paralleling all-in-one

GENSYS 2.0
All-in-one genset control
and paralleling unit
with integrated PLC
• Compact “all-in-one” module
• I/O flexibility
• Internal logic sequences,
programmable by equations
• New multi-function graphic display
• 5 isolated serial ports: RS485, 2 CAN bus,
Ethernet, SD card reader
• J1939 communications with electronic engines
• Fully compatible with all speed governors and AVRs

The GENSYS 2.0 is a control unit PROGRAMMING BY EQUATIONS

designed for generator electrical The GENSYS 2.0 controller is a real PLC unit where equations and
panels.
This “all-in-one” unit combines
all necessary functions:
• Three phase mains failure
• Engine start/stop and
protection
• Alternator control and
protection
• Mechanical parameters display
• Electrical parameters display
• Genset synchronization
• Load sharing and kW control
• Load sharing and kvar control
GENSYS 2.0 is configurable via its
front panel or via a PC with CRE
Config software (cf. p64). It has
an embedded web site which is
password protected.
The GENSYS 2.0 controller has
analog load sharing lines and
is compatible with all types of
analog load sharing modules.
sequences can be programmed directly by the user with text editor
software or Easy PLC software (cf p 66).
INPUTS / OUTPUTS WITH NO LIMIT
The number of input/outputs that can be added is one of the most
important on the market. Extension modules (DIN rail mounting) can be
added on the CAN bus. This extends the inputs/outputs up to 128 digital
inputs, 64 digital outputs, 44 analog inputs and 8 analog outputs.
MINIMUM OPTIONS
This compact controller is offered with a minimum of options to fit all
types of application without expensive add-on packages. The standard
GENSYS 2.0 unit is recommended for all types of power plant, from 1 to
14 generators.
For specific needs, GENSYS 2.0 can include the following options:
• Mains paralleling
• Phase shift compensation (ie: DYN 11)
INTER-UNIT ISOLATED CAN BUS
The GENSYS 2.0 has a inter-unit isolated CAN bus port for information
transfer (dead busbar management, static paralleling, kW and kvar load
sharing...).
The inter-unit bus allows more information exchanges between modules
and reduces the wiring and the number of I/O used on each module.

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 FOCUS
on SUPER DROOP

Super Droop was developed by Perfect for mobile or remote genset

CRE Technology to provide an applications
innovative new solution to the The digital Super Droop feature
genset industry. Thanks to its Super (wireless load sharing) makes it
Droop feature, your plant does not simpler. CRE Technology makes
need extra communication ports genset paralleling simple as cabling
for load sharing. The units only between units becomes useless.
communicate via the busbar. Unique on the market
In Super Droop mode, the load No communication between units
sharing is managed between is needed to achieve paralleling.
50.50Hz (0% load) and 50.00Hz The curve is almost isochronous at
(100% load). This is adjustable. +/-0,25Hz.
For this specific droop, it is not Super Droop is available on GENSYS
necessary to set the engine speed 2.0, Unigen and Unigen PLUS
precisely, and no connections are modules.
required between each unit, not
even the 0V.
• The kW and kvar load sharing is
managed with super droop
• The unit includes the usual
protections (phase sequence
protection included)

APPLICATIONS GENSETS WITH MAINS FEATURES

• Gas and fuel generators When several generators are paralleled Control and management
• Cogeneration with mains, the MASTER 2.0 is used • Manual and automatic engine
• Turbo-alternator (connection via inter-module CAN bus) for: control.
• Synchronization and power • Three phase mains failure • J1939 compatibility (Cummins,
management module (without • Paralleled gensets with several mains Volvo, Scania, MTU, CAT...)
engine control). control • Automatic start/stop control
• Electrical protection for power plant depending on load demand.
• 1 generator in change over mode
• Dead busbar management.
with mains. and mains
• Isochronous or droop kW load
• 1 generator in parallel with mains: • Electrical parameters display for sharing control (via CAN bus serial
Base load or Peak shaving. power plant and mains port, up to 14 generators)
• 2 to 14 gensets in parallel and • Manual and automatic paralleling • Constant voltage (or droop) kvar
change over with mains. with mains (frequency, phase and load sharing control (via CAN bus
• 2 to 14 gensets in parallel and voltage) serial port, up to 14 generators)
paralleled with mains for load • Power factor control when • Power factor control when
transfer. In this case, the Master paralleling with mains. paralleling with mains.
2.0 is used for mains paralleling via • KW power management with several • KW control (base load or peak
CAN bus. modes: shaving) when paralleling with
ͳͳ No break change over with load mains.
• Static paralleling (engine stopped)
• Tie breaker management. transfer Protections
ͳͳ Permanent paralleling in base load • Generator electrical protections:
ͳͳ Permanent paralleling in peak <F, >F, <U, >U, >I, >In, >P, <P, <-P,
>Q, <Q, <-Q
shaving mode (export/import)
FOCUS • Mains electrical protections
(option) : <F, >F, <U, >U, >P, <P, <-P,
on COMPATIBILITY >Q, <Q, <-Q, phase shit, df/dt.
Thanks to its versatile connectivity the GENSYS family is compatible • Short circuit protection.
with peripheral devices: • Phase sequence protection, phase
• Electronic engines: CAN bus J1939/MTU MDEC shift compensation.
• Speed govenors: ±10 VDC/Pulse/PWM 500Hz
• AVR: 0-10 KΩ/Pulse
• PLC/HMI: Modbus RTU RS485/Modbus TCP ethernet
• Power transducers: 4-20mA
• I/O extensions (only for GENSYS 2.0 and GENSYS 2.0 CORE): CAN open
• Mains: CAN inter-GENSYS
• Analog load sharers: parallel lines

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 paralleling
GENSYS 2.0
Synchronization
• Manual and automatic frequency
and phase synchronization
(differential frequency meter +
synchroscope available on screen).
• Manual and automatic voltage
synchronization (differential
voltmeter available on screen).
Information display
• Engine parameters display: oil
pressure, water temp, speed, hours
run meter…
• Generator electrical parameters
display:
ͳͳ Phase-phase Voltage
(3 phase RMS)
ͳͳ Phase-neutral voltage
(3 phase RMS)
ͳͳ Current (3 phase RMS)
ͳͳ Frequency
ͳͳ Active power (3 phase + total)
ͳͳ Reactive power
(3 phase + total)
ͳͳ Power factor (3 phase + total)
ͳͳ Active power energy (kWh)
ͳͳ Reactive power energy (kvarh)
• Mains electrical parameters display:
ͳͳ Phase-phase Voltage
(3 phase RMS)
ͳͳ Current (3 phase)
ͳͳ Frequency
ͳͳ Active power
ͳͳ Reactive power
ͳͳ Power factor
ͳͳ Import active power energy
(kWh)
ͳͳ Import reactive power energy
(kvarh)
Alarms and events
• The last 50 alarms and last 50
shutdowns are recorded on non
volatile memory.
• Data logging every 100ms.
Other
• Electronic droop function (droop
<1%). Allows load sharing without
inter-unit communication.
Quasisochronous® load sharing.
• “Watchdog” digital output for
microprocessor life signal.
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all-in-one
CHARACTERISTICS
Current, voltage and frequency
• DC voltage power supply input: 8
to 35VDC, 600mA at 12VDC and
300mA at 24VDC.
• AC voltage inputs: 100 to 480Vac,
100mA max. Neutral terminal does
not need to be connected.
• AC current inputs: 0 to 5A, 1VA.
Each phase is isolated from the
others.
• AC current overload: 15A during 10s.
• Frequency measurement: 45 to
70 Hz – 15VAC minimum between
phase and neutral.
• Voltage control signal: The voltage
control (AVR) is made either by a
+/-10VDC output with adjustable
span and offset or by voltage+/
voltage- contacts.
Environment
• Operating temperature: -20 to +70°C
• Storage temperature: -30 to +80°C
• Humidity: 5 to 95%. Tropic-proof
circuits for normal operation in
humid conditions.
Inputs, outputs
• Digital inputs: NO or NC to ground.
• Emergency stop input: Norm.
Closed 24V.
• Relay outputs (crank and fuel): 5A.
The 24V is provided through the
emergency push button.
• Relay outputs (breakers): 5A,
230VAC max. NO + NC available.
• Transistor outputs: 350mA, over-
current protected.
• Analog inputs (oil pressure and
water temp): 0 to 400 Ohms.
Calibration is configurable.
• Analog inputs (spare 1 and spare 2): 0
to 10 KΩ.
• Calibration for speed and frequency
control is made either by a +/-
10VDC output with adjustable span
and offset or by speed+/speed-
contacts.
• Magnetic pick up input: 100 to
10.000Hz, 2VAC minimum.
• PWM output for CAT and Perkins
engines
Ports
• 5 isolated serial ports are available:
ͳͳ RS485 for Modbus RTU (read
and write)/ male Sub-D 9 pins
120 ohm resistors selected by
micro-switch.
ͳͳ CAN bus for inter-GENSYS/
Master 2.0 connection:
male Sub-D 9 pins 120 ohms re-
sistors selected by micro-switch
ͳͳ CAN bus dedicated to options
J1939, I/O extensions:
male Sub-D 9 pins 120 ohm
resistors selected by micro-
switch
ͳͳ Ethernet: PC communication/
Modbus TCP
ͳͳ SD card reader
Size and weigh
• Size: 248x197x57mm
(9.76x7.76x2.24in)
• Panel cut out: 177x228mm
(6.97x8.98in)
• Weight: 1.9kg (4.2lb)
Certifications
• European Union Directives:
EN 50081-2, EN 50082-2, 73/23EEC
• Front panel: IP54 protection. Back
panel: IP20 protection.
Other
• LCD characteristics: 114x64mm, 60
cd/m² backlight, 3 character sizes.
• Terminals: 2 piece connectors,
2,5mm².
• Languages: English, Spanish,
French, Italian.
PART NUMBER
A53Z0
SOFTWARE
CRE Config / Easy PLC
CABLE
A53W1
ASSOCIATED PRODUCTS
Reduced: GENSYS 2.0 LT
Complementary: Master 2.0
 4 mm2 wire
governor
From speed
Pickup input

External Tank

power supply
isolated from
Chassis
Pickup +

G8
Capacitor
(optional)
governor
To speed
Pickup -

G7
-Alim
analog
Power Tank Speed out+

K1

controller
G9 G11 G10 K4

Speed
Speed ref

-
Power supply -

K3
Shield

OR
F
Power supply + PWM

ECU
K2
+
Pwm output

F
Emergency

A3
stop

Analog
+
Crank AVR out +

AVR
H2 H4 H3

G
CRANK relay out -

A1
AVR out -

+Alim
output 6
Shield 1
Fuel
relay out

A2
FUEL
output 7

F
Gen L1 100 - 480 V

B2

L1
F
Gen L2

B3

L2
F
Gen L3

B4

L3
SPARE Output 1

C1
Gen N

B1

N
S1
P1
Spare output examples: 1-5A
Gen I3+

D6
- +/- speed to speed governor
SPARE Output 2
- Engine preglow

C2
- Visual / Audio alarm Gen 3-

D5

S2
P2 S1
- Generator breaker trip

P1
- Lubrification pump
Gen I2+

D4
- Reverse power Output 3
- ... SPARE

C3
Gen I2-

D3

S2
P2 S1
P1
Gen I1+

D2
Output 4
SPARE C4
Gen I1-

D1

S2
P2
Gen Open Breaker

E4

- Alim
+Alim
SPARE Output 5
C5

Gen Close Breaker

E5
Gen Common

E6
Shield
F5

Not connected when

several generators
Oil pressure meas. - Mains Open Breaker

E1
F8

F8

Load
Oil pressure meas. +
F9

F9

Mains Close Breaker

E2

- Alim
Mains Common

E3
Water temp meas. -
F6

F6

P2
S2
Water temp meas + Bus / Mains I1 -

L6
F7

F7
If chassis not connected to 0V

If chassis connected to 0V

Bus / Mains I1 + L5
Engine meas. 1 -
F1

F1

S1 P2
P1
S2
Engine meas. + Bus / Mains I2 -
F2

F2

L4

Bus / Mains I2 +
L3

Engine meas. 2 -

S1

P1
F3

F3

P2
S2
Engine meas. 2 + Bus / Mains I3 -
L2
F4

F4

Bus / Mains I3 +
L1

S1
P1

L1
F

Bus / Mains L1
B5

Mains power by external

GENSYS 2.0

Shield
G2

transducer
F

Bus / Mains L2

L2
B6

+/- 20mA -
G3

L3
F

+/- 20mA or +/- 10V Bus / Mains L3

B7

+/- 20mA +
G1

100 - 500V

Shield
G5

Mains

Parallel +
G6

Parallel lines to GCR or

WOODWARD analog load
Mains breaker IN
J1

sharing
Parallel -
G4

Gen Breaker IN
J2

Spare input examples:

Remote start/stop - +/- speed inputs
J3
DB9 male
9 - 0V
8 - NC
7 - NC
6-A
5-B
4 - 0V
3 - 0V
2 - NC
1 - NC

COM 5
RS 485

- Low temp warning

Isolated RS485 / MODBUS RTU
Spare J4 /Oil press - Low water level
J4

- Low fuel warning

- Charger fault
Spare J5 /Water temp
J5

- Air damper shut

- Exter electrical fault
Spare input J6
DB9 male

COM 1 - ...
9 - NC
8 - NC
7 - CANH
6 - 0V
5 - 0V
4 - NC
3 - 0V
2 - CANL
1 - NC

J6
CAN 1

IsolatedCAN1 INTER-GENSYS
+ MASTER 2.0 Spare input J7
J7

Spare input J8
J8
DB9 male

Spare input J9
9 - NC
8 - NC
7 - CANH
6 - 0V
5 - 0V
4 - NC
3 - 0V
2 - CANL
1 - NC

COM 2
J9
CAN 2
1 genset to mains application
Wiring example :
REV.
c

d
a

Isolated CAN 2 J1939

Spare input J10
J10
DESCRIPT

R=120 ohms

Spare input J11

J11
Wiring Gensys 2.0 A53Z0

COM 3
DATE

Type B
USB

Isolated USB to PC Spare input J12

J12
PAR
LB

Spare input J13

J13
N° DESSIN
FEUILLE

A53Z0 A 2001 C

- Alim
J14

Spare input J14

COM 4
Memory slot
RJ45

COM 6

Isolated ETHERNET
Spare input J15
J15
1 DE 1

REV

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