 VDC
SW2-4, SW2-1 +/- 3 VDC
SW2-4, SW2-3 , +/- 9 VDC
SW2-2
Select the proper voltage range input as recommended by the
AVR manufacturer.
Generator Voltage can be manually controlled from the
Voltage Raise and Voltage Lower Discrete inputs to the GCP-
1. The rate of change for manual voltage adjustment is set in
the Reactive Load Control tuning menu, at the Voltage Ramp
Time setpoint. The voltage ramp time is the amount of time it
will take for the GCP-1 to send a 0 to 100%, or 0 to -100%
voltage bias signal to the AVR.
When operating in the TEST mode, manual voltage
adjustment is only allowed through the voltage raise and lower
inputs. This allows testing of the Voltage Bias output, and
generator voltage levels prior to operation with load on the
generator.
When operating in Isoch mode, the GCP-1 does not allow
manual adjustment of the voltage, unless the Load Control
setpoint in the Configuration tuning menu is set for “Droop”, or
the VAR/PF Control Setpoint in the Reactive Load Control
tuning menu is set to “Disabled”. Using either of these settings
implies that a manual voltage control will be used, and no
automatic reactive load control functions are active.
NOTE:
• It is highly recommended that the automatic reactive load
control in the GCP-1 be used for proper power
conditioning throughout the generator(s) load range. This
is achieved by setting the Load Control setpoint in the
Configuration tuning menu to Normal, or Soft Transfer
(depending on the application), and the VAR/PF Control
setpoint in the Reactive Load Control tuning menu to VAR
or PF control (depending on the application). For more
details on these functions see the Real Load Control and
Reactive Load Control sections of this manual.
The percent level of the voltage bias output can be monitored
in the I/O Display status screen of the GCP-1. This is a useful
point to monitor during initial start of the unit. By issuing
Voltage Raise and Lower inputs to the control while operating
in the Test Mode, confirmation of proper generator voltage
levels at various voltage bias points can easily be made. Battery Overvoltage Alarm
Typically the generator voltage should change no more than
Battery Undervoltage Alarm
+/- 10% for a +/- 100% voltage bias output from the GCP-1.
Alternator Protection
All other modes of generator set operation rely upon the
Reverse Power Shutdown
Reactive Load Control functions of the GCP-1. See the
information in the “Reactive Load Control” section of the Per-Phase Overvoltage Shutdown
manual for more details on voltage and reactive load control.
Per-Phase Undervoltage Shutdown
Generator Real Load Control Overfrequency Shutdown
The GCP-1 Control has four core modes of generator load Underfrequency Shutdown/Alarm
control operation. These four modes are:
Alternator Loss of Excitation Alarm
− Droop Load Surge Detection (while in Mains Parallel)
− Isochronous Load Sharing System Protection / Alarms
− Base Load Fail to Synchronise Alarm
− Process Control Mains Bus Overvoltage Alarm (Single Phase/Neutral)
The specific mode of generator control that the unit is in at any Mains Bus Undervoltage Alarm (Single Phase/Neutral)
given time can be monitored on the Control Overview Menu.
Mains Bus Overfrequency Alarm (Single Phase/Neutral)
A detailed description of each of these load control modes, Mains Bus Underfrequency Alarm (Single Phase/Neutral)
and the various operating states that will put the GCP-1 into
each respective load control operation can be found in section Up to 3 Spare Fault Channels
3.5 of this manual. 2.6 Standard Auxilliary Equipment

Generator Reactive Load Control PBC5: 5A Battery Charger (fitted to all 6000 series systems)

When a small generator is paralleled with a Mains, the 2.7 Standard Options
synchronizer voltage matching function adjusts the generator PBC5: 5A Battery Charger (Standard on all Systems)
voltage to match that of the Mains. Voltage variations that may
occur in the Mains system after paralleling can cause large PSB3: 5A Battery Charger With Boost
changes in reactive current in the generator. The VAR/Power PBL5: 5A Battery Charger Low Voltage (Standard on all low
Factor Control provides closed loop control of either VARs or voltage Systems)
power factor when operating in parallel with another power
WH: Water Heater Contactor
system when that system can accept the reactive load.
WHL: Water Heater Contactor Low Voltage
Voltage adjustment, however, can only affect reactive power
when another system is available to accept the reactive load. FP2: DC Fuel Pump Controls
So the VAR/Power Factor control functions are automatically FP3: AC Fuel Pump Controls
switched to Power Factor sharing when either single or
PML1: Oil Temperature Gauge
multiple units are operating in isochronous load sharing mode
on an isolated bus. PPE1: Earth Leakage (not available on 6200)

The 6000 series controller is capable of operating in 3 modes PPE2: Earth Fault
of reactive load control:- WS1: Low Coolant Level (Standard on CV12 / Dorman)
− VAr Control FS1: Low Fuel Level Shutdown
− Power Factor Control FS2: Low Fuel Level Alarm
− VAr Sharing
LS1: High Lube Oil Temp
The Reactive Load Control function may also be disabled if
desired. This mode is used as standard in 6100 and 6200 Crank Attempt Counter
systems. PSB: Emergency Stop Button With Security Key
A more detailed description of each of the above operating PAT1: Terminals For Customer Supplied Remote Emergency
modes can be found in section 3.5 of this manual. Stop
PAC1: Set of Volt Free Contacts For Common Alarm
2.5. Protective Features
PRM1: Electronic Mains Sensing Unit (Phase Failure Unit)
Engine Protection
PSB2: Canopy Mounted Emergency Stop
High Coolant Temperature Pre-Alarm
AH1: Anti-Condensation Heater With Control Panel Mounted
High Coolant Temperature Shutdown
Auto control System and Contactor
Low Oil Pressure Pre-Alarm
FV1: DC Tank Base Mounted Solenoid Valve (For Use With
Low Oil Pressure Shutdown FS3 or FS4)

Overspeed Shutdown FS3: 2 x Tank Mounted Fuel Level Switches (High and Low)
Fail to Start Shutdown
Emergency Stop Operated

5
FS4: 4 x Tank Mounted Fuel Level Switches (High, Extra High,
Low, Extra Low) ID Description
Number
E1: Electronic Governor (Standard on 6200 and 6300
Systems) 1 Mains Breaker / Contactor Close
WC1: Low Coolant Temperature Switch
2 Generator Breaker / Contactor Close
2.8. Communications Options
3 Engine Preglow
PC1: Remote Monitoring (Hardwired)
4 Fuel Control Solenoid
PC2: Remote Monitoring and Control (Hardwired)
TEL1: Remote Monitoring (Dial Up Link) 5 Engine Crank

TEL2: Remote Monitoring and Control (Dial Up Link) 6 Visual Alarm Relay
TEL3: Remote Monitoring and Control With Fault Alert 7 Local Bus PT Connect
Callback (Dial Up Link)
MOD1: Remote Monitoring and Control Utilising a ModBus 8 Mains Bus PT Disconnect
Communications Network
9 Mains Breaker Trip
2.9 Hardware
10 Generator Breaker Trip
Discrete Inputs and Outputs
11 Audible Alarm Relay
The discrete inputs and outputs of the GCP–1 control are
used to interface external commands to specific control The identification numbers associated with the discrete inputs
actions and operations, and to control external devices.
and outputs are used in the I/O status screen of the GCP–1.
The Discrete inputs are designed to be tied back into a switch
common on the GCP–1 when closed. Each switch input will AC Inputs
sink 5 mA of current at 12 VDC when closed.
The GCP–1 receives AC inputs from the generator, bus,
Below is a list of the discrete inputs available to the GCP–1 mains and engine. They are as follows:
control.
Loc. Description Signal Burden
ID Description
J5-19 Generator PT phase A Line AC Voltage
Number
J5-23 Generator PT phase A Neutral AC Voltage
1 Mode Control Input #1 (Auto)
J5-18 Generator PT phase B Line AC Voltage
2 Mode Control Input #2 (Test)
J5-22 Generator PT phase B Neutral AC Voltage
3 Mode Control Input #3 (Run with Load)
J5-17 Generator PT phase C Line AC Voltage
4 Volts Bias Raise
J5-21 Generator PT phase C Neutral AC Voltage
5 Volts Bias Lower
J5-9 Generator CT phase A Current AC Current .067
6 Speed Bias Raise ohms
J5-5 Generator CT phase B Current AC Current .067
7 Speed Bias Lower ohms

8 Generator Circuit Breaker / Contactor J5-1 Generator CT Phase C AC Current .067

Current ohms
Auxiliary
J5-10 Generator CT Neutral AC Current
9 Mains Circuit Breaker / Contactor Auxiliary
J5-20 Mains/Bus PT phase A Line AC Voltage
10 Mode Control Input #4 (Process)
J5-24 Mains/Bus PT phase A AC Voltage
11 High Engine Temperature Shutdown Neutral
Contact J1-2 +Magnetic Pickup AC Freq.

12 Low Oil Pressure Shutdown Contact J1-1 -Magnetic Pickup AC Freq.

13 Emergency Stop Input DC Inputs and Outputs

14 - 16 Spare Fault Channels 1 – 3 Location Description Signal I/O

J5-12 + power supply 9-15 VDC (12V unit) Isolated
Below is a list of the discrete outputs available. All discrete
outputs consist of double-pole relays rated at 10A at 120VAC, J5-8 - power supply 18-32 VDC (24V unit) Input
8A at 277VAC resistive. J5-2 + process signal 4-20 mA or 1-5 VDC 6 Watt
J5-6 - process signal typical
J1-17 + speed bias +/- 3 VDC Isolated
J1-13 - speed bias Output
J5-3 + voltage bias +/- 1, 3, or 9 VDC Isolated
J5-7 - voltage bias Output

6
 Communication Ports
Switch # Description Normal
2 x serial communications ports are provided on the 6000 series Status
controller (1 x RS-485 and 1 x RS-422). Details of connections
and uses are given below. SW1-1 Not used N/A
SW1-2 Not used N/A
Location Description Signal SW1-3 Not used N/A
SW1-4 Not used N/A
J8-2 - RS-485 communication line Intercontrol comms
SW1-5 Oil pressure shunt resistor (100 ohms when OFF
J8-1 + RS-485 communication line Intercontrol comms on)
SW1-6 Oil pressure shunt resistor (100 ohms when OFF
J8-4 + 5VDC Isolated Supply on)
J8-5 - 5VDC Isolated Supply SW1-7 Water temp shunt resistor (100 ohms when ON
on)
J8-3 + RXD RS-422 communication line Remote communications SW1-8 Water temp shunt resistor (100 ohms when ON
on)
J8-6 - RXD RS-422 communication line Remote communications
SW2-1 Voltage bias output scaling (ON for +/- 3VDC, OFF
J8-8 + TXD RS-422 communication line Remote communications OFF for others)
SW2-2 Voltage bias output scaling (ON for +/- 9VDC, OFF
J8-9 - TXD RS-422 communication line Remote communications OFF for others)
SW2-3 Voltage bias output scaling (ON for +/- 9VDC, OFF
OFF for others)
SW2-4 Voltage bias output scaling (OFF for +/- 1VDC, OFF
ON for others)
SW2-5 Voltage bias output scaling (ON for +/- 1VDC, ON
OFF for others)
SW2-6 Not used N/A
SW2-7 Not used N/A
SW2-8 Process input type selection ON
ON = 4-20 mA input, OFF = 1-5 VDC input (4-20
mA)
SW3-1 RS-422 Termination RxD+ ON
(end of
line
units)
SW3-2 RS-422 +5VDC pull-up ON
(end of
line
units)
SW3-3 RS-422 Termination RxD- ON
(end of
line
units)
SW3-4 RS-485 +5 VDC pull-up ON
(end of
line
units)
SW3-5 Not used N/A
SW3-6 Not used N/A
SW3-7 RS-485 Termination - ON
(end of
line
units)
SW3-8 RS-485 Termination + ON
(end of
line
units)

7
Explanation of Dip Switches

J1 J2
EXPLANATION OF
SWITCHES
SW-1
8 water temp shunt resistor (100 ohms) when ON
7 water temp shunt resistor (100 ohms) when ON
6 oil pressure shunt resistor (100 ohms) when ON
5 oil pressure shunt resistor (100 ohms) when ON
4 not used
3 not used
2 not used
1 not used
on off
8
7
CONTRAST
6 ADJ. SW-2
5
4
3
8 process I/E: ON = 4-20 mA @250 ohms; OFF = 1-5 VDC @ 30Kohms
7 not used.
2
1 J5 6 not used. +/- 1 +/- 3 +/- 9
SW-1 5 voltage bias output
4 voltage bias output VDC VDC VDC
scaling
3 voltage
scaling bias output SW2-5 SW2-4 ON SW2-4 ON
2 voltage
scaling bias output ON SW2-1 ON SW2-3 ON
1 voltage
scaling bias output scaling SW2-2 ON

8 RS-485 Termination +
7 RS-485 Termination -
on
8
off 6 not used.
7 5 not used.
6 4 RS-485 +5VDC pull up.
5
4
3 RS-422 Termination RxD -
3 2 RS-422+5VDC pull up.
2 1 RS-422 Termination RxD +
J8 on
8
off
1

7 SW-2
6
5
4
3
2
1

SW-3

Connector Wiring Diagram

Wiring Diagram for GCP-1
Connector Connector Connector
J5 J1 J2

+ 12 - + 17 9
Speed bias output Mains breaker close (DO1) n. o.
12 Vdc or 24 Vdc - 13 18
- 8 n. c.
- 1 27
Shield termination 4 MPU speed input
+ 2 8
+ 20 Generator Breaker Close (DO2) n. o.
Mains/Bus A phase PT +
- 24 5 17
Coolant temperature sensor n. c.
- 6 26
+ 19
Generator A phase PT Oil pressure sensor
- 23
+ 9 7
Engine Preglow (DO3) n. o.
Auto / manual (DI1) 16
+ 18 16
Test engine (DI2) n. c.
Generator B phase PT 25
- 22 10
Run with load (DI3) 34
+ 17 11
Voltage raise (DI4) Fuel Solenoid (DO4) n. o.
Generator C phase PT 12 35
- 21 n. c.
Voltage lower (DI5) 36
Generator A phase CT + 9 24
Speed raise (DI6)
Generator B phase CT + 5 19 6
Speed lower (DI7) Engine Crank (DO5) n. o.
Generator C phase CT + 1 20 15
Generator CB aux (DI8) n. c.
CT Neutral - 10 15 24
Mains CB aux (DI9) 22 31
+ 2 n. o.
Process import/export Process I/E (DI10) Visual Alarm (DO6)
(4-20 mA/1-5 Vdc) - 6 18 32
n. c.
Fault 1(DI11) 14 33
+ 3
Voltage bias output Fault 2 (DI12)
7 23 5
- n. o.
Fault 1(DI11) Local Bus PT Connect (DO7)
8 13
No Connect 11 n. c.
Fault 2 (DI12)
No Connect 13 7 23
Fault 1(DI11) 4 4
No Connect 14 n. o.
Fault 2 (DI12)
3 14
No Connect 15 Mains PT Disconnect (DO8) n. c.
21 22
No Connect 16
1
Mains Breaker Trip (DO9) n. o.
10
n. c.
Connector
J8 3

+ 1 2
Generator Breaker Trip (DO10) n. o.
RS-485 Network
- 2 11
Connector J5 is 24-pin male Trim Trio type n. c.
(male connector on PC board) Shield termination 7 12

+ 3 28
Connector J1 is 24-pin female Trim Trio type RS-422 RxD Audible Alarm (DO11) n. o.
(female connector on PC board) - 6 29
n. c.
+ 8 30
Connector J2 is 36-pin female Trim Trio type RS-422 TxD
(female connector on PC board) - 9 No Connect 19

No Connect 4 No Connect 20
Connector J8 is 9-pin male Trim Trio type
(male connector on PC board) No Connect 5 No Connect 21

8
 Any Values Falling out side of these ranges will appear on the
3. Configuration - Outline of Setpoints screen with a pound sign (#) next to them. This indicates the
value is out of range, and the engine will not operate until the
3.1 Configuration Menu # symbol is cleared by entering the correct values.

Security Code - 4 Levels of Access CT Ratio (numeric : 5)

• Operator: Access to Alarm Log and Network
Priority
• Supervisor: Allows access to Network Address and
Time Set in addition to above access.
• Technician: Allows access to all setpoints except
engine run time and calibration
• Factory: Allows access to all setpoints
Network Address (1 to 8)
Unique Address for Each Unit in the System
Maximum of 8 units on network
Network Priority
Scales sensed CT input for Amperage as seen at generator
Used for Load Sensing Algorithm (KVA,KW,KVAR,PF)
PT Ratio (numeric : 1)
Scales sensed PT input to Voltage Levels as measured at the
Generator
Used in Load Sensing Algorithm (KVA, KW, KVAR, PF)
Used for Voltage Matching
Voltage Input (Wye L-N, Delta L-L)
Set for sensing/transformer used between generator and Gen
Part 6000.

Unique Priority for Each Unit in the System
Lowest Active Priority is considered Master
Maximum of 8 units on network
Sequencing effective from lowest to highest priority
“Set All” Function
When priority is reduced below 1, the value will change to “Set
All”. If the commit key is pressed when this value is on the
display, the display will change to represent all units in auto on
the network, and their priority. The network priority of any unit
can be changed by using the left/right and up/down keys n the
control. Once changes are made, the changes are committed
by pressing the commit key twice.
Defines which calculations will be used for kW, KVA, KVAR,
etc.
Wye (Star) Generator or Transformer Connection
4 Wire - volts measured Line to Neutral
Delta Generator or Transformer Connection
3 Wire - volts measured Line to Line
Voltage Reference (numeric)
Operating Voltage of Generator per Generator Spec.
Used for Var/PF Sharing as the Reference that multiple
generators share reactive load to. This maintains the voltage
reference while in Power Factor Sharing or KVAR Control
mode on an isolated bus.

Number of Poles (numeric) Load Control Mode

Determines Speed/Frequency Relationship Normal: Standard setting for load control and VAR/PF
functions
Used for Speed/Frequency Mismatch Alarm/Shutdown
Soft Transfer: Standard load control and VAR/PF functions,
Number of Teeth (numeric) but unit will issue mains breaker open command while in
process control if process reference is reached, or while in
Determines RPM Scaling
base load and base load reference is reached.
Engine Speed Readouts/Alarms
Droop: Manual Load and Voltage Control used primarily for
System Frequency (50/60 Hz) commissioning

Used as a basis for generator waveform analysis Process Action (direct, indirect)

Defines typical operating frequency of generator Defines action of speed bias when unit is operating in process
control in parallel with the mains.
Rated Speed (numeric) Direct action = Unit increases speed bias (fuel) to increase
process 4- 20 ma input
Synchronous Speed of Generator Set
Indirect action = Unit decreases speed bias (fuel) to increase
Used in Speed Calculation to determine “sample” period for process 4-20 ma input.
MPU input
Circuit Breaker Control (Breaker, Contactor)
Rated kW (numeric)
Defines action of Generator and Mains closure command
Rated kW of Generator
Breaker issues momentary close signal, momentary open
Rated kVA (numeric) signal independently.

Used to determine Rated Current of Generator Contactor issues continuous close signal. Removes this signal
Equation: I=KVA/Rated Voltage to open contactor.

Rated kVAr (numeric)

Breaker Close
Rated KVAR of Unit Normally Open and de-
energised on mains
Typically .6 x Rated KVA
and generator
NOTE:-

• Rated KVA must be less than or equal to the Voltage

Breaker Open
Normally Open and
Reference x CT Ratio Primary. energised on generator
Rated kW must be less than or equal to the Rated KVA
Rated KVAR must be less than or equal to the Rated KVA Normally Closed and
de-energised on mains

9
 Contactor
Close/Open
Normally Open and
de-energised on generator
Normally Closed and
de-energised on mains
Check Mains Breaker (enabled, disabled)
Used to activate checking of mains c.b. aux. input when
enabled
If disabled, unit relies on other units with this setpoint enabled
to broadcast state of mains c.b. aux. contact over network
Operating Mode
Mains Parallel or No Mains Parallel
Mains Parallel will allow the unit to synchronise to the mains,
and carry load while in parallel with the mains as well.
No Parallel will allow the unit to operate with load until the
mains breaker is sensed as being open
All units operating in a load sharing system must be set for the
same parameter, i.e. mains parallel, or no parallel.
Number of Units (single, multiple)
Defines whether unit is part of a multiple unit system or not.
If single unit, there is no auto starting, auto sequencing, load
or pf sharing with other units under any circumstances. Unit
displays “single unit no sequencing” on sequencing screen.
If multiple unit, auto starting, auto sequencing, load and var/pf
sharing are active between all units in multiple. Unit displays
system-sequencing information on sequencing screen.
Auto Sequencing (enabled, disabled)
Enables or Disables Auto Sequencing for that unit
Can be used to disable sequencing for a particular unit in a
sequencing system if needed
RS-422 Protocol (Modbus, Servlink, Upload Setpoints)
Used to select between different types of communication
options as outlined below:
• ModBus
Utilises the industry standard ModBus protocol.
More details on ModBus communications
With the 6000 series system can be found in section xxxx
of this manual.
The controller must be re-booted if this option is selected
to initialise ModBus communications
• Servlink
Utilises the Servlink protocol.
This option is used in conjunction with the PC1, PC2,
TEL1, TEL2 and TEL3 communications options.
The controller must be re-booted if this option is selected
to initialise Servlink communications.
• Upload Setpoints
Used for uploading the stored setpoints from the
controller to a storage file on a PC compatible computer.
This option should not be used by any personnel other
than FGW commissioning personnel who have
undergone the appropriate training.
Modbus ID (numeric)
Used to uniquely identify each controller on a ModBus network
Any changes will not take effect until the controller has been
re-booted
10
Modbus Timeout (seconds)
Maximum time delay allowed between successive polls of the
slave controller by the master.
This should be set to greater then the polling period of the
ModBus master.
If this time is exceeded a link failure error will be logged.
Modbus Reset (True, False)
Used to reset all static ModBus error messages
3.2 Shutdowns, Alarms
Shutdowns and Alarms menu is used to configure the various
safety functions of the Gen Part 6000.
Each alarm setpoint can be set for:
• Disabled: Disables alarm indication and logging.
• Warning: LED on Control Flashes.
• Visual Alarm: LED Flashes, and Visual Alarm relay
energises.
• Audible Alarm: LED Flashes, Visual and Audible
Alarm relays energise.
• Soft Shutdown: LED Turns On, Visual and Audible
Alarm relays energise, Fuel Solenoid relay de-
energises. Unit soft unloads and cycles through cool
down timer when applicable.
• Hard Shutdown: Same as above, but immediately
opens generator breaker and de-energises fuel
solenoid.
The following alarms have ‘special’ functions:
• Mains Voltage High
• Mains Voltage Low
• Mains Frequency High
• Mains Frequency Low
• Load Surge
These alarms cannot be set to ‘Soft Shutdown’ or ‘Hard
Shutdown’ but may be set to the following two extra functions:
• Loss Of Mains
- Triggers an internal Loss of Mains condition
- No alarm indication triggered
• Loss Of Mains With Alarms
- Triggers an internal Loss of Mains condition
- Triggers an audible alarm
Load Surge (numeric %/sec)
Used only in Base Load or Process Control (Mains Parallel
Operations)
Set to trigger at a percent setpoint of total generator load shift
per second while operating in Mains Parallel
Instantaneous Trigger
Load Surge Alarm
Type of alarm triggered on Load Surge event
Can be set for Loss of Mains Detection
Mains Volts High Limit
Maximum mains bus voltage for mains to be considered stable
Mains Volts High Alarm
Type of alarm triggered on Mains Volts High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Volts Low Limit
Minimum mains bus voltage for mains to be considered stable
Mains Volts Low Alarm
Type of alarm triggered on Mains Volts Low event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency High Limit
Minimum mains bus frequency for mains to be considered
stable
Mains Frequency High Alarm
Type of alarm triggered on Mains Frequency High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency Low Limit
Maximum mains bus frequency for mains to be considered
stable
Mains Frequency Low Alarm
Type of Alarm triggered on Mains Frequency Low event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Generator Frequency High Alarm
Type of alarm triggered on a Generator Frequency High event
Generator Frequency Low Limit
Sets minimum allowable generator output frequency
If frequency is below Low Limit, generator is not considered
stable, and is unfit for breaker closure.
The controller will not allow speed biasing which will cause the
generator output frequency to go below this level even if the
alarm is disabled.
Generator Frequency Low Alarm
Type of alarm triggered on a Generator Frequency Low event
Speed / Frequency Mismatch
Compares generator frequency to engine RPM and alarms on
difference
Used to indicate loss of MPU, or Loss of Generator Field
Voltage

Loss of Mains (LOM) Action Delay Overspeed

Sets Time Delay for LOM Action to begin once Loss of Mains Set for overspeed limit of engine
is detected. Typically set for Hard Shutdown for safety
Typically Delay time From LOM to engine start command Typically Set for 10% above Rated Speed of engine
Voltage Range Alarm Overspeed Alarm
Type of alarm triggered once voltage bias signal to AVR Type of alarm triggered on a overspeed event
reaches +/- 100%
Overcurrent Level
Generator Volts High Limit
3 Phase Sensing
Sets maximum allowable generator voltage level
Set for Per Phase Overcurrent
Triggered of any individual phase
Over Current Detection begins when current exceeds rated
If voltage is above High Limit, generator is not considered current as determined by Voltage Reference and Rated KVA
stable, and is unfit for breaker closure. values in Configuration menu: (KVA/Voltage Ref)/3.
The controller will not allow voltage biasing which will cause Uses Inverse Time Function as basis for overcurrent
the generator voltage to go above this level even if the alarm detection. This allows different levels of overcurrent based on
is disabled. time span.
Generator Volts High Alarm Per Phase Overcurrent Inverse Time Function
amps
Type of alarm triggered on a Generator Volts High event Overcurrent Trip Zone
Generator Volts Low Limit overcurrent level

Sets minimum allowable generator voltage level

Triggered of any individual phase 100% rated current

If voltage is below Low Limit, generator is not considered overcurrent time

stable, and is unfit for breaker closure. delay
The controller will not allow voltage biasing which will cause
the generator voltage to go below this level even if the alarm is
Over Current Level
disabled.
Generator Volts Low Alarm High Current, Short Duration

Type of alarm triggered on a Generator Volts Low event amps

Overcurrent Trip Zone
Voltage Alarm Delay overcurrent level
Delay between detecting a Generator Voltage High or Low
condition and activating the configured alarm
Generator Frequency High Limit time
overcurrent
Sets maximum allowable generator output frequency delay

If frequency is above High Limit, generator is not considered

stable, and is unfit for breaker closure. Overcurrent Level
The controller will not allow speed biasing which will cause the
generator output frequency to go above this level even if the Notice area of over current is the same
alarm is disabled.

11

amps Overcurrent Trip Zone
overcurrent level
overcurrent
delay
Overcurrent Delay
Setpoint used in conjunction with the Overcurrent Level
setpoint to determine tripping time on an overcurrent condition
Overcurrent Alarm
Type of alarm triggered on an Overcurrent event
Reverse Power
Reverse Power Condition begins when sensed kW on
generator goes negative. Reverse Power
Trip levels depend upon amplitude and duration of reverse
power condition.
Reverse Power Delay
Reverse Power also uses an inverse time function.
Reverse Power
Minimum Reverse Power
Minimum reverse power level which can trigger a reverse
power alarm. Reverse power levels below this setpoint will
never cause a reverse power alarm condition, regardless of
duration. See diagram above.
Reverse Power Alarm
Type of alarm triggered on a reverse power event.
Loss of Excitation (LOE)
Set as a percentage of total KVAR load on the generator that
can be applied as a block reactive load to the unit. If control
senses changes in KVAR loads instantly applied greater than
this value the LOE alarm triggers.
Used to indicate loss of field excitation to the generator
Loss of Excitation (LOE) Alarm
Type of alarm triggered on an LOE event.
Battery Voltage High Limit
Maximum permissible DC voltage supply to 6000 control
Can be used to detect faulty charging circuit
Battery Voltage High Alarm
Type of alarm triggered on a Battery Voltage High event
Battery Voltage Low Limit
Minimum permissible DC voltage supply to 6000 control
Used to detect weak battery/failed charger
Automatically Disabled during engine cranking
Battery Voltage Low Alarm
Type of alarm triggered on a Battery Voltage Low event
High Oil Pressure Limit
Sets the trigger point for the High Oil Pressure Alarm
Uses Engine mounted pressure sensor
Active when generator is stable
Sensed in Bar
High Oil Pressure Alarm
Type of alarm triggered on a High Oil Pressure event
time Approaching Low Oil Pressure
Sets the trigger point for the Approaching Low Oil Pressure
pre-alarm
Uses Engine mounted pressure sensor
Active when generator is stable
Sensed in Bar
Approaching Low Oil Pressure Alarm
Type of alarm triggered on an Approaching Low Oil Pressure
event
Approaching High H2O Temp
Sets the trigger point for the Approaching High H2O Temp pre-
alarm
Uses Engine mounted temperature sensor
Active when generator is stable
Sensed in ºC
Approaching High H2O Temp Alarm
Type of alarm triggered on an Approaching High H2O Temp
event
Low H2O Temperature
Sets the trigger point for the Low H2O Temp alarm
Uses Engine mounted temperature sensor
Active when generator is stable
Sensed in ºC
Low H2O Temperature Alarm
Type of alarm triggered on an Approaching High H2O Temp
event
High Engine Temperature
Sets the type of alarm activated upon the application of the
external High Engine Temperature volt-free signal.
Normally set to ‘Soft Shutdown’
Set to ‘Hard Shutdown if combined with an external Low
Coolant Level sensor
Only activated 15 seconds after the engine has reached the
crank cut-out speed
High Engine Temperature Timer
Additional delay between the application of the external High
Engine Temperature volt-free signal and the activation of the
configured alarm type
Not active when engine not running
Low Oil Pressure
Sets the type of alarm activated upon the application of the
external Low Oil Pressure volt-free signal.
12
Normally set to ‘Hard Shutdown’ Crank Cut-out

Only activated 15 seconds after the engine has reached the Engine RPM level where crank command is cancelled
crank cut-out speed
Crank Delay
Low Oil Pressure Timer Time between engine crank attempts
Additional delay between the application of the external High
Crank Repeats
Engine Temperature volt-free signal and the activation of the
configured alarm type Number of times the 6000 control will attempt to re-start the
engine. The number of actual cranking attempts = Crank
Not active when engine not running Repeats +1
Emergency Stop Crank Fail
Sets the type of alarm activated upon the application of the Type of alarm triggered once the generating set has
external Emergency Stop volt-free signal. completed its full crank sequence and the engine has not yet
Normally set to ‘Hard Shutdown’ started.

Emergency Stop Timer Cool down Time

Delay between the application of the external High Engine Time allowed for cool down after coming off-line during a
Temperature volt-free signal and the activation of the normal stop sequence
configured alarm type Only activated if the generating set load has exceeded the
Always activated Cool down Limit

Spare Fault #1 Cool down Limit

Sets the type of alarm activated upon the application of the kVA setpoint at which, when exceeded will cause the engine
external Spare Fault #1 volt-free signal. will execute a cool down during a stop sequence

Normally set to ‘Disabled’ Engine Run Time

Hours of run time on the engine
Spare Fault #1 Timer
Delay between the application of the external volt-free signal Increments in hours
and the activation of the configured alarm type Retained in EE memory - retains value after power loss
Always activated May be re-set or pre-programmed by anyone with level 3
Spare Fault #2 security access

Sets the type of alarm activated upon the application of the MW Hours
external Spare Fault #2 volt-free signal. MW hours supplied by the generating set
Normally set to ‘Disabled’ increments in 0.1 MW hour steps
Spare Fault #2 Timer Retained in EE memory
Delay between the application of the external volt-free signal
May be re-set or pre-programmed by anyone with level 3
and the activation of the configured alarm type
security access
Always activated
3.4 Synchroscope
Spare Fault #3 Synchroniser Mode
Sets the type of alarm activated upon the application of the • Permissive
external Spare Fault #3 volt-free signal.
- Acts as a synch check device.
Normally set to ‘Disabled’ - 6000 will not issue speed or voltage bias commands,
but if synchronisation conditions are within spec
Spare Fault #3 Timer
(phase and voltage), control will issue a breaker
Delay between the application of the external volt-free signal close command.
and the activation of the configured alarm type • Check
Always activated - Used for checking synchroniser prior to
3.3 Engine Control commissioning
- 6000 control actively synchronises generator by
Preglow Time issuing speed and voltage bias commands, but does
not issue breaker closure command
Time of preglow allowed prior to engine crank cycle
• Run
Maintained through engine cranking
- Normal operating mode
Resets after every crank attempt
- Actively synchronises and issues breaker closure
Crank Time command
- Control MUST be in RUN to operate as a dead bus-
Maximum allowable time for engine cranking closing device.

13
 - In multiple unit systems 6000 control MUST have
AUTO input active to enable dead bus closing
Synchroniser Gain
Sets Gain of synchroniser speed bias output
Synchroniser Stability
Sets Stability of synchroniser speed bias output
Both Gain and Stability are used to tune the synchroniser
dynamic response.
Voltage Matching
Enables/Disables Voltage Matching feature of 6000 control
Enables Voltage Window Setpoint
Voltage Window
Overall percentage of error allowed between generator and
bus, or generator and mains
6000 control will not issue a breaker closure if error is greater
than voltage window
Maximum Phase Window
Maximum allowable phase angle deviation from phase
matched condition.
6000 Control will not issue breaker closure if phase angle
between generator and bus, or generator and mains exceeds
this window
Dwell Time
The period of time that the generator must be within the Max.
Phase Window for before the 6000 control will issue a breaker
closure
Longer dwell times will give typically give better stability after
the breaker closes
Shorter dwell times reduce amount of time required to
synchronise unit
C.B. Hold Time
Time in Seconds that Breaker/Contactor Close output is held
after breaker close command is issued
Close Attempts
Number of Close Attempts allowed while synchronising
Close attempt incremented if breaker does not send back
continuous CB aux. signal to 6000.
Reclose Delay
Time in Seconds before 6000 control attempts re-
synchronisation after failed closure attempt
Synch Reclose Alarm
Alarm setpoint if number of close attempts is depleted
Synch Timeout
Sets time allowed for synchronisation in seconds
Begins timing when synchroniser activates
Active for all gen and mains breaker open and close
commands from 6000 control
A setting of zero (0) seconds disables synch. time-out - infinite
synch time allowed
14
Synch Timeout Alarm
Sets alarm mode if synch time-out is exceeded
Dead Bus Closure
Enables/Disables Dead Bus Closing Feature
Only active in multiple unit systems. Dead bus closing is
always active in single unit configuration.
Unit must be within voltage and frequency high/low limits to be
considered for dead bus closure.
Dead Bus Closure uses Token Passing Scheme to assure
that only one unit in a networked system will close onto the
dead bus at any given time.
Multiple unit systems must have Auto switch input to allow
dead bus closing between networked units
3.5 Real Load Control
Load Control Gain
Sets gain response of load control
Active in load ramping and base load operations
Load Share Gain
Sets gain response of proportional load sharing
Active in load sharing operations
Load Stability
Sets stability response of load control
Active in load ramping and baseload operations
Load Derivative
Sets derivative response of load control
Active in load ramping and baseload operations
Load Control Filter
Low pass filter used to attenuate higher frequency transients
for better stability
Active in proportional load sharing, load ramping and baseload
control modes
Baseload
Load Level Generator will automatically ramp to when
operating in Base Load
Unload Trip
Load Level where Generator Breaker/Contactor open
command will be issued when 6000 control is off loading
generator set
Load Droop
Percentage of kW droop used when 6000 control is operating
in a droop mode
Load Time
Time in Seconds for generator to load from unload trip level to
base load level. This rate is applied during any automatic
loading function, including ramping to load sharing
Unload Time
Time in Seconds for generator to unload from base load level
to unload trip level. This ramp rate is applied during any
automatic unload functions, including ramping from load
sharing
Raise Load Rate
Percent Load per Second ramp rate used when the raise load
contact input is used during base load operation.
Lower Load Rate
Percent per Second Ramp Rate used when the load lower
input is active in base load control operation
Fast Xfer Delay
Time required for a transition in switching from Mains to
Generator operations, and from Generator to Mains
operations. This includes transition times between bus and
mains sensing.
Mains Stable Delay
Period of time required for the mains to be declared stable
before transition from generator(s) to mains.
Generator Stable Delay
Period of time generator must be declared stable before
transition from Mains to Generator, as well as dead bus
closing
Load High Limit
Maximum allowed load while operating in Base load or
Process control modes
Prevents overload of unit
High Limit Alarm
Sets alarm mode when unit is at or above High Load Limit
Active during all load control operations
Load Low Limit
Minimum allowed load while operating in Base load or Process
control modes
Prevents reverse current of unit
Low Limit Alarm
Sets Alarm Mode when unit is at or below Low Load Limit
Active during all load control operations
Maximum Generator Load
% system load on all units with gen breakers closed, and on
the same network, in Auto,and in Load Sharing or Process
control modes, at which active master unit will begin timing to
sequence next unit on line.
Next Generating set Delay
Period of time that will pass before master auto sequences an
additional generator on line.
Delay is effective only in active master unit
Rated Load Delay
Delay when system load exceeds 100%, before master starts
next generating set in sequence
Maximum Start Time
Time allowed by master to see next unit to be sequenced on
line in an “active” condition, i.e. started and ready to load.
15
This is determined by a flag, which indicates the unit is ready
to load, is sent over the network by the unit being sequenced
on by the master.
If master does not detect this flag within the Max. Start Time
allowed, it will go to the next lower priority unit and try starting
it, or if no other units are available, it will retry the start
command on the same unit.
Minimum Generator Load
% of system load at which active master begins timing to
sequence units off line
Master may have to wait until system load is below this level if
unit next in line to be sequenced off will cause the system load
to increase above the Max Gen Load setpoint of the Master.
Reduced Load Delay
Time in seconds which the active master waits before
sequencing units off line.
Delay is effective only on active master unit
Lowest priority units are sequenced off line first
Maximum Stop Time
Time in seconds allowed by master for slave to sequence off
line
Master begins sequencing next lowest priority unit off line if
system load is still above Min. Gen. Load setpoint at the end
of the Max Stop Time Limit.
3.6 Reactive Load Control
VAr / PF Mode
Can be set to one of three modes
• Disabled
- Unit does not PF share, or control PF under any
circumstances
- This setting should be used for all 6100 and 6200
systems
• VAR Control
- Unit PF shares in isolated bus load sharing mode
- Unit controls KVAR in Base Load and Process
Control Modes
• PF Control
- Unit PF shares in isolated bus load sharing mode
- Unit controls PF in Base Load and Process Control
Modes
VAr / PF Gain
Controls Gain Response of unit in Var/PF control mode
NOT active in PF sharing mode
Voltage Ramp Time
Ramp time from 0 to +/-100% voltage bias output
Controls response of units in PF sharing modes
Controls ramp time of voltage during synchronisation
Controls ramp time of voltage during manual voltage adjust
VAr / PF Share Gain
Not Active in any modes (reserved for future use)
VAr / PF Stability
Controls Stability Response of unit in Var/PF control mode
NOT active in PF sharing mode
kVAr Reference
When KVAR control mode is selected, this references the
amount of KVAR the generator will produce while in Base
Load or Process control modes
Can be set for generate or absorb levels of KVAR
KVAR levels limited by Rated KVAR of unit
PF Reference
PF level that will be maintained by the generator while in Base
Load or Process control modes.
Can be set for leading or lagging power factor
Scaled from 0 (unity) to - .5 (.5 leading) to +.5 (.5 lagging)
PF Deadband
+/- deadband around PF reference point
set in PF
Active in PF and PF sharing modes
Can be used to stabilise units at low loads if needed
3.7 Process Control
Process Master Uses Process PID to control
Gain, Stability, Derivative, Filter, Droop
Slaves to the Process Master use Load Control PID Values to
track master system load reference
Load Gain, Stability, Derivative, and Filter
Process Gain
Sets system gain response while in process control
Effective at active master unit only. Slaves rely on Load
Control dynamic settings to control response to master load
reference
Should be set with maximum number of units operating in
process control mode
Process Stability
Sets system stability response while in process control
Effective at active master unit only. Slaves rely on Load
Control dynamic settings to control response to master load
reference
Should be set with maximum number of units operating in
process control mode
Process Derivative
Sets system derivative response while in process control
Effective at active master unit only. Slaves rely on Load
Control dynamic settings to control response to master load
reference
Should be set with maximum number of units operating in
process control mode
16
Process Deadband
+/- deadband around process reference point
Set in mA
Process Droop
Introduces negative feedback on the process reference as the
process input increases
Used to add stability to marginally stable processes
Process Filter
Low Pass Filter attenuates higher frequency transients on
process 4-20 mA input signal
The higher the filter is set, the more active the process control
will be to higher frequency process transients
The lower the filter is set, the less active, and more stable the
process control will be to higher frequency process transients
Process Reference
The reference point, in mA, at which the master will control the
process input.
Also used in Soft Transfer modes to set the level of process at
which the transfer from mains to generator will occur
Raise Rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a raise load contact input
while operating in process control mode
Lower rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a lower load contact input
while operating in process control mode
Process High Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process High Limit Alarm
Sets alarm mode when process High Limit is reached
Process Low Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process Low Limit Alarm
Sets alarm mode when process reference reaches the Low
Limit
Process Low Limit Alarm
Sets alarm mode when Process Low Limit is reached
3.8 Calibration
While each unit will be factory calibrated at Woodward prior to
shipment, there are bound to be some inputs/outputs affected
by external wiring and/or interfaces (relays, transformers, etc.)
that will require calibration at the site during commissioning.
The Calibration Menu allows calibration of all the analogue
inputs to the 6000 control, as well as the speed bias and
voltage bias outputs.
All calibration points in the 6000 control are used to make the
actual value of an input such as generator voltage, read out on
the respective display screen of the 6000 control, the proper Measure actual gen. currents with clamp on ammeter, or
value of the signal being monitored. panel ammeter.

Example: Calibrate phase A CT reading in phase overview.

380VAC measured line to line on the generator should read
CT Phase B Scale
380VAC in the line to line voltage measurement area of the
6000 control “generator overview” menu. Calibrates CT Phase B sensing of 6000 control

Any differences between the measured and actual values can Load generator and monitor gen. currents in phase overview
be corrected using the generator PT calibration points in the menu.
calibration menu.
Measure actual gen. currents with clamp on ammeter, or
Process In Scale panel ammeter.

Actual Input - 4-20 mA, or 1- 5VDC process signal from Calibrate phase B CT reading in phase overview.
external transducer.
CT Phase C Scale
Monitor the Pin (process in) reading in the Load Control
Calibrates CT Phase C sensing of 6000 control
Monitor menu
Load generator and monitor gen. currents in phase overview
Calibrate Process input scale until Pin reads accurately what
menu.
measured process signal is.
Measure actual gen. currents with clamp on ammeter, or
Engine must be in a test or run mode and operating to
panel ammeter.
observe the Pin value in the Load Control Monitor menu
Calibrate phase C CT reading in phase overview.
Speed Bias Offset
If CT polarity is reversed, that phase will read negative kW
Factory calibrated for 0VDC offset on +/- 3 VDC range.
when loaded in the Phase overview menu.
All Woodward Speed controls operate with this bias output, so
If CTs are on the incorrect phases, then KVAR readings in
no calibration should be required to operate with these
phase overview will be off.
controls

Calibration may be required for other manufacturer’s speed Bus PT Scale

controls.
Voltage Bias Offset
Factory set for zero Volts DC.
Dip Switch selectable +/- 1VDC, +/- 3 VDC, +/- 9 VDC range.
Some regulators require a positive voltage bias offset because
they cannot receive a negative voltage bias command.
6000 control will always reset to the voltage bias offset when
off line.
PT Phase A Scale
Calibrates PT phase A voltage input
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
and adjust PT Phase A scale until these values match
measured generator voltage on A phase
PT Phase B Scale
Calibrates PT phase B voltage input
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
and adjust PT Phase B scale until these values match
measured generator voltage on A phase
PT Phase C Scale
Similar to Gen PT scaling, but this scale is for single phase
bus PT input to the 6000 control.
Put 6000 control synchroniser in “check” mode in synchroniser
setup menu.
Start engine in run/load mode to a live bus (either paralleling
to another generating set, or the Mains).
Monitor Synchroscope status menu. Observe and calibrate U:
volts reading until measured matches monitored.
Synchroscope Offset
Calibrates phase angle error detection of 6000 control.
Factory calibrated for zero phase angle error between bus and
A phase generator inputs
With synchroniser in “check” mode, and a live bus, monitor the
synchroscope menu of the 6000 control for “phase angle”.
Monitor Voltage across open gen contactor/breaker or panel
synchroscope for phase angle error between generator and
bus.
Adjust synchroscope calibration for lowest voltage across gen
breaker, or 12 o’clock reading on panel mounted
synchroscope.

Calibrates PT phase C voltage input Battery VCO Gain

Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N) Sets slope of battery VCO over operating range
and adjust PT Phase C scale until these values match
measured generator voltage on A phase

CT Phase A Scale
Calibrates CT Phase A sensing of 6000 control

Load generator and monitor gen. currents in phase overview

menu.

17
 Analog inputs to VCOs (Voltage Controlled Osc.)
Water Temp VCO Sensor without shunt
Freq.
(Hz) Sensor with shunt

VCO
Freq.

Analog Input

Water Temperature
Used for Batt Volts, Water Temp (Ain2) and Oil Pressure (Ain1)
Voltage Controlled Oscillators Shunt Resistor Switches 7 and 8 closed on SW-1 of 6000
control
NetComm Dropouts
Increasing offset
The number of lost or corrupted network communications
tolerated by the receiving unit.
Freq.
Excess numbers of NetComm Dropouts on network due to
faulty wiring, improper shielding, or improper setup will result
Decreasing offset
in the unit experiencing the dropouts to flash intermittently in
the Sequencing Menu of the 6000 control. Typically set at 5 to
Analog Input 10 dropouts.

Calibrated Unit
When set for true, indicates unit has been factory calibrated.
Requires level 4 security code to change.

Increasing gain 4.0 6100 - Single Generating set, Automatic Mains Failure
Functional Description
In this mode of operation an external changeover system must
be used in conjunction with the 6000 Control System to handle
Decreasing gain all mains sensing and load transfer functions providing a volt
free start signal.
Normal Switch Positions
Battery VCO Offset
OFF / Generating Set off
Sets level, or offset of Battery VCO over operating range
• If selected while engine is running the generating set will
Battery Voltage is a linear increasing type VCO function stop immediately.
Ain1 VCO Gain NOTE:
Oil Pressure sensor input • The 6100 control system has no control over the load
0-200 ohm sensor on engine is a direct, mostly linear VCO transfer, therefore the load should be removed from the
generating set before shutting down.
function
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated
Sets slope of oil pressure input to VCO frequency into the changeover system. The 6100 control system
can be programmed to perform the cooldown function
Ain1 VCO Offset itself if required but must be requested prior to build.

Sets level, or offset of oil pressure input to VCO frequency • If selected while the engine is stopped will disable engine
starting.
Ain2 VCO Gain
WARNING:
Sets slope of water temp. input to VCO frequency

Ain2 VCO Offset

! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
Sets level, or offset of VCO frequency to water temperature at the battery.
slope AUTO / Auto Start Position
• Generating set awaits an external (Volt Free) start signal
indicating a mains failure from the changeover system.
Upon receiving this signal the generating set will start and
assume any load on the local bus.
• The generating set will continue supplying the load until
the start signal is removed.
• Upon removal of this start signal the generating set will
stop immediately.

18
NOTE:
• All load transfer functions and mains failure detection are
handled by an external changeover system.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into
the changeover system. The 6100 control system can be
programmed to perform the cooldown function itself if required
but must be requested prior to build.
TEST / Generating Set Test Position
• If selected the generating set will start and assume any
load on the local bus.
NOTE:
• The 6100 control panel has no control over the load
transfer and so the generating set can carry out a test
without load by using this switch position only if the
changeover system used will not cause a load transfer
under these conditions.
• If the mains fails while the generating set is running and a
load transfer is initiated by the changeover system the
generating set will assume the load and run
isochronously.
RUN / Generating Set Manual Run
• Same as for ‘TEST’ position in this mode since the
generating set has no control over the load transfer.
4.1 6200 - Multiple Generating set, No Mains Parallel
Functional Description
In this mode of operation an external changeover system must
be used in conjunction with the 6000 Control System to handle
all mains sensing and load transfer functions providing a volt
free start signal. In this mode the generators only parallel with
other similarly equipped generating sets (up to a total of 8
sets). Where there is a group of generating sets each set is
given its own unique identifying number (1-8). There are two
main operational variants within the 6200 operating mode, i.e.
Prime Power and Automatic Mains Failure (AMF). Depending
on the configuration set-up the generating sets may be started
manually, start automatically if a machine in the running group
fails, start automatically according to load demand (load
dependant sequencing) and, in the case of the AMF variant,
start automatically on a failure of the mains supply.
4.2. Prime Power Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running the generating set
will ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on
the local bus the next available generating set in the
network may be sequenced on before the generating set
will initiate a stop sequence.
The 6200 control system has no control over the load
transfer to/from the mains and so this should not be used
to initiate a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated
into the changeover system. The 6200 control system
can be programmed to perform the cooldown function
itself if required but must be requested prior to build.
• If selected while the engine is stopped will disable engine
starting.
19
WARNING
! if maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the system is dead and no generating
sets are online the generating set will start and assume
the load.
• If selected while the engine is stopped with other
generating sets of only lower priorities online the
generating set will start, synchronise and close to the
local bus, soft load ramp then load share with the other
generating sets online. The generating set will now
assume master status and sequence the lowest priority
generating set offline if the system load is less than the
‘Min Gen Load’ setpoint. The generating set will continue
running online until a shutdown fault occurs or the control
switch is turned out of ‘AUTO’.
• If selected with at least one generating set of a lower
priority online the generating set will start, synchronise
and close to the local bus, soft load ramp then load share
with the other generating sets online. The lowest priority
generating set may now sequence offline automatically if
the system load is less than the ‘Min Gen Load’ setpoint
on the active master generating set. The generating set
will now revert to normal load dependant automatic
sequencing and will be brought on and offline by the
active master generating set as required.
• If selected with other generating sets of only higher
priorities online the generating set will go directly into auto
sequencing and will not start unless the system load is
greater than the ‘Max Gen Load’ setpoint on the active
master generating set. If this is the case the generating
set will start, synchronise and close to the local bus, soft
load ramp then load share with the other generating sets
online. The generating set will now revert to normal load
dependant automatic sequencing and will be brought on
and offline by the active master generating set as
required.
TEST / Generating Set Test Position
• If selected while the engine is stopped the generating set
will start and run off load. The generating set will
continue to run off load until the control switch is turned
out of ‘TEST’.
NOTE:
• During this time the generating set will be unavailable for
automatic sequencing and will never close onto the load.
RUN / Generating Set Manual Run
• If selected while the system is dead and no generating
sets are online the generating set will start and assume
the load.
• If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets
online. The generating set will now assume master
status and sequence the lowest priority generating set
offline if the system load is less than the ‘Min Gen Load’
setpoint. The generating set will continue running online
until a shutdown fault occurs or the control switch is
turned out of ‘RUN’.
• If selected with at least one generating set of a lower
priority online the generating set will start, synchronise
and close to the local bus, soft load ramp and then load
share with the other generating sets online. The lowest
priority generating set may now sequence offline
 automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will
prevent this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
• If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets
online. The next lowest priority generating set online may
be sequenced offline if the system load is less than the
‘Min Gen Load’ setpoint on the active master generating
set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will
prevent this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
Prime Power Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’
position on the control switch on startup. This will bring all
generating sets on line supplying the load and will allow the
6000 Control System to initialise all load dependant
sequencing correctly. After approximately 2 mins of running
all generating sets can be placed in the ‘AUTO’ position for
normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run.
As the load increases then the number of sets increase and
vice versa. The generating sets have a pre-set starting priority
as the load increases. As the load decreases they stop in
reverse order. The starting and stopping order sequence can
be changed by the operator at any time. Another feature in
the automatic mode is that if a generating set stops because
of a fault then the next generating set in the sequence starts
up and synchronises automatically to the load. When the
faulty generating set is repaired it will automatically take its
place back in the running sequence (see section on ‘AUTO’
switch position). The 6200 mode requires that there must be
a minimum of one generating set running.
4.3. AMF Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running the generating set
will ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on
the local bus the next available generating set in the
network may be sequenced on before the generating set
will initiate a stop sequence.
The 6200 control system has no control over the load
transfer to/from the mains and so this should not be used
to initiate a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated
into the changeover system. The 6200 control system
can be programmed to perform the cooldown function
itself if required but must be requested prior to build.
If selected while the engine is stopped will disable engine
starting.
20
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the system is dead and no generating
sets are online the generating set awaits an external (Volt
Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online.
The generating set will continue to run online for at least
5 minutes then revert to normal load dependant
automatic sequencing.
• If selected while the engine is stopped with other
generating sets of only lower priorities online the
generating set awaits an external (Volt Free) start signal
indicating a mains failure from the changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online.
The generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint.
The generating set will continue running online until a
shutdown fault occurs or the control switch is turned out
of ‘AUTO’.
• If selected with at least one generating set of a lower
priority online the generating set awaits an external (Volt
Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
lowest priority generating set may now sequence offline
automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline
by the active master generating set as required.
• If selected with other generating sets of only higher
priorities online the generating set awaits an external
(Volt Free) start signal indicating a mains failure from the
changeover system.
Upon receiving this signal the generating set will go
directly into auto sequencing and will not start unless the
system load is greater than the ‘Max Gen Load’ setpoint
on the active master generating set. If this is the case
the generating set will start, synchronise and close to the
local bus, soft load ramp then load share with the other
generating sets online. The generating set will now revert
to normal load dependant automatic sequencing and will
be brought on and offline by the active master generating
set as required.
TEST / Generating Set Test Position
• If selected while the engine is stopped and the external
start signal is not active the generating set will start and
run off load. The generating set will continue to run off
load until the control switch is turned out of ‘TEST’ or the
generating set receives the external start signal.
Upon receiving this signal the generating set will
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online.
The generating set will continue to run online for at least
5 minutes then revert to normal load dependant
automatic sequencing.
• If selected while the engine is stopped with other
generating sets of only lower priorities online and the
external start signal active the generating set will start,
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online.
 The generating set will now assume master status and
sequence the lowest priority generating set offline if the
system load is less than the ‘Min Gen Load’ setpoint. The
engine will continue to run until the control switch is
turned out of ‘TEST’ and will remain online until the
external start signal is deactivated.
• If selected with at least one generating set of a lower
priority online and the external start signal active the
generating set will start, synchronise and close to the
local bus, soft load ramp then load share with the other
generating sets online. The lowest priority generating set
may now sequence offline automatically if the system
load is less than the ‘Min Gen Load’ setpoint on the active
master generating set. The generating set will now revert
to normal load dependant automatic sequencing and will
be brought on and offline by the active master generating
set as required. The engine will continue to run until the
control switch is turned out of ‘TEST’ and will be
sequenced on and offline by the active master generating
set as required.
• If selected with other generating sets of only higher
priorities online, the engine is stopped, with the external
start signal active and the system load less than the ‘Min
Gen Load’ setpoint the generating set will start and run
off load. The generating set will continue to run off load
until the control switch is turned out of ‘TEST’ or the
system load becomes greater than the ‘Max Gen Load’
setpoint on the active master generating set. If this is the
case the generating set will start, synchronise and close
to the local bus, soft load ramp then load share with the
other generating sets online. The generating set will now
revert to normal load dependant automatic sequencing
and will be brought on and offline by the active master
generating set as required. The engine will continue to
run until the control switch is turned out of ‘TEST’ and will
be sequenced on and offline by the active master
generating set as required.
• If selected with other generating sets of only higher
priorities online, the engine is stopped, the external start
signal active and the system load greater than the ‘Max
Gen Load’ setpoint the generating set will start,
synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline
by the active master generating set as required. The
engine will continue to run until the control switch is
turned out of ‘TEST’ and will be sequenced on and offline
by the active master generating set as required.
NOTE:
• If it is required to disable the generating set from going
online the local alternator output circuit breaker should be
placed in the open position.
RUN / Generating Set Manual Run
• If selected while the system is dead and no generating
sets are online the generating set will start and assume
any load on the local bus.
• If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets
online. The generating set will now assume master
status and sequence the lowest priority generating set
offline if the system load is less than the ‘Min Gen Load’
setpoint. The generating set will continue running online
until a shutdown fault occurs or the control switch is
turned out of ‘RUN’.
• If selected with at least one generating set of a lower
priority online the generating set will start, synchronise
and close to the local bus, soft load ramp and then load
share with the other generating sets online. The lowest
21
priority generating set may now sequence offline
automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set.
• If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets
online. The next lowest priority generating set online may
be sequenced offline if the system load is less than the
‘Min Gen Load’ setpoint on the active master generating
set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will
prevent this generating set from being sequenced offline.
Switching the control switch to the ‘AUTO’ position will
enable the automatic load dependant sequencing on this
generating set.
AMF Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’
position on the control switch on startup. This will bring all
generating sets on line supplying the load and will allow the
6000 Control System to initialise all load dependant
sequencing correctly. After approximately 2 mins of running
all generating sets can be placed in the ‘AUTO’ position for
normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run.
As the load increases then the number of sets increase and
vice versa. The generating sets have a pre-set starting priority
as the load increases. As the load decreases they stop in
reverse order. The starting and stopping order sequence can
be changed by the operator at any time. Another feature in
the automatic mode is that if a generating set stops because
of a fault then the next generating set in the sequence starts
up and synchronises automatically to the load. When the
faulty generating set is repaired it will automatically take its
place back in the running sequence (see section on ‘AUTO’
switch position). The 6200 mode requires that there must be
a minimum of one generating set running.
5. 6300 - Automatic Synchronising of One Generating Set
with Mains
5.1 Functional Description
In addition to the automatic mains failure function (with soft
load retransfer), this variant can operate in base load mode,
peak lopping mode or soft load transfer mode. The operating
mode is pre-programmed at the factory and must be specified
when ordering.
In all variants the 6300 Control System must have full control
of both the generator and mains breakers with state feedback
provided for each by means of an auxiliary contact.
5.2. Base Load Operation
In this mode the generating set may be manually started. It
will automatically synchronise to the mains grid and take up
load to a pre-set value (usually the full output of the generating
set). If there is insufficient local load for the generating set
then it will export its excess power to the mains.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker
control is disabled. If the mains fails during this time and
the mains breaker subsequently opens the control system
will not attempt to close the breaker until the control
switch is turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is
to be taken out of service for prolonged periods of time
that the maintenance switch inside the control panel
should be switched to the ‘Maintenance’ position. This
will re-close the mains breaker on a short term mains
failure.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the system is dead and the mains is
supplying the load, the generating set is operating in AMF
mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
• If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
22
unload ramp, open the generator breaker and continue
running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
• If selected while the engine is stopped with the mains
supplying the load the generating set will start,
synchronise with the mains, close the generator breaker
and soft load ramp to a preset ‘Baseload’ level against
the mains supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
5.4. Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set so that a minimum load is kept on the mains
and the rest is supplied by the generating set. This continues
until the generating set is at its maximum load then any further
loading is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the
mains until the control switch is returned to the OFF position
or to the AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.5. Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off
load, disconnect the generating set, cooldown (if
required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
• When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
 unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker
control is disabled. If the mains fails during this time and
the mains breaker subsequently opens the control system
will not attempt to close the breaker until the control
switch is turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is
to be taken out of service for prolonged periods of time
that the maintenance switch inside the control panel
should be switched to the ‘Maintenance’ position. This
will re-close the mains breaker on a short term mains
failure.
WARNING:
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
• If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker and continue
running offline.
NOTE:
23
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a pre-set import power level from the mains supply.
The generating set will maintain this import power level as the
site load varies.
NOTE:
• It may be necessary to fit external protection to prevent
the generating set from exporting power to the mains
utility. Consult the local mains provider for exact
requirements.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
5.6. Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set to the point where zero load is being supplied
by the mains then opens the mains breaker so assuming the
full site load. On removal of the time clock start signal the
generating set will resynch with the mains supply and perform
a soft load retransfer (closed retransfer) of the site load back
to the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or
to the AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
5.7. Soft Transfer Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off
load, disconnect the generating set, cooldown (if
required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
 synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker
control is disabled. If the mains fails during this time and
the mains breaker subsequently opens the control system
will not attempt to close the breaker until the control
switch is turned to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is
to be taken out of service for prolonged periods of time
that the maintenance switch inside the control panel
should be switched to the ‘Maintenance’ position. This
will re-close the mains breaker on a short term mains
failure.
6. 6400 - Automatic Synchronising of Multiple Generating
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an exercise timer is fitted to the generating set leaving
the control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
• If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker and continue
running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
24
• If selected while the engine is stopped with the mains
supplying the load the generating set will start,
synchronise with the mains, close the generator breaker
and soft load ramp to the point where there is no load
being imported from the mains at which point the control
system will open the mains breaker and assume the full
site load.
NOTE:
• It may be necessary to fit external protection to prevent
the generating set from exporting power to the mains
utility. Consult the local mains provider for exact
requirements.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
sets with Mains
6.1. Functional Description
In addition to the automatic mains failure function (with soft
load retransfer), this variant can operate in base load mode,
peak lopping mode or soft load transfer mode. The operating
mode is pre-programmed at the factory and must be specified
when ordering.
This section describes the functionality of the ‘standard’
system which consists of up to 4 generating sets paralleling
with each other onto a local generator bus and with a single
mains supply. This system is fitted with a mains breaker,
feeder breaker and a separate generator breaker for each
generating set. For a detailed outline of the system wiring
consult the relevant drawings and / or a member of the
Electrical Drawing Office. The Electrical Drawing Office
should also be consulted if the requirements of the proposed
installation dictate changes in the basic configuration of the
system as this may require significant modification to the
control system philosophy.
6.2. Base Load Operation
In this mode the generating sets may be manually started
either by an external start signal starting all generating sets
which are in ‘AUTO’ or individually by selecting ‘RUN’ on the
control switch. Any generating sets told to run in baseload will
automatically synchronise to the mains grid and take up load
to a pre-set value (usually the full output of the generating
set). If there is insufficient local load for the generating sets
then surplus power over and above the site load will be
exported to the mains.
With the generating sets in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. In his case the system will open
the feeder breaker and attempt to start all generating sets
simultaneously. After all available generating sets have come
on-line and have closed to the local bus the feeder breaker will
close. The number of generating sets required to be on-line
before the feeder breaker will close can be customised for
each individual application. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
6.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect from the local bus, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
and externally triggered starting functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable engine
starting.
WARNING:
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see
section 6.3.4).
TEST / Generating Set Test Position
• If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’, the mains
supply goes outside specification or the external start
signal is received.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs. When the
mains returns the generating set will wait for the duration
of the mains stable delay timer then synchronise to the
mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
• If an external start signal is received the generating set
will parallel to the mains supply and go into RUN mode
(see section 6.3.)
NOTE:
25
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating Set Manual Run
• If selected while the engine is stopped with the mains
supplying the load the generating set will start,
synchronise with the mains, close the generator breaker
and soft load ramp to a pre-set ‘Baseload’ level against
the mains supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
6.4 Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock or externally applied run signal and
run in parallel with the mains supply. After synchronising with
the mains an external watt transducer provides a signal which
is representative of the loading applied to the mains supply.
The 6400 uses this signal to adjust the load on the generating
set so that a minimum load is kept on the mains. This
continues until the generating set is at its maximum load after
which any further loading is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the
mains until the control switch is returned to the OFF position
or to the AUTO position with the external start signal removed.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in
the event of a mains failure. The generating set will perform a
soft load retransfer (closed retransfer) of the load back to the
mains supply on return of the mains.
6.5 Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
• If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off
load, disconnect the generating set from the local bus,
cooldown (if required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
 mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable engine
starting.
WARNING:
! if maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
• If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see
section 6.5.).
TEST / Generating set Test Position
• If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker and continue
running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating set Manual Run
• If selected while the engine is stopped with the mains
supplying the load the generating set will start,
synchronise with the mains, close the generator breaker
and soft load ramp to a preset import / export power level
from the mains supply. The generating set will maintain
this import / export power level as the site load varies.
NOTE:
• It may be necessary to fit external protection to prevent
the generating set from exporting power to the mains
utility. Consult the local mains provider for exact
requirements.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
26
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
6.6 Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a preset time clock or externally applied start signal and
run in parallel with the mains supply. After synchronising with
the mains an external watt transducer on the mains provides a
signal of the load on the mains. The 6400 uses this signal to
adjust the load on the generating set to the point where zero
load is being supplied by the mains then opens the mains
breaker so assuming the full site load. On removal of the time
clock start signal the generating set will resynch with the
mains supply and perform a soft load retransfer (closed
retransfer) of the site load back to the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or
to the AUTO position with the external start signal removed.
NOTE:
• If only one generating set is turned into the RUN position
the site load may exceed the maximum generating set
load in which case the generating set will never reach the
zero load transfer point and will not disconnect the mains
supply.
With the generating set in the AUTO position the system
will operate in AMF Mode and will start and supply the
site load in the event of a mains failure. The generating
set will perform a soft load retransfer (closed retransfer)
of the load back to the mains supply on return of the
mains.
6.7 Soft Transfer Variant - Normal Switch Positions
OFF / Generating set Off
• If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off
load, disconnect the generating set from the local bus,
cooldown (if required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
• If selected while the generating set is supplying the site
load and the mains is dead the generating set will
continue supplying the site load until the mains returns or
a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If selected while the generating set is supplying the site
load and the mains has returned after a mains failure but
the mains stable delay timer has not timed out the
generating set will synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker, cooldown and stop.
• If selected while the engine is stopped will disable disable
engine starting.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 • If selected while the generating sets are stopped and the
mains supplying the load the generating set will enter in
AMF mode and will not start.
• If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site
load. The generating set will continue to run online until
the mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker, cooldown and
stop.
• If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see
section 6.7.).
TEST / Generating set Test Position
• If selected while the engine is stopped and the mains
8. Remote Control and Monitoring Via a PC:
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
• If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load.
The generating set will continue to run online until the
mains returns or a shutdown fault occurs.
When the mains returns the generating set will wait for
the duration of the mains stable delay timer then
synchronise to the mains, close the mains breaker, soft
unload ramp, open the generator breaker and continue
running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open
position.
RUN / Generating set Manual Run
• If selected while the engine is stopped with the mains
supplying the load the generating set will start,
synchronise with the mains, close the generator breaker
and soft load ramp to the point where there is no load
being imported from the mains at which point the control
system will open the mains breaker and assume the full
site load.
NOTE:
• It may be necessary to fit external protection to prevent
the generating set from exporting power to the mains
utility. Consult the local mains provider for exact
requirements.
• If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site
load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for
exact requirements.
7. Alarm / Event Indication and Logging
Fault conditions on the 6000 Series Control Panel are set as
warnings, alarms, soft shutdowns and hard shutdowns.
Warnings flash the ALARM light only, alarms energise the
audible alarm and flash the ALARM lamp, soft shutdowns
unload the generator, open the breaker and perform a
cooldown cycle if required. Hard shutdowns immediately open
the breaker and shut the generating set down. All alarms are
27
logged with a timestamp in the ALARM / EVENT LOG. These
settings are intrinsic to the setup parameters in the software
and can only be changed with suitable security clearance.
When a hard shutdown fault is sensed, the alarm lamp
illuminates, the audible alarm is energised and the generating
set is automatically shut down immediately. The audible alarm
will remain energised until the ALARM RESET pushbutton is
pressed. The engine remains locked out until the fault has
been acknowledged. The alarm lamp will flash until the enter
( ) pushbutton is pressed while in the ALARM / EVENT LOG.
This will acknowledge the alarm and allow the generator to
start but will not clear it from the log. The alarm may be
cleared from the log by pressing the ALARM RESET
pushbutton while in the ALARM/EVENT LOG subject to
technician level or higher security clearance. The possible
fault conditions available for sensing are dependant on the
particular operating mode of the generating set. See earlier
section for a list of all available alarms/shutdowns.
8.1 System Outline
The PC-Tools package is available in two main forms, which
are subdivided into 5 variants in total. A brief description of
each is given below:
• PC options:
PC1: This option offers monitoring of the 6000 series
system only via a direct hardwired connection to the
control system.
PC2: This option offers monitoring and control of the
6000 series system via a direct hardwired connection to
the control system.
• TEL options:
TEL1: This option offers monitoring of the 6000 series
system only via a standard telephone line.
TEL2: This option offers monitoring and control of the
6000 series system via a standard telephone line.
TEL3: This option offers monitoring and control of the
6000 series system via a standard telephone line with
fault alert callback.
The PC1 and PC2 options use a separate control box per
control system to interface between the RS-232 serial
communications port of the monitoring PC and the RS-422
communications network used by the 6000 series control
panels. The GP 6000 software in conjunction with the Servlink
software then utilises the information transmitted by this
communication path to allow users to monitor or control
various aspects of the 6000 series control panel from the
computer.
The TEL1, TEL2 and TEL3 options also use a separate but
different control box per system to interface between the RS-
422 network used by the 6000 series control panels and the
telephone line.
Each 6000 series control system should have its own
dedicated communications path, e.g. one hard wired
connection with one PC1 interface panel per 6100 or 6300
panel with PC1option, and one telephone line with one PC1
interface panel per 6200 or 6400 system with PC1 option.
Each control box requires a mains supply but does contain
battery backup to enable uninterrupted remote
communications even in the event of a mains and/or generator
system failure.
The control box used with the TEL3 option differs from that
used with the TEL1 and TEL2 options in that it also
incorporates the fault callback unit. This control box will
require two dedicated telephone lines, one for data transfer
and one for the recorded message callback facility.
8.2 Functional Description
The GP 6000 software duplicates the front panel of the 6000
series hardware platform. All the monitoring information which
can be obtained from the hardware can also be accessed by
the GP 6000 software in a format which is identical to that of
the hardware. This makes the software
very familiar to those accustomed to the 6000 controller
keypad functions and LCD readout displays.
There are two main information display sections within the GP
6000 software. These are the ‘Master Situation Monitor’ and
the ‘Front Panel Display’. The ‘Master Situation Monitor’
displays the essential information from up to eight of the
individual control panels in the system. The parameters
displayed are:
• Network Address
• Network Priority
• Present kW loading of the generating set
• Alarm Status (ALARM or OK)
An example of a typical 3 generating set 6200 system display
is shown below:
In this example the Master Situation Monitor is showing an
alarm condition on generating set number 3. Highlighting
generating set number 3, and then clicking on the front panel
display icon in the lower right corner of the Master Situation
Monitor brings up the front panel display for generating set
number 3:
The operator can now carry out any of the functions
accessible by using the membrane keypad on the hardware
control itself. This is done by simply clicking on the
28
appropriate button on the front panel display, which will cause
the 6000 series control to react in exactly the same manner as
if the button was pressed locally.
In addition to the Monitoring version of the GP6000 software
there is also a version which gives the remote operator the
capability to simulate the operation of the control switch, panel
mounted emergency stop button, and the speed/volts
raise/lower buttons. This version is used with the PC2, TEL2
and TEL3 options. An example of the front panel display for
this version is shown below:
As it can be seen, this version is identical to the monitoring
only version with the exception of the added control buttons on
the right side of the display.
These control buttons not only allow the remote operator to
perform all the basic control functions but also indicate the
current state of these control inputs, i.e. if the panel mounted
emergency stop is locked on or has been released etc.
The control system works by acknowledging a change of state
of any of these switch inputs, whether triggered locally or
remotely, as the last valid control input. This means that there
is no overriding priority put on either the local or remote inputs,
and so it is quite conceivable that the local control switch
could be in the AUTO position but due to the remote operator
pressing the RUN button, the generating set will be operating
in the RUN mode. It should be noted however that the
status as indicated on the remote display will always
match the current operating mode of the controller.
The Emergency Stop control operates in a slightly different
manner however due to safety constraints. In this case the
local panel mounted emergency stop always has priority while
pressed. This prevents the remote operator from starting the
generating set if the local emergency stop button is still locked
on due to the occurrence of a dangerous or potentially
dangerous situation. Once the local emergency stop button
has been released the alarm can be reset and the generating
set started either locally or remotely.
It should also be noted that in the case of a 6100, or 6200
system that as all mains failure and load transfer functions are
performed by an external changeover system the PC2, TEL2
and TEL3. Options cannot be used to initiate a manual load
transfer/ re-transfer of the load to/from the mains supply.
8.3 Hardware Specifications
Communications:
RS-422 protocol
9600 Baud (fixed maximum)
No Parity
1 Stop Bit
Computer Requirements: TEL1 Option
Minimum: 1 x TEL1 interface box.
1 x GP6000 Monitoring Software package.
PC compatible running Windows 95 or Windows NT 4.0 and 1 x Telephone cable (cable connectors fitted will depend on
above, 3 MB hard drive space. country).
Recommended: TEL2 Option
100 MHz Pentium PC, 16 MB RAM, 3 MB hard drive space, 1 x TEL2 interface box.
running Windows 95 or Windows NT 4.0 and above. 1 x GP6000 Monitoring and Control Software package.
Modem Requirements (for TEL1, TEL2 and TEL3 options 1 x Telephone cable (cable connectors fitted will depend on
only): country).

Remote PC end: TEL3 Option

9600 Baud Capability (minimum) 1 x TEL3 interface box with integral fault alert callback.
1 x GP6000 Monitoring and Control Software package.
8 Data Bits 2 x Telephone cables (cable connectors fitted will depend on
country).
No Parity
1 Stop Bit 9. Initial Startup and Commissioning
Recommended: 9.1 Test Procedure for Single Generating set Systems.
Multitech MT1932ZDX-K, MT2834ZDX-K, MT2834ZPX- Pre-Startup Instructions
Internal
− Check all electrical connections.
US-Robotics Sportster 14.4 Vi Fax/Modem, Sportster 14.4
Fax/Modem, Sportster Voice 33.6 Fax/Modem, Courier Dual − Check engine oil and coolant level.
Std, Courier HST.
− Ensure that the control switch is in the OFF position.
Miracom Courier HST
− Power up the 6000 series control panel.
Megahertz CC3144/CC4144 PCMCIA
− The unit will carry out a RAM check after which it will
Xircom PS-CEM28 range display the application code version installed in the unit.
NEC (AT&T) 14.4 Kbps Data/Fax Modem Verify that this is the latest version. If not, download the
latest version. The unit should now display the ‘Control
Tornado FM144E Overview’ screen.
PC1 and PC2 communications path. − Enter security code.
Standard RS-422 protocol communications. − Check all program setpoints.
Recommended cable: 6-core (3 x twisted pair), overall − Set synchroniser to ‘Run’.
screened, min core diameter of 0.5mm2.
− Set ‘Load Control Mode’ to ‘Droop’.
Maximum length: 1km (special attention must be paid to cable
routing to minimise interference). − For multiple unit systems set ‘Number of Units’ to
‘Single’.
Connection Method: daisy chain (parallel looped) with PC
interface box at one end of the line - screen earthed at one Ensure that the generating set is connected to a isolated bus
place only but interconnected. or load bank.
TEL1, TEL2, and TEL3 communications path. Start engine using the ‘RUN’ position on the control switch.
Hardwired RS-422 connection as in PC1, PC2 option. Check operation of Emergency stop button.
Each TEL1 and TEL2 option requires one dedicated, analogue Re-start generating set by clearing Emergency stop fault while
telephone line. control switch still in ‘RUN’.
Each TEL3 option requires two dedicated, analogue telephone
Check the RPM reading on the ‘Engine Overview’ screen.
lines.
Set up electronic governor (if fitted).
NOTE:
Ensure that generator breaker closes.
• Connection of the TEL1, TEL2 and TEL3 option interface
Ensure that generating set is running in ‘Droop’ mode by
boxes to a digital telephone line, such as used on some
looking at the ‘Synchroscope’ screen.
PBX switchboard systems, may result in permanent
damage to the interface system. Check that the Volts and Speed Bias outputs on the ‘I/O
Status’ screen are both zero.
8.4 Equipment Supplied With Each Option:
Check the generator output voltage on the load bank.
PC1 Option
Calibrate the Line-Neutral voltages as seen on the ‘Gen
1 x PC interface box. Phases’ screen.
1 x 9-pin serial cable.
1 x GP6000 Monitoring Software package. Adjust output voltage at AVR to specified voltage.
PC2 Option Verify operation of the Volts raise/lower switches (if
applicable).
1 x PC Interface box.
1 x 9-pin serial cable. − Verify that ‘Volts Bias’ reading in ‘I/O Status’ screen
1 x GP6000 Monitoring and Control Software package. changes when raise/lower switches are pressed.
− Set ‘Voltage Ramp Time’ if necessary.

29
Verify operation of the Speed raise/lower switches (if
applicable).
− Verify that ‘Speed Bias’ reading in ‘I/O Status’ screen
changes when raise/lower switches are pressed.
− Set ‘Load Raise Rate’ and ‘Load Lower Rate’ if
necessary.
If the 6000 series control panel is controlling the
generating set volts:
− Set AVR ‘Droop’ potentiometer to halfway.
− Set AVR ‘Trim’ pot to give +/- 10% output voltage swing
for +/- 100% voltage bias output (by using the Volts
raise/lower switches).
If Mains PT connected:
− Check mains voltage readout (U:) in ‘Synchroscope’
screen.
Calibrate if necessary.
Apply a small load to the generating set.
Check CT polarity by observing current readouts in the ‘Gen
Phases’ screen.
Load generating set to full load.
Check current readouts on ‘Gen Phases’ screen.
Calibrate current readouts if necessary.
Remove load.
Turn control switch to ‘OFF’.
Verify that generating set shuts down correctly.
Set ‘Load Control Mode’ to ‘Normal’.
Start generating set by turning the control switch to ‘RUN’.
Check operation of all shutdowns and alarms.
Load up generating set to full load and complete full load test.
Remove load and shut down generating set.
Test Procedure for Multiple Generating set Systems.
Test each individual unit in single generating set mode as
outlined above.
Connect all generating sets to common local bus.
Set up RS-485 communication lines.
− Connect proper RS-485 twisted pair, overall screened
cable of characteristic impedance of 120 ohms between
all generating sets in system.
− If RS-485, 120 ohm cable is not available standard
twisted pair, overall screened cable should suffice.
− Connect screen to panel earth at one end only ensuring
that the screen connection is carried right through to the
opposite end of the system.
− Ensure proper RS-485 termination by setting DIP
switches 4, 7, and 8 on switch bank SW-3 (located
beside J-8) are in the ‘ON’ position on both units at the
end of the communication path.
− Ensure DIP switches 4-8 on switch bank SW-3 are in the
‘OFF’ position on all other units.
Ensure all control switches is in the ‘OFF’ position.
Power up all 6000 series panels.
Enter security code.
Set up all controllers as follows:
− Set synchroniser to ‘Check’ on all but first machine.
− Set synchroniser to ‘Run’ on fist machine only.
30
− Set ‘Number of units’ setpoint to ‘Multiple’.
− Set ‘Load Control Mode’ to ‘Normal’.
− Disable any Loss of Mains detection.
− Set up network addresses and priorities ensuring that
network addresses are all unique.
− Disable closure of all generating set breakers, except first
unit, by disconnecting the close signal from the control
panel.
Turn all control switches to Auto and verify network
communications:
− All generating sets in ‘AUTO’ should be shown in the
‘Control Overview’ screen after the ‘UNIT:’ prompt.
− If any controllers are missing from the display, check that
there is no duplication of network priorities, check all RS-
485 cable connections and that the end of line
termination resistors are set correctly (see above).
− If all of the above are correct, but any controllers are still
missing from the display, increase the ‘NetComm
Dropouts’ setpoint to 10.
− If communications still not correct, replace faulty
controller and repeat all previous setup procedures.
Turn all control switches back to ‘OFF’.
Turn control switch on first unit to ‘RUN’.
Verify that first unit starts and closes onto the bus.
Calibrate Synchroniser on all remaining units.
− Turn control switch on next unit to ‘RUN’.
− Change to the ‘Synchroscope’ screen.
− Verify that the ‘Mains/Bus’ sensing changes to ‘BUS’.
− Verify that the ‘Dead Bus’ display changes to ‘NO’.
− Verify the Bus Volts readout, ‘U:’ on screen, is correct
and calibrate if necessary.
− Verify synching by measuring volts across generating set
breaker.
− When satisfied that synchroniser is correct, shut down
generating set and repeat steps 1-7 for next unit.
Check synchroniser operation on next unit:
− Ensure that first unit is running and closed onto the bus.
− Apply a load of approx. 1/2 full load capacity of first
generating set.
− Turn the control switch on the next generating set to
‘RUN’.
− Confirm phase/voltage matching and synchroniser
operation.
− Verify generating set breaker closure.
Check ‘Load Control’:
− Verify load ramping operation.
− Verify that ramp rate is reasonable.
− Reduce ‘Load Control Gain’ setting if unstable during
ramping.
− Verify that operating mode changes to ‘ISOCH’ when
ramping complete.
− Increase bus load to approximately 1/2 full load capacity
of all generating sets currently on-line.
− Verify real load sharing operation.
− Reduce ‘Load Share Gain’ if unstable during load
sharing.
− Verify Var/PF sharing (if applicable).
− Reduce ‘VAR/PF Gain’ if unstable during Var/PF sharing.
Repeat Synchroniser and Load Control operational checks for
all remaining generating sets.
Once all sets are on line and correctly set up, increase load on
bus to full system load capacity.
Run on full load for 5-10 mins to verify long term stability.
Take units off line one at a time ensuring that bus load does
not exceed full load capacity of remaining units.
− Verify unload ramping.
− Verify unload trip.
− Verify cooldown operation.
Carry any further application specific operational tests
required.

31
10. Troubleshooting

10.1 Control Hardware and I/O

Problem Probable Cause Corrective Action

Unit does not power up No input power supply Check +12 Vdc or +24 Vdc power supply
Input power supply reversed Ensure proper polarity of power supply to
GCP-1

Discrete inputs don’t show active in I/O STATUS Faulty wiring of discrete input switches Verify wiring of discrete input switches
screen when switches are activated
Displayed generator voltages are very small Faulty wiring of generator Potential Verify wiring of generator Potential
Transformers(PT’s) Transformers(PT’s)
Generator PT inputs are improperly Calibrate the appropriate PT input
calibrated channel(s). See section 1.10 Calibration
of Control Inputs and Outputs
I/O STATUS shows relay(s) is energized, but Faulty wiring of relay output contacts Verify wiring of relay output contacts
action(i.e. alarm) does not occur
Generator voltage fluctuates or is unstable at no load AVR dynamics are improperly set up Tune the AVR dynamics for stable
on generator operation. See AVR manufacturer’s
instruction manual for more details
Voltages or currents displayed by GCP-1 are different GCP-1 PT inputs are inaccurately Calibrate the appropriate PT input
than measured parameter calibrated channel(s). See section 1.10 Calibration
of Control Inputs and Outputs

10.2 Engine Control / Sensing Parameters

Problem Probable Cause Corrective Action

Start command(i.e. test or run with load) does not
start engine
Configuration menu has not
accepted or entered properly
been Enter the configuration set points in the
Configuration menu such that all “*” and
“#” symbols are removed from the lower
two lines of the display. See section
1.3.4 Description of set points for more
details.

An active alarm condition exists Commit or reset alarm condition(s). See

Starter motor stays engaged after engine starts
Relay output contacts are not properly
connected to engine starter, fuel solenoid
Crank cutout set point in Engine control
menu is to large
section 1.3.2 Description of Screens
Verify wiring of relay output contacts
Set CRANK CUTOUT set point to
appropriate value. See section 1.3.4
Description of set points

Engine starts, but starter re-engages while engine is
running
Engine speed is unstable when unit is at no load
When crank command is issued, GCP-1 loses power
and conducts a reset and RAM test
Inadequate MPU signal to GCP-1 input
Inadequate MPU signal to GCP-1 input
Speed control dynamics are improperly
set up
Battery is too weak for the current
demand of the starter motor
Faulty wiring of power supply to the GCP-
1 control
Verify MPU wiring, and that adequate
MPU signal exists at input to GCP-1
control
Verify MPU wiring, and that adequate
MPU signal exists at input to GCP-1
control
Tune the speed control dynamics for
stable operation. See speed control
manufacturer’s instruction manual for
more details
Install a higher capacity battery or a more
efficient starter motor
Verify wiring of power supply to the GCP-
1 control

32
10.3 Synchronisation
Problem
Unit never adequately matches phase
Synchronizer displays small phase difference, but
measured phase difference is large
Synchronizer matches phase, but never closes
breaker/contactor
Synchronizer displays matched phase, but measured
phase difference is ~180 degrees, or when breaker
closes it crash parallels the set 180 degrees out of
phase
Unit won’t close to dead bus
Synchronizer won’t voltage match
Synchronizer does not voltage match within spec.
10.4 Breaker Close / Open Control
Problem
When generator set is in synchronization, the
breaker never closes
Contactor closes for a brief moment and then
opens
Breaker close relay stays energized when a
close command is given and never issues an
Probable Cause
Synchronizer Mode set point in
synchroscope menu set to PERMISSIVE
Synchronizer dynamics in synchroscope
menu are improperly set up
Generator A phase PT input is L-L and
bus A phase PT input is L-N or vice versa
Bus and/or generator PT inputs are not A
phase
Synchronizer improperly calibrated
Synchronizer Mode set point
synchroscope menu is set to CHECK
Dwell time set point in synchroscope
menu is too large
Generator or bus PT is reversed polarity
(faulty wiring)
Multiple unit system with DEADBUS
CLOSING set point in configuration menu
set to DISABLED
Synchronizer set point is set to CHECK
VOLTAGE MATCHING set point
synchroscope menu is DISABLED
Generator A phase PT and/or Bus A
phase PT input(s) are inadequately
calibrated
Voltage matching tolerance set point in
synchroscope menu is too large
Probable Cause
Synchronizer set to CHECK
Faulty wiring causing the relay output to not
make connection to the breaker
Dwell time set point in the synchroscope menu
is too long
C B CONTROL set point in configuration menu
is set for BREAKER
C B HOLD TIME set point in synchroscope
menu is too short
Faulty wiring on C.B. aux contacts
C B CONTROL set point is set for
CONTACTOR
33
Corrective Action
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Tune synchronizer dynamics. See
section 1.3.4 Description of Set points
Verify that Generator A phase PT input
bus A phase PT input are the same form
(i.e. L-N or L-L)
Verify that Bus and generator PT inputs
are A phase
Calibrate synchronizer. See section 1.10
Calibration of Control Inputs and Outputs
in Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Reduce Dwell Time set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify correct polarity of Generator and
bus PT inputs
ENABLE DEADBUS CLOSING set point
in configuration menu. See section 1.3.4
Description of Set points
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
in ENABLE the VOLTAGE MATCHING set
point in synchroscope menu. See section
1.3.4 Description of Set points
Calibrate the Generator A phase PT and
Bus A phase PT inputs. See section 1.10
Calibration of Control Inputs and Outputs
Appropriately set the Voltage matching
tolerance set point in synchroscope
menu. See section 1.3.4 Description of
Set points
Corrective Action
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of Set
points
Verify wiring of the relay output contacts.
Reduce Dwell time set point in the
synchroscope menu. See section 1.3.4
Description of Set points
Appropriately set the C B CONTROL set
point in configuration menu. See section
1.3.4 Description of Set points
Increase C B HOLD TIME set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify wiring of C.B. aux contacts to GCP-1
input
Appropriately set the C B CONTROL set
point in configuration menu. See section
 open command 1.3.4 Description of Set points

10.5 Real Load Control

Problem Probable Cause Corrective Action

kW for a phase(s) reads negative.
Current transformer(CT) has reversed Verify/reverse polarity of current
polarity transformer for effected channel(s)
NOTE: engine generator set must be
off to safely open circuit a current
transformer

Unit carries improper proportion of real load during Rated kW set point in configuration menu Appropriately set Rated kW set point in
isochronous load sharing set at incorrect value configuration menu. See section 1.3.4
Description of Set points

Real load control is unstable when paralleled with the
mains source
Process control operation causes overload or reverse
power
A proportional dc speed error exists on the
speed control unit (no-load speed not set
to match bus frequency)
Real load control dynamics in real load
control menu are improperly set up
PROCESS ACTION set point in process
control menu set for incorrect action
Adjust speed setting of speed control to
match the bus frequency. If unit is
carrying too little load, the speed setting
needs increased. If unit is carrying too
much load, the speed setting needs
decreased.
Tune Real load control dynamics in real
load control menu. See section 1.3.4
Description of Set points
Appropriately set PROCESS ACTION set
point in process control menu. See
section 1.3.4 Description of Set points

Loading and/or unloading is too fast/slow Load and/or unload ramp rates in the real Appropriately increase/decrease the Load
load control menu are set incorrectly and/or unload ramp rates in the real load
control menu. See section 1.3.4
Description of Set points
Engine speed/load has an instability that fluctuates very Speed control dynamics are improperly set Tune the speed control dynamics for
quickly. up stable operation. See speed control
manufacturer’s instruction manual for
more details

10.6 Reactive Load Control

Problem Probable Cause Corrective Action

Phase power factors do not agree. Two of the three CT’s are connected to incorrect phase Verify CT’s are connected to the
phases are extremely far out of range inputs appropriate input terminals
NOTE: engine generator set must be
off to safely open circuit a current
transformer

Unit carries improper proportion of reactive load during Rated kVA set point in the configuration Appropriately set the Rated kVA set point
isochronous load sharing menu is set at incorrect value in the configuration menu. See section
1.3.4 Description of Set points

Generator A phase PT input(s) are Calibrate the Generator A phase PT

improperly calibrated input(s) of the generator set(s). See
section 1.10 Calibration of Control Inputs
and Outputs
Reactive load control is unstable when paralleled with Reactive load control dynamics in the Tune the Reactive load control dynamics
the mains source reactive load control menu are improperly in the reactive load control menu. See
set up section 1.3.4 Description of Set points

Unit maintains a constant VAR load rather than a VAR/PF set point in the reactive load Appropriately set the VAR/PF set point in
constant power factor when paralleled with the mains control menu is set to VAR CONTROL the reactive load control menu. See
source section 1.3.4 Description of Set points
Unit maintains a constant power factor load rather than VAR/PF set point is set to PF CONTROL Appropriately set the VAR/PF set point in
a constant VAR when paralleled with the mains source the reactive load control menu. See
section 1.3.4 Description of Set points
Multiple generator sets are unstable when VAR/PF VOLTS RAMP TIME set point in reactive Appropriately set the VOLTS RAMP TIME
sharing at light loads load control menu is not adjusted properly set point in reactive load control menu.
See section 1.3.4 Description of Set
points
Droop Current Transformer not properly Verify the connection of the Droop
connected to AVR Current Transformer to the AVR. See
AVR manufacturer’s instruction manual
for more details

34
10.7 Sequencing
Problem
Unit number(s) does not show up in the sequencing
order in the sequencing screen/unit doesn’t auto
sequence
When system load is large enough to require
additional gen-sets, more than one set is sequenced
on line
When system load is small enough to take additional
sets off line, more than one set is sequenced off line
10.8 Mains / Bus Sensing
Problem
Unit(s) do not respond to loss of mains
Unit does not recognize when mains are in spec.
10.9 Communications
Problem
A unit number(s) does not show up in the sequencing
order in the sequencing screen
If a unit with the network termination is powered
down, communications become unreliable or
completely cease
Probable Cause
switch in manual position
Automatic mode set point in the configuration
menu set to disabled
Unit has an active alarm
RS-485 Network not connected at unit(s)
RS-485 Network is inadequately terminated
NEXT GENERATING SET DELAY set point
in sequencing menu is too short
MAX START TIME set point in sequencing
menu is too short
REDUCED LOAD DELAY set point in
sequencing menu is too short
MAX STOP TIME set point in sequencing
menu is too short
Probable Cause
Shutdown/alarm set points for mains
sensing not set for LOSS OF MAINS
Unit(s) do not have an active auto switch
input
Set points for mains high/low frequency
and high/low voltage in shutdown/alarm
menu are set too tight for sensing when
mains are in spec
Probable Cause
RS-485 Network is inadequately
terminated
RS-485 Network not connected at unit(s)
RS-485 network is connected with
reverse polarity at one or more units
+5Vdc power supply is not linked
between units (inadequate wiring)
35
Corrective Action
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
ENABLE the Automatic mode set point in
the configuration menu. See section 1.3.4
Description of Set points
Commit or reset alarm condition(s). See
section 1.3.2 Description of Screens
Verify that the RS-485 network is
connected to all GCP-1 controls in
system.
Verify that the RS-485 Network is
correctly terminated. See section 1.9.6
Inter-Control Communications (RS-485)
Increase NEXT GENERATING SET
DELAY set point in sequencing menu.
See section 1.3.4 Description of Set
points
Increase MAX START TIME set point in
sequencing menu. See section 1.3.4
Description of Set points
Increase REDUCED LOAD DELAY set
point in sequencing menu. See section
1.3.4 Description of Set points
Increase MAX STOP TIME set point in
sequencing menu. See section 1.3.4
Description of Set points
Corrective Action
Appropriately set mains high/low
frequency and high/low voltage set points
in shutdown/alarm menu. See section
1.3.4 Description of set points
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
Increase Mains high frequency and
voltage and decrease mains low
frequency and voltage set points in the
shutdown/alarm menu. See section 1.3.4
Description of Set points
Corrective Action
Verify that the RS-485 Network is
correctly terminated. See section 1.9.6
Inter-Control Communications (RS-485)
Verify that the RS-485 Network is
connected to the GCP-1 RS-485 input at
all units
Verify the polarity of the RS-485 network
on all units
Verify that the +5Vdc power supply is
linked between all units
11. Definition of Terms
AMF Automatic Mains Failure. The ability of a control
to detect, and take action on a mains failure
condition. The GCP–1, which has AMF
capabilities, can be programmed to sense a loss
of mains condition based on mains voltage,
frequency, or a sudden load surge on a
generator operating in parallel with the mains.
The action taken by the GCP–1 when it senses a
mains failure can be programmed for either an
alarm action, or a standby power action where all
generators start and tie to the load after the
failed mains have been isolated from that load.
Automatic A control mode used by the GCP–1 to activate
Control several automatic functions within the control.
These functions, which are dependent upon
program setpoints and system configuration, are
Loss of Mains detection, Automatic Sequencing,
and Automatic dead bus closing, Automatic
control also effectively connects those GCP–1
units in automatic to the Local Operating
Network (LON).
Auto Switch A discrete input to the control which will initiate
automatic operation of the GCP–1.
ATS Automatic Transfer Switch. A device which
isolates the mains upon a sensed fault in the
mains, or through manual operation. The ATS
selects a secondary power source, such as a
diesel generator to supply the load when the
mains have been isolated. The ATS will also re-
connect the load to the mains when they are re-
established and stable. The GCP–1 control has
ATS functions.
Audible An alarm condition used by the GCP–1 for
Alarm various alarm settings which will cause the
audible alarm relay output to energize when
reaching or exceeding the alarm parameters.
Automatic The automatic addition, or subtraction of
Sequencing generators to/from the load based on
predetermined load levels being crossed for
specific periods of time. Automatic sequencing is
a function of a multiple generator system which
is operating in load sharing mode isolated from
the mains, or process control mode in parallel
with the mains.
AVR Automatic Voltage Regulator. A device which
controls the field excitation of an AC generator in
such a way as to maintain a specific voltage
level over the operating load range of the
generator. The GCP–1 control biases the voltage
setting of the AVR to voltage match during
synchronization and to control reactive load
during load share and mains parallel operation.
Base A term used to describe a generator loading
Load condition in which the generator is paralleled to
another source of power, typically the mains, and
loaded to a fixed kW level. The generator
maintains this kW level regardless of load on the
Mains.
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Breaker A device used to connect one power source to a
load, or to another power source. Breakers can
be either manually or automatically operated,
and will usually contain overcurrent protection.
The GCP–1 controls motorized breakers by
issuing a momentary breaker close output to
energize the breaker coil, and a separate
breaker open output to shunt trip the breaker to
open it.
Contactor A device used to connect one power source to a
load, or to another power source. Contactors are
typically automatic in operation, and are
energized for closure from an external source.
The GCP–1 controls contactors by issuing a
contactor close output to close the contactor,
and removing this output to open the contactor.
Dead Bus The ability of a generator breaker control device
Closing to sense, and safely close onto a load which has
no other generators or sources of power tied to
it. Dead Bus Closing must not allow two
generators to attempt closure to the dead bus at
the same time, since an out of phase paralleling
situation would likely occur. The GCP–1 uses its
Local Operating Network to ensure safe dead
bus closing among all units tied to this network.
The units have a single dead bus token, which
allows the unit possessing it to close to the dead
bus. Only one token exists on the network, so
there is no possibility of multiple units closing to
the dead bus simultaneously. Dead Bus Closing
is always active in single unit configurations.
Droop A reduction in the reference of a controlled
parameter as the amplitude of that parameter
increases (negative feedback). The GCP–1 uses
Kilowatt Droop as a manual means of loading
the generator when paralleling to another
generator, or to the mains.
Dwell A term used to describe the amount of time
Time required during synchronization in which one
power source is within a specified phase angle
window of another source it is synchronizing to.
Hard A shutdown condition used by the GCP–1 for
Shutdown various alarm settings which will cause the unit
to immediately open its generator breaker if on
load, and shut down by immediately opening its
fuel solenoid output when reaching or exceeding
the alarm parameters.
Isochronous A term which is used to describe a generator set
which will maintain its frequency at a constant
level as the load on that generator changes. The
GCP–1 typically uses isochronous load control
when in load sharing, or when operating as a
single unit. This assures a constant frequency
under all generator loads which are within the
capacity of the generator.
Inverse Time A time delay used for over current and reverse
Delay power detection, which utilizes both time and
amplitude of the condition to determine the
active trip level. The inverse time delay accounts
for rapid high amplitude conditions to cause a
 trip, as well as long duration low amplitude
conditions.
Isolated Bus A bus which is electrically isolated from the
mains.
KVA Kilovolt-Amps. The power rating of the generator
set KVA is determined by multiplying the rated
voltage of the generator by the rated current.
KVAR Kilovolt-Amps Reactive. Reactive load is
produced by a phase angle differential between
the volts and the amps of the generator. KVAR
can either be a product of inductive or capacitive
loads when operating on an isolated bus, or can
be produced by the generator when operating in
parallel with another power source such as the
mains.
kW Kilowatts. Watts are the product of the voltage of
the generator and the current, which is produced
within the voltage cycle. kW load is resistive in
nature.
Load Typically the kW load on the generator at any
given time.
Load Surge A condition in which a step load on the
generator, which is operating in a mains parallel
mode (base load or process) above a certain
amplitude can be used to trigger a Loss of Mains
condition.
Loss of A condition in which the sensed mains PT input
Mains to the GCP–1 falls below certain voltage and/or
frequency setpoints for a given period of time.
Load Surge can also be used to detect a Loss of
Mains condition. The GCP–1 can be configured
to trigger a Loss of Mains (LOM) reaction to
these conditions, and provide on site power
generation to supplement the load until such
time as the mains return and are stable.
Mains To synchronize and close an operating generator
Parallel to the mains. The GCP–1 can be configured for
Mains Parallel operation.
Master The Highest Priority unit in an operating
automatic system. The Master Control controls
load sharing, VAR/PF sharing, sequencing,
synchronization to the mains, mains breaker
closure/opening, and multiple unit starting.
Manual A switch input to the GCP–1 which puts the
control in a manual operating mode. When in
manual, the GCP–1 does not communicate with
other units on the network, and if in a multiple
unit system, will not issue a dead bus closing
command. Being in manual also cancels any
Loss of Mains detection for that particular unit.
Network A unique address assigned to each unit, which is
Address operating in an automatic system. The network
address is that particular units “name” on the
network so that it can be properly identified by
other units operating on the same network.
Network A unique number assigned to each unit
Priority operating in automatic on the network. Network
priority defines the sequence in which units will
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No Parallel An operating mode of the GCP–1 which will not
allow the generators to operate in parallel with
the mains under any circumstances. All
transitions to and from the mains are completed
using an open transition action.
Parallel To synchronize and close an operating generator
to another generator, or to the mains.
Power A right triangle which is used to determine the
Triangle amplitude relationship between KVA, KW, and
KVAR
Process A switch input which selects a mode of control
Control used while in parallel with the mains. When
operating in process control, the GCP–1
receives a 4-20 mA, or 1-5 VDC input from an
external transducer. This transducer monitors a
variable which is affected by the generator
operation. Variables such as imported power to a
site, exported power to the mains, exhaust
temperature, and fuel gas pressure levels are
typical for monitoring with a transducer. The
GCP–1 uses an internal reference level for the
process input, and compares this reference to
the transducer input.The GCP then raises or
lowers the amount of load on the generator to
maintain the process transducer input to the
referenced value.
Proportional A mode of load control used by the GCP–1 while
Load operating multiple units on an isolated bus.
Proportional Load Sharing measures the total
Sharing
KVA capacity of all the units on the bus and
divides the total KVA load on the bus by this
capacity. This value is then sent over the
network as a load reference for all units
operating in parallel on the bus. The result of this
is the ability of various KVA rated units operating
at their respective proportion of the total load on
the bus. This allows consistent load sharing
among units of various sizes throughout their
entire operating load range.
Run With A discrete input to the GCP–1 which signals the
Load unit to operate the generator on load. The way
that the control puts the generator on load
depends upon software configuration, and the
type of system the GCP–1 is configured for.
Slave A GCP–1 with lower network priority (Higher
numerical value) than the master.
Soft A shutdown condition used by the GCP–1 for
Shutdown various alarm settings which will cause the unit
to softly unload and cooldown when reaching or
exceeding the alarm parameters.
Soft Transfer A Load Control Mode of the GCP–1 which allows
the unit, or group of units to transfer power from
the mains to the on site generators. Upon
reaching either a base load reference, or
process control reference level, the GCP–1 will
issue a command to open the mains breaker.
This results in a complete transition of power
from the mains to the on site generators.

Synchronize To match the frequency, phase angle, and

voltage of a generator to another power source
such as a generator or the mains. This will allow
a safe smooth breaker closure of that generator
to the power source. The GCP–1 uses Phase
and Voltage Matching to ensure there is a
minimum of potential across the breaker prior to
closure.

Test A discrete input to the GCP–1 which is used to

start the engine for test and initial start check
out. The test input is also used with the run with
load or process inputs, and a software setpoint,
to put the GCP–1 into a soft transfer mode.

VAR/PF The ability to control a level of VAR or PF on a

Control generator while in parallel with the mains. The
GCP–1 has VAR/PF control features which allow
the user to set a desired VAR or PF level on the
generator while in parallel with the mains. The
VAR or PF level is maintained by changing the
excitation level of the generator. This is
accomplished by changing the voltage reference
level of the AVR from the GCP1.

VAR/PF The ability to share the VAR and PF load on

Sharing multiple units operating on an isolated bus. Like
load sharing, the GCP–1 VAR/PF sharing
measures the VARs of the load on the isolated
bus, and divides this value by the total VAR
capacity of the generators tied to the load. A
proportional VAR/PF level is then maintained
between all units tied to the load based on their
rated VAR capacity.

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