KOEL GREEN

Welcome to training programme on

SEDEMAC's

Genset Control Unit –

KG-645 KOEL Green

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Instructions : KOEL GREEN

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Course contains KOEL GREEN

● Introduction of KG-645
● Features
● Specifications
● KG-645 Modes – a) Monitoring Mode
b) Configuration Mode
● Expansion Module Interface
● Do's & Dont's
● Hands on practical training on GCU

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Introduction of KG-645 KOEL Green KOEL GREEN

● KG-645 is modern and feature rich genset controller

● Controller have user friendly interface and full graphics LCD

● Controller have highly versatile software & extensive I/O's

● KG-645 controller supports a wide variety of industry standard features in

Diesel engine genset

● KG-645 controller’s smart software offers flexibility to configure individual

input and output for specific application

● KG-645 can be configured through SEDEMAC's windows PC utility as well

as by using keypad of controller

● Built in E-governor feature (*This feature is due in the next release)

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Special Features
● KOEL GREEN

Real time counter Upto 100 event AMF feature Service Due
logs Alarm

Reverse Built in Password

KWH Counter
Polarity Protection E-Governor Protection
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Key Features KOEL GREEN

● KG-645 supports for Auto & Manual start/stop for 1-Ph

& 3-Ph DG genset.

● KG-645 is integrated with Electronics governor

● KG-645 provides communication: USB Port, RS485

● Expansion module interface

● Real time clock based event log upto 100 entries

● KG-645 sense the RPM through Alt Frequency or

MPU
● KG-645 having full graphics LCD with power saving

feature

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Specifications KOEL GREEN

● Front fascia of KG-645 KOEL Green.

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Specifications KOEL GREEN

● Back side of KG-645 KOEL Green.

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Specifications KOEL GREEN

1. Specifications
1.1 Power supply specification
Connector Pin No. 1, 2 (Ground and Battery positive
respectively)
Supply Voltage Range 8 To 32 VDC
Maximum Reverse Voltage -32VDC

1.2 Generator Voltages and Frequency Measurements

Connector Pin No. 27, 28, 29, 30 (N, B, Y, R respectively)*
Phase To Neutral Voltage 15VAC To 415VAC
Phase To Phase Voltage 15VAC To 750VAC
Voltage Accuracy ±1 % of full scale
Frequency Range 3Hz To 75Hz
Frequency Accuracy 0.1 Hz

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Specifications KOEL GREEN

1.3 Generator Current Measurement

Connector Pin No. 35 and 36(For phase B),37 and 38(For
phase Y), 39 and 40(For phase R)
Nominal CT Secondary Current Rating 5A
Burden 0.25VA
Accuracy ±1 % of Nominal

1.4 Mains Voltage and Frequency Measurements

Connector Pin No. 31, 32, 33, 34 (N, B, Y, R respectively)*

Phase To Neutral Voltage 15VAC To 415VAC
Phase To Phase Voltage 15VAC To 750VAC
Voltage Accuracy 2% of full scale
Frequency Range 3Hz To 75Hz
Frequency Accuracy 0.25 % of full scale

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Specifications
2 Inputs
2.1 Digital Inputs
Connector Pin No.
Number of Inputs
Type
Open Circuit Voltage
2.2 Analogue Inputs
2.2.1 I/P: ANLG / DIG F
Controller terminal number
Display range
Type
Range
Accuracy
SED-MR-QF-10, Rev-03
KOEL GREEN
10, 11, 12, 21, 22
5
Negative Sensing (Connect to ground for
activation)
(VBATT – 1) V-DC
26 (CANOPY_Temp / LOP sensor / LUBE oil
Temp)
-25°c to 200°c / 0 to 10 Bar
Ratio Metric Sensing
10 - 5000 Ohm (5 KΩ) (Open Ckt = 5.5 K)
1.5% of Full Scale
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Specifications KOEL GREEN

2.2.2 I/P: ANLG FL / DIG G

Controller terminal number 25 (Fuel_Level sensor)

Display range 0 to 100 %
Type Ratio Metric Sensing
Range 10 - 5000 Ohm (5 KΩ)
Accuracy ±1.5 % Of Full Scale

2.2.3 I/P: ANLG TEMP / DIG H

Controller terminal number 24 (Eng_temp sensor)

Display range -25 to 200 °C depending on sensor
Type Ratio Metric Sensing
Range 10 - 5000 Ohm (5 KΩ) (Open Ckt = 5.5K)
Accuracy 1 % of full scale (for 50 to 1000 Ω)
15 % of measured value (for 2500 Ω)
17 % of measured value (for 5 KΩ)
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Specifications KOEL GREEN

2.2.4 I/P: ANLG (0–5V / 4–20 mA)

2.2.4.1 Lube Oil Pressure (4–20 mA)

Controller terminal number 23

Surge As per ISO 7637-3
Type Analog current sensing
Range 25 mA
Accuracy ±1.5 % of Full Scale

2.2.4.2 Analog Voltage Input

Controller terminal number 23

Type Analog voltage sensing
Range 0 to 5V-DC
Accuracy 0.5 % of Full Scale (5 V-DC)

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Specifications KOEL GREEN

2.2.5 Sensor Common

Controller terminal number 41 SCP (Sensor Common Point)

2.2.6 Magnetic Pick Up Input

Controller terminal number 42

Type Single ended
Input voltage range 200 mV to 70 V-AC RMS
Accuracy 0.25%

2.2.7 D+ Charge Alt

Controller terminal number 7

Voltage range 0 to 35 V
Accuracy 2%

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Specifications KOEL GREEN

3. Outputs
3.1 Digital Outputs
Connector Pin Number 3, 4, 5, 6, 8, 9
Number of Outputs 6
Type High Side Driver
Rating 0.75 A (Max 1A)

3.2. Actuator Outputs

Connector Pin Number 17, 18, 19, 20
Type Stepper Motor Drive
Maximum Current 1A Each Coil

Note: The Actuator Outputs should be used only for the SEDEMAC Actuator, if installed

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Specifications KOEL GREEN

3.3 Communication Ports

USB Used To Flash the Firmware (USB 2.0)

RS485 Used For Data Communication
Controller terminal number for 15, 16
RS485
CAN Used for communication between
controller and SEDEMAC's input/output
expansion module
Controller terminal Number for CAN 13, 14

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KG-645 Modes KOEL GREEN

A) Power on Screen :

1.1 LOGO 1.2 Product Info

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KG-645 Modes KOEL GREEN

B) Monitoring mode:
● In monitoring mode the screen will scroll automatically after a predefined time which

can be Configured in configuration menu or you can use the Navigation

UP/DOWN Keys to scroll / browse the screens. Screen will be steady for 2 min once
you scroll the screen manually

● Monitoring mode screens are grouped and identified by different symbols at top left
corner of screens, following table will provide more details

Sr. # Symbols for Screen's Group Name of Screen's Group

1 Status & Info screens

2 Generator screens

3 Mains screens

4 Engine screens

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Monitoring Mode KOEL GREEN

1. Status & Info screens

1.1 Manual Mode 1.2 Auto Mode

1.3 Test Mode 1.4 Start - Manual Mode

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Monitoring Mode KOEL GREEN

1.5 Alarm - Manual Mode 1.6 Alarm - Manual Mode

1.7 Contactor – Status 1.8 Off Mode

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Monitoring Mode KOEL GREEN

2. Generator screens

2.1 Generator Voltage 2.2 Generator KW load

2.3 Generator kVA load 2.4 Generator Output/Current

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Monitoring Mode KOEL GREEN

2.5 Generator Power Factor 2.6 Generator Energy

3. Mains screens

3.1 Mains Healthy 3.2 Mains Failed

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Monitoring Mode KOEL GREEN

4. Engine screens

4.1 Engine Battery 4.2 Engine Temp

4.3 Engine Oil Pressure 4.4 Engine Fuel

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Monitoring Mode KOEL GREEN

4.5 Engine Speed 4.6 Engine Run Time

4.7 Canopy Temp 4.8 Alarm

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Configuration Mode KOEL GREEN

● Functional Keypad of KG-645 KOEL Green

● Press Arrow
Key/s to clear
the Alarms
and Warnings

Display
Menu
Navigation
UP Key

Alarm LED

Menu
Navigation
DOWN Key

Press
And hold
● Press and Auto Key
hold Stop to enter into
Key to enter Test Mode
into Off Mode

Stop Key Start / Select Key Auto/Manual/ Test Select Key

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Configuration Mode KOEL GREEN

1. Configuration Mode
To enter into the configuration mode press and hold “STOP” and “Down Arrow”
key simultaneously. (Fig. 01)

Fig. 01. Press Stop & Down Fig. 02. Press Stop or Start
● To enter into edit mode please press ”START”. If you wish to read the configuration
press “STOP”. For edit mode enter the password (Fig. 02).

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Expansion Module Interface KOEL GREEN

● SEDEMAC's input/output expansion module can be used in

conjunction with KG-645
● Expansion module provides additional 5 Digital Inputs, 5 Analog
Inputs and 5 Digital Outputs
● Green LED of module indicates power status and Red LED blinks
when data communication between KG-645 and expansion
module is active
● KG-645 & Expansion module connection :

KG-645 controller Expansion Module

Terminal Sr. No. Description Connector Pin no Description

13 CAN H 16 CAN H

14 CAN L 3 CAN L

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Expansion Module Interface KOEL GREEN

Pin# Name Description

1 ANLG_IN_EX- Analog input from
S1 sensor S1
2 ANLG_IN_EX- Analog input from
S2 sensor S2
3 CAN L CAN L
4 ANLG_IN_EX- Analog input from
S5 sensor S5
5 DIG_IN EX-D Input from switch –
D
6 DIG_IN EX-E Input from switch –
E
7 Not used NA
8 OUT EX-E Digital Output – E
9 OUT EX-D Digital Output – D
10 OUT EX-C Digital Output – C SEDEMAC Expansion Module
11 OUT EX-B Digital Output – B
12 OUT EX-A Digital Output – A
13 BATTERY - Battery ground
14 ANLG_IN_EX- Analog input from
S3 sensor S3
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Expansion Module Interface KOEL GREEN

Pin# Name Description

15 SENSOR Connection to
COMMON Sensor Common
16 CAN H CAN H

17 ANLG_IN_EX-S4 Analog input from

sensor S4
18 DIG_IN EX-C Input from switch – C

19 DIG_IN EX-B Input from switch – B

20 DIG_IN EX-A Input from switch – A

21 Not used NA Connector of Expansion Module

22 Not used NA
23 Not used NA
24 Not used NA
25 BATTERY + Battery Positive
26 BATTERY + Battery Positive

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Do's & Dont's KOEL GREEN

● DO: Follow the provided wiring circuit diagram

● DO: Check the all connections are done properly, check for lose connections
● DO: Check the “Genset IN” & “Mains IN” connections are properly connected
as per the given sequence
● DO: Check the each & every Digital Output's are used along with automotive
relay's, if loading current is higher than controller output specification
● DO: Connect the Batt -ve on pin no #1 & Batt +ve on pin no. #2 of GCU
properly
● DO: Handle GCU carefully and use proper tools to interface the GCU, Use
TAPARIA 810 screw driver or with the size of 2.3 x0.4 mm to make
connections to GCU's terminals
● DONT: Don't Connect AC voltage to GCU's Battery voltage Pin's
● DONT: Don’t remove 12V / 24V battery when the genset is ON
● DONT: Don't modify the parameters of the GCU without permit from KOEL

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Hands on practical training on GCU KOEL GREEN

● Configuration & Connections

● Manual Mode operation
● Auto Mode operation – a) AMF Function
b) Remote Start/Stop
● Safety Alarms

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SEDEMAC's Product Support KOEL GREEN

1) Mr. Mahesh Kotagi

Tel: +91-8551039888 / +91-2135-623252
Email: mahesh.kotagi@sedemac.com

2) Mr.Anil Ghodekar
Tel: +91-8551043888 / +91-2135-623240
Email: anil.ghodekar@sedemac.com

3) Mr. Atul Yadav

Tel: +91-8551933888 / +91-2135-623241
Email: atul.yadav@sedemac.com
4) Mr. Sangram Jadhav
Tel: +91-8551041888 / +91-2135-623242
Email: sangram.jadhav@sedemac.com

For more updates visit : WWW.SEDEMAC.COM

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