Sed Man Gc2100 002 Manual For Gc2100 Controller

ABSTRACT
This manual is intended as

an information guide for
operating SEDEMAC's GC2100
genset controllers.
MANUAL FOR Doc #SED-MAN-GC2100-002
Date: 16-Jul-2018
GC2100:
GENSET
CONTROLLERS
Product Manual Version #1.00
Copyright
All rights reserved. No part of this publication may be reproduced, distributed or transmitted
by any means (including photocopying or storing in any medium by electronic means or other)
without the prior written permission of the copyright holder. Any reference to trademarked
product names used within this publication is owned by their respective companies.
SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document
without prior notice. For permission requests and applications to reproduce any part of this
publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
SEDEMAC Mechatronics Pvt. Ltd.

C9-10, C Block, MIDC Bhosari
Pune 411026, INDIA
Web Support:
Email: support@sedemac.com
Website: www.sedemac.com
Telephonic Support:
+91-20-67313500
+91-8551041888
+91-8551043888
+91-8551933888
+91-8551039888
GC2100 SEDEMAC
Safety Instructions
General Instructions
✓ This document includes important instructions that should be followed during installation and
maintenance of the generator Set controller.
✓ For safety reasons, the manufacturer recommends that this equipment be installed and serviced by
an authorized service personnel. Follow all applicable state and local electrical codes.
✓ Efficient and safe operation of the controller can be acquired only if the equipment is correctly
operated, configured and maintained. Many accidents arise due to ignorance or illiteracy towards the
elemental rules of safety and precautions.
The following safety notations found throughout this document indicate potentially hazardous
conditions to the operator, service personnel or the equipment.
• Highlights an essential element of a procedure to ensure correctness
• Indicates a procedure or practice, which could result in damage or

destruction of equipment, if not strictly observed
• Indicates a procedure or practice, which could result in injuring

personnel or loss of life, if not followed correctly
Electrical Safety
✓ Electric shock can cause severe personal injury or death.
✓ Ensure the generator set must be grounded before performing any installation or service.
✓ Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock.
Prevent contact with terminals, bare wires, connections, etc., while the generator and related
equipment are running. Do not tamper with interlocks.
✓ To handle the maximum electrical current, sizes of wire gauge used for electrical connections and
wirings must be appropriate to which they will be subjected to.
In Operation Safety
✓ Before installing genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.
Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal
electrical shock.
✓ Remove electric power supply before removing controller or touching other electrical parts.
✓ Use extreme caution when working on electrical components. High voltage can cause injury or death.
✓ Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
✓ Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
✓ Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. It may result in severe electrical shock.
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GC2100 SEDEMAC
✓ Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
✓ In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. Avoid direct contact with the
victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live
conductor. If the victim is unconscious, apply first aid and get immediate medical help.
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GC2100 SEDEMAC
List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer
their respective description. This list does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
BTS* Base Transceiver Station
CHG Charging
CKT Circuit
CT Current Transformer
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
OV Over Voltage
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
*BTS is also referred as Site Battery Monitoring in this user manual
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GC2100 SEDEMAC
Table of Contents
Introduction ......................................................................................................................... 1
Key highlights of the product ........................................................................................... 1
Product Features ............................................................................................................ 1
Specifications ..................................................................................................................... 3
Terminals ........................................................................................................................ 3
Power Supply Specifications ........................................................................................... 3
Genset Voltages and Frequency Measurements ............................................................ 4
Genset Current Measurements ....................................................................................... 4
Earth leak Measurements ............................................................................................... 4
Mains Voltages and Frequency Measurements .............................................................. 5
Digital Inputs ................................................................................................................... 5
Analog Resistive Sensor Inputs ...................................................................................... 5
Site Battery Inputs........................................................................................................... 6
Digital outputs .............................................................................................................. 6
D+ CHG ALT ................................................................................................................ 7
Sensor common point .................................................................................................. 7
Deep Sleep Mode Feature........................................................................................... 7
Communication ports ......................................................................................................... 8
Installation ........................................................................................................................... 9
Dimensions ..................................................................................................................... 9
Mounting on panel .......................................................................................................... 9
Terminal Pin Details ...................................................................................................... 10
Typical Wiring Diagram ................................................................................................. 13
Monitoring Mode ............................................................................................................... 14
Description of Control Keys ............................................................................................ 16
Configuration mode....................................................................................................... 16
Configurable parameters .............................................................................................. 17
Modes selection in GC2100 ............................................................................................. 33
Start and Stop Sequence .............................................................................................. 34
Operation modes .............................................................................................................. 36
Auto mode .................................................................................................................... 36
Manual mode ................................................................................................................ 41
Load sensing ..................................................................................................................... 44
Load Sensing in Manual mode ..................................................................................... 44
Load Sensing in Auto mode .......................................................................................... 44
Features ............................................................................................................................. 44
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GC2100 SEDEMAC
Auto Config Exit Mode ............................................................................................... 44
Load Histogram ......................................................................................................... 44
Alarms................................................................................................................................ 45
Troubleshooting ................................................................................................................ 49
Communication protocol ................................................................................................. 51
Connection Details..................................................................................................... 51
Precautions................................................................................................................ 51
Supported Functions.................................................................................................. 52
Communication settings .................................................................................................. 52
Notes ......................................................................................................................................... 59
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GC2100 SEDEMAC
List of Figure
Figure 1: GC2100 genset controller's front fascia ........................................................................ 2
Figure 2: Connectors of 5.08 mm pitch ........................................................................................ 3
Figure 3: Connectors of 10.16 mm pitch ...................................................................................... 3
Figure 4: SCP connection ............................................................................................................ 6
Figure 5: Dimensions of the GC2100 genset controller ............................................................... 9
Figure 6: Fixing clip and screw supplied along with controller .................................................... 10
Figure 7: Controller mounting on the panel using the fixing clips ............................................... 10
Figure 8: Rear view of the controller for terminal detail .............................................................. 11
Figure 9: Power circuit when used in the Auto Mains Failure Mode ........................................... 13
Figure 10: Control keys function ................................................................................................ 16
Figure 11: Configuration mode screen ....................................................................................... 16
Figure 12: Configuration mode authentication page screen ....................................................... 16
Figure 13: Saving setting screen ................................................................................................ 17
Figure 14: Mode selection screen .............................................................................................. 33
Figure 15: Flow chart of start sequence ..................................................................................... 34
Figure 16: Flow chart of stop sequence ..................................................................................... 35
Figure 17: Flow chart of Site monitoring mode........................................................................... 36
Figure 18: Flow chart of cyclic mode .......................................................................................... 38
Figure 19: Flow chart of Auto Mains Failure (AMF) mode .......................................................... 39
Figure 20: Flow chart of remote start/stop mode ........................................................................ 40
Figure 21: Flow chart of manual mode ....................................................................................... 41
Figure 22: Pictorial reference for starting the engine ................................................................. 42
Figure 23: Pictorial reference for stopping the engine ................................................................ 42
Figure 24: Pictorial reference to acknowledge the alarm in any mode ....................................... 43
Figure 25: RS485 MODBUS connection with the help of two core shielded twisted pair cable . 51
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GC2100 SEDEMAC
List of Tables
Table 1: Feature list ...................................................................................................................... 1
Table 2: Terminals ........................................................................................................................ 3
Table 3: Power supply specifications ........................................................................................... 3
Table 4: Genset voltage and frequency measurements ............................................................... 4
Table 5: Genset current measurements ....................................................................................... 4
Table 6: Earth leak measurements ............................................................................................... 4
Table 7: Mains voltages and frequency measurements ............................................................... 5
Table 8: Digital inputs ................................................................................................................... 5
Table 9: Analog resistive sensor inputs ........................................................................................ 5
Table 10: Site battery inputs ......................................................................................................... 6
Table 11: Digital outputs ............................................................................................................... 6
Table 12: D+ CHG ALT ................................................................................................................. 7
Table 13: Sensor common point ................................................................................................... 7
Table 14: Communication ports .................................................................................................... 8
Table 15: Details of GC2100 terminals ....................................................................................... 11
Table 16: Screens of engine status and operating modes ......................................................... 14
Table 17: List of configurable parameters .................................................................................. 17
Table 18: Digital input source selection ...................................................................................... 29
Table 19: LOP (Resistive) sensor calibration ............................................................................. 30
Table 20: Fuel level sensor calibration ....................................................................................... 30
Table 21: Engine / shelter temperature sensor calibration ......................................................... 30
Table 22: Auxiliary (S1/S2) resistive sensor calibration .............................................................. 30
Table 23: Auxiliary (S3/S4) current sensor calibration ................................................................ 30
Table 24: LOP sensor calibration ............................................................................................... 30
Table 25: Auxiliary (S3/S4) (0 – 5V) voltage sensor calibration .................................................. 30
Table 26: Digital output source selection .................................................................................... 30
Table 27: Types of alarms actions and their descriptions ........................................................... 45
Table 28: Alarms and their causes ............................................................................................. 45
Table 29: Troubleshooting .......................................................................................................... 49
Table 30: Details of function codes ............................................................................................ 52
Table 31: RS485 MODBUS communication configuration setting .............................................. 52
Table 32: Command from MODBUS master for Function 4 ....................................................... 52
Table 33: Normal response from GC2100 slave for Function 4 .................................................. 52
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GC2100 SEDEMAC
Table 34: Register map .............................................................................................................. 53
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GC2100 SEDEMAC
Introduction
This document presents information necessary for operating SEDEMAC's GC2100 genset
controller.
SEDEMAC’s GC2100 is a modern and feature rich genset controller with user-friendly HMI and full
graphics LCD. The GC2100 controller comes bundled with highly versatile software & extensive
I/O's and thereby supports a wide variety of industry standard features in diesel/gasoline genset
applications. GC2100 controller offers Site battery monitoring feature by which there is significant
saving in fuel consumption. In the above feature Shelter temperature monitoring feature is also
supported. Apart from this it also supports Auto (AMF, remote start /stop modes, cyclic mode and
exerciser mode) manual and test modes. The GC2100 controller's smart software offers flexibility
to configure each individual Input and Output for a specific function or application. The powerful
micro controller contained within the module allows for incorporation of a range of complex features
such as:
• LCD display
• True RMS Voltage and Current monitoring
• RS485 base communication
• Monitoring of engine and alternator parameters
• Fully configurable inputs and outputs for range of functions
Key highlights of the product

• Auto (Site battery backup, AMF, remote start /stop, cyclic modes and exerciser mode), Manual
and Test modes
• Site battery monitoring
• Shelter Temperature Monitoring
• Mains partial healthy detection
• Real time clock
• Fuel theft alarm
• Cyclic timer
• RPM sensing using genset’s output frequency
• Backlit and full graphics display
Product Features
GC2100 is a very enhanced and feature rich genset controller. It has 9 digital inputs and 7 analog
inputs. Full features list is provided in below Table 1.
Table 1: Feature list
Features Spec / Remark
Digital Switch Input 9
Analog Resistive Inputs 5
Analog Current/Voltage Inputs 2
Differential input (±60V DC) for Site battery voltage Y
Mains V-Input (AMF) Y
DG Alt V-Input, D+ CHG ALT I/O Y
Digital HSD 7
Event logs Y
USB port for PC based configuration Y
RS-485 for MODBUS communication Y
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GC2100 SEDEMAC
Features Spec / Remark
Operating Battery Supply Voltage (with -32V reverse protection) 8 to 32V DC
Operating Temperature Range (deg C) -20 to 65
Ingress Protection with Optional Gasket IP65
Sensor common Input with ±2V Sensing Range Y
Warning auto clear enable/disable Y
Fuel reference selection input Y
Figure 1: GC2100 genset controller's front fascia
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GC2100 SEDEMAC
Specifications
Terminals
GC2100 controller host two types of terminal blocks as shown in Figure 2 and Figure 3 given below:
Table 2: Terminals
Connector Male (on Female
Pitch SM Part No SM Part No Quantity
type controller) (mating part)
3-Pin 5.08 mm 5447366 SM0003213 5441977 SM0003292 1
4-Pin 5.08 mm 5447379 SM0003207 5448637 SM0003451 1
5-Pin 5.08 mm 5447382 SM0003205 5448640 SM0003293 1
6-Pin 5.08 mm 5441919 SM0003203 5441964 SM0003452 1
8-Pin 5.08 mm 5441935 SM0003201 5441951 SM0003294 1
9-Pin 5.08 mm 5447395 SM0003198 5448653 SM0003453 1
10-Pin 5.08 mm 5447405 SM0003196 5448666 SM0003501 1
4-Pin 10.16 mm 5474274 SM0003195 5453499 SM0001163 2
Figure 2: Connectors of 5.08 mm pitch
Figure 3: Connectors of 10.16 mm pitch
Power Supply Specifications

Following table gives a brief overview of power supply specifications
Table 3: Power supply specifications
GCU connector terminal # 1 & 2 (Ground & Battery +Ve respectively)
Supply voltage range 8 to 32 V-DC (Suitable for 12/24 V-DC system)
Cranking drop out period 50 mS
Maximum reverse voltage protection -32 V-DC
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GC2100 SEDEMAC
Measurement accuracy (Battery Voltage) ±1% full scale
Resolution 0.1 V
~ 0.4 A @ 12 V-DC (Excluding the current load for the
Maximum current consumption
high side driver output's)
Standby current consumption ~0.09 A @ 12V or 24V
Genset Voltages and Frequency Measurements

Following table gives a brief overview of genset voltage and frequency measurements
Table 4: Genset voltage and frequency measurements
GCU connector terminal # 54, 55, 56, 57 (N, B, Y, R respectively)
Measurement type True RMS
Phase to Neutral voltage reading limit 20 to 350 V-AC RMS
Phase to Phase voltage reading limit 20 to 606 V-AC RMS
Measurement accuracy (Voltage) (P-P / P- ±1% of full scale for Phase to Neutral
N) ±1.5% of full scale for Phase to Phase
1 V-AC RMS for Phase to Neutral
Resolution (Voltage)
2 V-AC RMS for Phase to Phase
Frequency range 5 to 75 Hz
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For 1 phase genset application, it is mandatory to connect the genset phase and
Neutral cables to the genset controller's phase R and Neutral terminals respectively.
Genset Current Measurements

Following table gives a brief overview of genset current measurements
Table 5: Genset current measurements
47 & 46 (for phase B), 45 & 44 (for phase Y),
GCU connector terminal #
43 & 42 (for phase R)
Maximum CT secondary current rating 5A
Burden 0.25 VA
Measurement accuracy ±1.4% of nominal
Earth leak Measurements

Following table gives a brief overview of earth leak measurements
Table 6: Earth leak measurements
GCU connector terminal # 48 & 49
Maximum CT secondary current rating 5A
Burden 0.25 VA
Measurement accuracy ±1% of nominal
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GC2100 SEDEMAC
Follow the recommended phase sequence while connecting the Current

Transformer (CT).
Mains Voltages and Frequency Measurements

Following table gives a brief overview of Mains voltages and frequency measurements
Table 7: Mains voltages and frequency measurements
GCU connector terminal # 50, 51, 52, 53 (N, B, Y, R respectively)
Phase to Neutral voltage 20 to 350 V- AC RMS
Phase to Phase voltage 20 to 606 V-AC RMS
±2% of full scale for Phase to Neutral
Measurement accuracy (Voltage)
±2.5% of full scale for Phase to Phase
1 V-AC RMS for Phase to Neutral
Resolution (Voltage)
2 V-AC RMS for Phase to Phase
Frequency range 3 to 75 Hz
Measurement accuracy (Frequency) 0.25% of full scale
Resolution (Frequency) 0.1 Hz
For single phase application, it is mandatory to connect the mains phase and neutral
cables to the genset controller's phase R and Neutral terminals respectively.
Digital Inputs
Following table gives a brief overview of digital inputs
Table 8: Digital inputs
GCU connector terminal # 33, 34, 35, 36, 37, 38, 39, 40, 41
Number of inputs 9
Type Negative sensing (connect to ground for activation)
0.8 V-DC maximum (measured at the genset
Low level threshold
controller’s terminals and battery ground terminal)
8 V-DC minimum (measured at the genset controller’s
High level threshold
terminals and battery ground terminal)
Emergency stop, Remote start/ stop, etc. Please refer
Software configurable options
Table 18 for more details.
Analog Resistive Sensor Inputs

Following table gives a brief overview of analog resistive sensor inputs
Table 9: Analog resistive sensor inputs
GCU connector terminal # 11, 12, 13, 14, 15 (LOP, Fuel, Temp, Aux1, Aux2)
Number of inputs 5
Type Ratio-metric sensing
Range 10 to 5000Ω
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GC2100 SEDEMAC
Open circuit detection Above 5.5 KΩ
Measurement accuracy ±2% of full scale (for range 50 to 1000Ω)
Figure 4: SCP connection
Site Battery Inputs

Following table gives a brief overview of site battery inputs
Table 10: Site battery inputs
GCU connector terminal # 24, 25
Number of inputs 2
Type Differential
Range ±60V
Resolution 0.1V
Accuracy ±2% of full scale (0 to +Ve max/ 0 to -Ve max)
Site battery run hours: In this feature, controller calculates the run hours for which the site runs on the
battery backup. Site battery run hours are incremented only when both the mains and genset
contactors are not latched and when site battery voltage is greater than low battery voltage threshold.
Digital outputs
Following table gives a brief overview of digital outputs
Table 11: Digital outputs
GCU connector terminal # 3, 4, 5, 6, 7, 8, 9
Number of outputs 7
Type High side driver
Maximum current rating 5A (3 & 4), 1A (5, 6, 7, 8, 9)
Software configurable options Start relay, Fuel relay, Close genset contactor, close
mains contactor, Stop solenoid and many more.
Please refer Table 26 for more details.
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GC2100 SEDEMAC
1) Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID”

directly to the controller's output terminals and it is recommended to
connect 3 & 4 to start & stop.
2) Genset & mains contactor latching relays should be compiled against
4kVA surge as per IEC-61000-4-5 standard.
D+ CHG ALT
Following table gives a brief overview of D+ CHG ALT
Table 12: D+ CHG ALT
GCU connector terminal # 10
Voltage range 0 to VBATT ; VBATT = 8 to 30 V-DC
Excitation PWM (Current limited to 250mA)
Accuracy ±2% of full scale
*The charge fail is a combined input and output terminal. When the genset starts, the terminal provides
the excitation current to the charge alternator field winding. After the excitation is successfully done, the
controller reads the charging alternator's output voltage for monitoring its health. The action for charge
fail is configurable.
Sensor common point

The sensor common point (SCP) terminal (Pin # 16) of the controller should be directly connected to an
electrically sound point on the engine body. This point on the engine body should serve as a common
reference point for all analog sensors such as those for measuring lube oil pressure, engine
temperature and fuel level. The electrical cable used for the connection should not be shared with any
other electrical connection. Such a wiring practice is strongly recommended to ensure that there is
negligible potential difference, if any, between the engine body and the controller's SCP terminal, and,
predictable and accurate analog sensor measurements are always available in a wide variety of field
conditions.
Table 13: Sensor common point
GCU connector terminal # 16
Range ±2V
Accuracy ±2% of full scale
Resolution 0.1 V
The sensor common point (SCP) terminal (Pin # 16) of the controller should be
directly connected to an electrically sound point on the engine body. This point on the
engine body should serve as a common reference point for all analog sensors such
as those for measuring lube oil pressure, engine temperature and fuel level. The
electrical cable used for the connection should not be shared with any other electrical
connection. Such a wiring practice is strongly recommended to ensure that there is
negligible potential difference, if any, between the engine body and the controller's
SCP terminal, and, predictable and accurate analog sensor measurements are always
available in a wide variety of field conditions.
Deep Sleep Mode Feature

Deep Sleep Mode is a useful feature to prolong the battery life.
In this mode, normal functions of the controller are suspended, and controller is placed into its lowest
power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode.
When the controller wakes up, normal operations are resumed automatically.
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GC2100 SEDEMAC
The controller goes in Deep Sleep Mode when there is no user interaction for the pre-set Deep Sleep
Mode Delay.
GCU does not go to Deep sleep mode in following conditions:
• In auto (Site, cyclic, exercise and remote start/stop) modes
• Mains monitoring is enabled, and mains contactor configured as output
• MODBUS communication is enabled
Comes out of deep sleep mode by pressing (not press & hold):
• Stop key
• Start key
• Auto key
• Ack key
Communication ports
Following table gives a brief overview of communication ports
Table 14: Communication ports
USB 2.0 Type B used for connection to PC running
USB
SEDEMAC Smart config.
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
RS485 Serial Port Termination resistor of 120Ω is provided between
output pin A & B
Common-mode operating range
Maximum distance of line is 1200m
GCU connector terminal # 30, 31, 32 (GND, A, B respectively)
The RS485 port on GC2100 genset controller supports a protocol based on MODBUS.
• Pin 30 should be connected to master’s isolated ground only

• Use two core shielded twisted pair cable for MODBUS RS485 connection.
• Keep pin 30 connection open if shielded cable is not available

• Do not connect pin 30 to battery -ve
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GC2100 SEDEMAC
Installation
Dimensions
Figure 5: Dimensions of the GC2100 genset controller

Recommended mounting panel cut-out dimensions: 189 mm X 143 mm.
Mounting on panel
To mount the controller into the panel, use the fixing clips provided along with the controller.
Follow the given steps:
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GC2100 SEDEMAC
Figure 6: Fixing clip and screw supplied along with controller
Figure 7: Controller mounting on the panel using the fixing clips

• Insert the fixing clip into the slot provided on the side of the controller.
• Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is
properly fitted inside the slot provided on the controller.
• Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the
panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum
tightening torque is 0.19 N-m.
Over tightening of the screws may damage the controller casing.
Terminal Pin Details

Following figure shows rear view of the GCU which has terminal details printed on it.
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GC2100 SEDEMAC
Figure 8: Rear view of the controller for terminal detail

Table 15: Details of GC2100 terminals
Mating
Pin # Name Description
connector part
1 GND Power ground
2 BATT + Power supply positive
3 OUT A High side driver output – A
4 OUT B High side driver output – B
5 OUT C High side driver output – C
BCP-508-10GN
6 OUT D High side driver output – D
7 OUT E High side driver output – E
8 OUT F High side driver output – F
9 OUT G High side driver output – G
10 D+ CHG ALT Input for charging alternator control
Analog input from Lube Oil Pressure
11 ANLG LOP / DIG J
Sensor/Digital Input J
Analog input from Fuel Level Sensor / BCP-508-6GN
12 ANLG FUEL LEVEL / DIG K
Digital Input K
13 ANLG ENG TEMP / DIG L Analog input from Engine Temperature
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GC2100 SEDEMAC
Mating
connector part
Sensor / Digital Input L
Analog input auxiliary/Analog input from
14 ANLG AUX 1 / DIG M
Shelter Temperature Sensor/Digital Input M
15 ANLG AUX 2 / DIG N Analog input auxiliary/Digital Input N
16 SCP Sensor common point
17 RESERVED RESERVED
NA
Analog input auxiliary /0-5V/4-20 mA (LOP)
21 ANLG AUX 3/ DIG 0
/ Digital Input O
22 MPU (RESERVED) Input from engine speed sensor (Inductive)
BCP-508-5GN
Analog input auxiliary / 0-5V/ 4-20 mA/
23 ANLG AUX 4 / DIG P
Digital Input P
24 Site BATT I/P Input 1 from Site battery
25 Site BATT I/P Input 2 from Site battery
27 RESERVED RESERVED NA
30 RS485- GND RS485 – GND
31 RS485- A RS485 – A BCP-508-3GN
32 RS485- B RS485 – B
33 DIG IN A Input from switch – A
34 DIG IN B Input from switch – B
35 DIG IN C Input from switch – C
36 DIG IN D Input from switch – D
BCP-508-9GN
37 DIG IN E Input from switch – E
38 DIG IN F Input from switch – F
39 DIG IN G Input from switch – G
40 DIG IN H Input from switch – H
41 DIG IN I Input from switch – I
42 GEN CT IN R2 CT input 2 from Phase R
43 GEN CT IN R1 CT input 1 from Phase R
44 GEN CT IN Y2 CT input 2 from Phase Y
45 GEN CT IN Y1 CT input 1 from Phase Y BCP-508-8GN
46 GEN CT IN B2 CT input 2 from Phase B
47 GEN CT IN B1 CT input 1 from Phase B
48 GEN CT IN EL2 CT input 2 from Earth Leakage
49 GEN CT IN EL1 CT input 1 from Earth Leakage
50 MAINS V N Voltage input from Mains Neutral BCP-508-7GN-
51 MAINS V B Voltage input from Mains Phase B 4PA
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GC2100 SEDEMAC
Mating
connector part
52 MAINS V Y Voltage input from Mains Phase Y
53 MAINS V R Voltage input from Mains Phase R
54 GEN V N Voltage input from Gen Neutral
55 GEN V B Voltage input from Gen B
56 GEN V Y Voltage input from Gen Y
57 GEN V R Voltage input from Gen R
58 CAN L (RESERVED) CAN Low
59 CAN H (RESERVED) CAN High
BCP-508-4GN
Typical Wiring Diagram

The typical wiring diagram of GC2100 for Auto Mains Failure application
Figure 9: Power circuit when used in the Auto Mains Failure Mode
1) Genset & mains contactor latching relays should be compiled against 4kV
surge as per IEC-61000-4-5 standard.
2) Wiring drawing is for representation purpose only. Please refer wiring as per
given genset application drawing.
3) Relay cards that used with controller should have protection against reverse
battery voltages.
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GC2100 SEDEMAC
Monitoring Mode
In monitoring mode, the screen will scroll automatically after a predefined time which can be
configured in configuration menu or one can use the “Navigation UP/DOWN Keys” to scroll/browse
the screens.
Table 16: Screens of engine status and operating modes
STATUS SCREEN
MANUAL MODE AUTO MODE
DG AND MAINS LOAD STATUS*
LOAD KVA LOAD KW
Load Current
*These 3 screens are common for DG and Mains

Mains Healthy Mains Cumulative energy
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GC2100 SEDEMAC
Generator Voltage Shelter temperature
ENGINE SCREENS
ENGINE LUBE OIL PRESSURE ENGINE FUEL LEVEL
ENGINE SPEED ENGINE TEMPERATURE
HISTOGRAM AUXILIARY SENSOR
ENGINE BATTERY / SITE BATTERY

PRODUCT INFO
VOLTAGE
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GC2100 SEDEMAC
Description of Control Keys
1
5
2 6
7
3
4 8
Figure 10: Control keys function

1. Display 5. Menu Navigation up & down key
2. Mains contactor latching key 6. Genset contactor latching key
3. Start key 7. Auto/Manual/Test mode selection key
4. Stop/Config key 8. Acknowledgement key
Configuration mode
To configure the controller please follow the below mentioned instructions:
• To enter the configuration mode press and hold “STOP” key, at least for 3 seconds. Following
screen will appear on the GCU
Figure 11: Configuration mode screen

• If you want to only view the configuration, press “STOP” key of the GCU. If you wish to change
the configuration, press “START” key of the GCU
• The GCU will ask for password (4 digit). Enter the password by using up & down arrow key for
digit and “START” key for entering the digit. The 4 digits will start blinking individually as go on
selecting. Press “START” button as mentioned earlier to enter the right digit.
Figure 12: Configuration mode authentication page screen

• After completion of parameter configuration, press and hold “STOP” key to exit from
configuration mode. Before existing from configuration mode controller will show the following
screen.
Page | 16
GC2100 SEDEMAC
Figure 13: Saving setting screen
Configurable parameters
Following are the configuration parameters along with the range & value for the GCU, one gets to
configure after entering the “write” mode.
* Level 2 names in sentence case are written how they display on Smart Config GUI and names
in bracket with capital case are written how they display on controller.
Table 17: List of configurable parameters
Level 1 (On
Level 0 Level 2 (On screen) * Possible Value
screen)
Profile Name profile 1
Power on Mode
Manual/Auto
(POWER ON MODE)
Power on Lamp Test
Enable/Disable
(POWER ON LAMP TEST)
Deep Sleep Mode
General Enable/Disable
(DEEP SLEEP MODE)
(GENERAL)
Load Histogram
Enable/Disable
(LOAD HISTOGRAM)
Auto-Clear Warning Alarm
Enable/Disable
(AUTO CLEAR WARNINGS)
Language
English/Chinese
(LANGUAGE SUPPORT)
Contrast
Module 0 – 100 %
Display (CONTRAST)
(MODULE)
(DISPLAY) Power Save Mode
Enable/Disable
(POWER SAVE MODE)
Communication Mode
None/MODBUS-SEDEMAC
(COMM MODE)
Slave ID
Communication 1 – 247
(MODBUS SLAVE ID)
(RS485 COMM)
Baudrate 1200/2400/4800/9600/19200/
(BAUDRATE) 38400/57600/115200
Parity Bit
None/Even/Odd
(PARITY)
Site Battery Battery Monitoring
Yes/No
Monitoring (BATTERY MON)
(SITE BAT Low Voltage Threshold
CONFIG) 15.0 – 60.0 V
(LOW BATT THRESHOLD)
Page | 17
GC2100 SEDEMAC
Level 1 (On
screen)
Battery Monitoring Delay
5 – 300 sec
(LOW BATT MON DELAY)
Genset Run Duration
1 – 720 min
(GEN RUN DURATION)
Cyclic Mode
Enable/Disable
(CYCLIC MODE)
Cyclic Mode
Genset Off Time
(CYCLIC 1 – 720 min
(GEN OFF DURATION)
CONFIG)
Genset On Time
1 – 720 min
(GEN ON DURATION)
Auto Exercise
Enable/Disable
(EVENT 1)
Event Occurrence
Daily/Weekly/Monthly
(EVENT OCCURENCE)
Auto Exercise – Event Day Runs Every day/Week
Event 1 (EVENT DAY) Days/1 – 28
(AUTO Start Time
EXERCISE – 1) 00 hr 00mins – 23 hr 59 mins
(START TIME)
Duration
00 hr 01mins – 99 hr 59 mins
(GEN ON DURATION)
Load Transfer
Enable/Disable
(LOAD TRANSFER)
Auto Exercise
Enable/Disable
(EVENT 2)
Event Occurrence
Daily/Weekly/Monthly
(EVENT OCCURENCE)
Event Day Runs Every Day/ Week
Auto Exercise – (EVENT DAY) Days/1 – 28
Event 2 (AUTO
EXERCISE – 2) Start Time
(START TIME)
Duration
(GEN ON DURATION)
Load Transfer
Enable/Disable
(LOAD TRANSFER)
Night Mode
Enable/Disable
(NIGHT MODE RESTRICT)
Night Mode Night Mode Start Time
(NIGHT MODE) (START TIME)
Night Mode Off Duration
1 – 1440 mins
(GEN OFF DURATION)
Digital Input X Source
Refer Table 18
Inputs (DIG IN X) (SOURCE)
(INPUTS) X= A/B/C/D/E/ Polarity Close to Activate/Open to
F/G/H/I (POLARITY) Activate
Page | 18
GC2100 SEDEMAC
Level 1 (On
screen)
Action None/Warning/Electrical
(ACTION) Trip/Shutdown/Notification
Activation Never/From Engine Start/
(ACTIVATION) From Monitoring On/Always
Activation Delay
1 – 180 sec
(ACTIVATION DELAY)
Use Input As Not used/Dig In J/LOP
(SENSOR SELECTION) Sensor
(Digital) Source
Refer Table 18
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
(Digital) Action None/Warning/Electrical
((DIG) ACTION) Trip/Shutdown/Notification
(Digital) Activation Never/From Engine Start/
((DIG) ACTIVATION) From Monitoring On/Always
Analog Input 1 (Digital) Activation Delay
1 – 180 sec
(LOP RES / DIG ((DIG) ACTIVATION DELAY)
J) (LOP) Low Level Shutdown
Enable/Disable
(SHUTDOWN)
(LOP) Shutdown Threshold
0 – 9.8 Bar
(SHUTDOWN THRESHOLD)
(LOP) Low Level Warning
Enable/Disable
(WARNING)
(LOP) Warning Threshold
0.2 – 10 Bar
Analog Inputs (WARNING THRESHOLD)
(LOP) Circuit Fault Action None/Warning/Electrical
(OPEN CKT ALARM) Trip/Shutdown/Notification
(LOP) Lube Oil Pressure
Refer Table 19
Calibration Table
Use Input As Not used/Dig In K/Anlg In
(SENSOR SELECTION) Fuel LVL
(Digital) Source
Refer Table 18
((DIG) SOURCE)
Analog Input 2 (Digital) Action None/Warning/Electrical
(FUEL LVL / DIG ((DIG) ACTION) Trip/Shutdown/Notification
K) (Digital) Activation Never/From Engine Start/
(Digital) Activation Delay
1 – 180 sec
((DIG) ACTIVATION DELAY)
(FLS) Low Fuel Level
Shutdown Enable/Disable
(SHUTDOWN)
Page | 19
GC2100 SEDEMAC
Level 1 (On
screen)
(FLS) Shutdown Threshold
0 – 78 %
(FLS) Low Fuel Level
Warning Enable/Disable
(WARNING)
(FLS) Warning Threshold
2 – 80 %
(WARNING THRESHOLD)
(FLS) Fuel Tank Capacity
2 – 1000 Litres
(FUEL TANK SIZE)
(FLS) Fuel Theft Warning
Enable/Disable
(FUEL THEFT ALARM)
(FLS) Fuel Theft Alarm
Threshold 1 – 100 % per hour
(FUEL LVL THRESH)
(FLS) Circuit Fault Action None/Warning/Electrical
(FLS) Fuel Sensor Reference Battery Negative/Engine
(FUEL LVL REF) Body
(FLS) Fuel Level Sensor
Refer Table 20
Calibration Table
Use Input As Not used/Dig In L/Anlg In
(SENSOR SELECTION) Eng Temp
(Digital) Source
Refer Table 18
((DIG) SOURCE)
Analog Input 3 (Digital) Activation Delay
1 – 180 sec
(ENG TEMP / ((DIG) ACTIVATION DELAY)
DIG L) (ETS) High Level Shutdown
Enable/Disable
(SHUTDOWN)
(ETS) Shutdown Threshold
27 – 300 deg C
(ETS) High Level Warning
Enable/Disable
(WARNING)
(ETS) Warning Threshold
25-298 deg C
(WARNING THRESHOLD)
(ETS) Circuit Fault Action None/Warning/Electrical
(ETS) Engine Temperature
Refer Table 21
Sensor Calibration Table
S1 Sensor Use Input As Not used/Dig In M/Auxiliary
(AUX S1 (SENSOR SELECTION) Sensor/Shelter Temperature
Page | 20
GC2100 SEDEMAC
Level 1 (On
screen)
RES/DIG M) (Digital) Source
Refer Table 18
((DIG) SOURCE)
1 – 180 sec
(S1) Threshold Type Greater Than Threshold /
(THRESHOLD TYPE) Less Than Threshold
(S1) Shutdown
Enable/Disable
(SHUTDOWN)
(S1) Shutdown Threshold
0 – 1000 units
(S1) Warning
Enable/Disable
(WARNING)
(S1) Warning Threshold
0 – 1000 units
(WARNING THRESHOLD)
(S1) Circuit Fault Action None/Warning/Electrical
(S1) Calibration Table
Refer Table 22
(Resistive)
(STS) High Temp Threshold
25 – 300 deg C
(SHELT TEMP THRESH)
(STS) Shelter temperature
hysteresis 1 – 100 deg C
(SHELT TEMP HYST)
(STS) Shelt Temp Monitoring
Delay 5 – 300 sec
(SHELT TEMP DELAY)
(STS) Shelt Temp Run
Duration 1 – 720 sec
(GEN RUN DURATION)
(STS) Calibration Table
Refer Table 21
(Resistive)
Use Input As Not used/Dig In N/Auxiliary
(SENSOR SELECTION) Sensor
(Digital) Source
S2 Sensor Refer Table 18
((DIG) SOURCE)
(AUX S2 RES /
DIG N) (Digital) Polarity Close to Activate/Open to
Page | 21
GC2100 SEDEMAC
Level 1 (On
screen)
1 – 180 sec
(S2) Threshold Type Greater Than Threshold/Less
(THRESHOLD TYPE) Than Threshold
(S2) Shutdown
Enable/Disable
(SHUTDOWN)
(S2) Shutdown Threshold
0 –1000 units
(S2) Warning
Enable/Disable
(WARNING)
(S2) Warning Threshold
0 –1000 units
(WARNING THRESHOLD)
(S2) Circuit Fault Action None/Warning/Electrical
(S2) Calibration Table
Refer Table 22
(Resistive)
Use Input As Not used/Dig In O/Dig In P/

S3 Sensor/S4 Sensor/0 – 5V
(SENSOR SELECTION) Sensor/LOP
(Digital) Source
Refer Table 18
((DIG) SOURCE)
Analog S3 ((DIG) ACTION) Trip/Shutdown/Notification
Current Sensor/
Digital Input O (Digital) Activation Never/From Engine Start/
(AUX S3 CURR /
DIG O)/LOP * (Digital) Activation Delay
1 – 180 Sec
And (S3/S4/LOP) Threshold Type Greater Than Threshold/Less
(THRESHOLD TYPE) Than Threshold
Analog S4 (S3/S4/LOP) Shutdown
Current Sensor/ Enable/Disable
(SHUTDOWN)
Digital Input P
(AUX S4 CURR / (S3/S4/LOP) Shutdown
DIG P) * Threshold 0 – 1000 units
(S3/S4/LOP) Warning
Enable/Disable
(WARNING)
(S3/S4/LOP) Warning
Threshold 0 – 1000 units
(WARNING THRESHOLD)
(S3/S4/LOP) Circuit Fault
Trip/Shutdown/Notification
(OPEN CKT ALARM)
Page | 22
GC2100 SEDEMAC
Level 1 (On
screen)
(S3/S4/LOP) Calibration Refer Table 23 for S3/S4 and
Table (Current) Refer Table 24 for LOP
(0-5 V Sensor) Shutdown
Enable/Disable
(SHUTDOWN)
(0-5 V Sensor) Shutdown
(0-5 V Sensor) Warning
Enable/Disable
(WARNING)
(0-5 V Sensor) Warning
(WARNING THRESHOLD)
(0-5 V Sensor) Threshold
Type Greater Than Threshold/Less
Than Threshold
(THRESHOLD TYPE)
(0-5 V Sensor) Circuit Fault
(OPEN CKT ALARM)
(0-5 V Sensor) Calibration
Refer Table 25
Table (Voltage)
Source
Output X Refer Table 26
Outputs (SOURCE)
(OUT X)
(OUTPUTS) On Activation
X=A/B/C/D/E/F/G Energise/De-energise
(ON ACTIVATION)
Crank Hold Time
1 – 15 sec
(CRANK HOLD TIME)
Crank Rest Time
Cranking 2 – 60 sec
(CRANK REST TIME)
(CRANKING
TIMER) Manual Start Delay
0 – 300 sec
(MANUAL START DELAY)
Auto Start Delay
0 – 300 sec
(AUTO START DELAY)
Safety Monitoring Delay
10 – 60 sec
(SAFETY MONITOR DELAY)
Timers Mains Detect Delay
1 – 300 sec
(TIMERS) (MAINS DETECT DELAY)
Alternator Detect Delay
1 – 30 sec
(ALT DETECT DELAY)
Start / Stop
Warm-Up Delay
(START / STOP 0 – 60 sec
TIMER) (WARM-UP DELAY)
Return To Mains Delay
0 – 600 sec
(RETN-TO-MAINS DELAY)
Engine Cooling Time
0 – 300 sec
(ENG COOL TIME)
Stop Action Time
10 – 120 sec
(STOP ACTION TIME)
Page | 23
GC2100 SEDEMAC
Level 1 (On
screen)
Additional Stopping Time
0 – 120 sec
(ADDN STOPPING TIME)
Load Transfer Delay
1 – 60 sec
(LOAD TRANSFER DELAY)
Power Save Mode Delay
5 – 1800 sec
(PWR SAVE MODE DELAY)
Screen Changeover Time
1 – 1800 sec
(SCRN CHNGOVER TIME)
Deep Sleep Mode Delay
General 5 – 1800 sec
(DEEP SLP MODE DELAY)
(GENERAL
TIMER) Sounder Alarm Time
1 – 300 sec
(SOUNDER ALARM TIMER)
Test Mode Timer
1 – 720 min
(TEST MODE TIMER)
Auto Exit Config Mode
10 – 1800 sec
(AUTO EXIT CNFG MODE)
Alternator Present
Yes/No
(ALT PRESENT)
Number of Poles
2/4/6/8 Poles
(NUMBER OF POLES)
AC system
1/3 Phase
(ALT AC SYSTEM)
Min Healthy Voltage
50 – 350 V Ph - N
Alternator (MIN HEALTHY VOLT)
Configuration Min Healthy Frequency
10 – 75 Hz
(ALT CONFIG) (MIN HEALTHY FREQ)
Phase Reversal Detection
(PHASE REVERSAL Enable/Disable
DETECT)
Phase Reversal Action
None/Warning/Electrical
Generator (PHASE REVERSAL
(GENERATOR) ACTION)
Auto Load Transfer
Enable/Disable
(AUTO LOAD TRANSFER)
Under-voltage Shutdown
Enable/Disable
(UNDER VOLT SHUTDOWN)
Under-voltage Shutdown
Threshold 50 – 295 V Ph-N
Voltage (UV SHUTDOWN THRESH)
Monitoring Under-voltage Warning
Enable/Disable
(VOLT (UNDER VOLT WARNING)
MONITOR) Under-voltage Warning
Threshold
55 – 300 V Ph - N
(UV WARNING
THRESHOLD)
Over-voltage Shutdown Enable/Disable
Page | 24
GC2100 SEDEMAC
Level 1 (On
screen)
(OVER VOLT SHUTDOWN)
Over-voltage Shutdown
Threshold 105 – 350 V Ph - N
(OV SHUTDOWN THRESH)
Over-voltage Warning
Enable/Disable
(OVER VOLT WARNING)
Over-voltage Warning
Threshold
100 – 345 V Ph - N
(OV WARNING
THRESHOLD)
Under-frequency Shutdown
(UNDER FREQ Enable/Disable
SHUTDOWN)
Under-frequency Shutdown
Threshold 10.0 – 59.0 Hz
(UF SHUTDOWN THRESH)
Under-frequency Warning
Enable Enable/Disable
(UNDER FREQ WARNING)
Under-frequency Warning
Threshold
11.0 – 60.0 Hz
Frequency (UF WARNING
Monitoring THRESHOLD)
(FREQ Over-frequency Shutdown
MONITOR) Enable Enable/Disable
(OVER FREQ SHUTDOWN)
Over-frequency Shutdown
Threshold 26.0 – 75.0 Hz
(OF SHUTDOWN THRESH)
Over-frequency Warning
Enable Enable/Disable
(OVER FREQ WARNING)
Over-frequency Warning
Threshold
25.0 – 74.0 Hz
(OF WARNING
THRESHOLD)
CT Ratio
0 – 8000 / 5
(LOAD CT RATIO)
Over-current Action None/Warning/Electrical
(OVER CURR ACTION) Trip/Shutdown/Notification
Current Over-current Threshold
Monitoring 5 – 10000 Amp
(OVER CURR THRESHOLD)
(CURRENT
MONITOR) Over-current Delay
1 – 600 sec
(OVER CURR DELAY)
CT Correction Factor 0.900 – 1.100
CT Location On Alt Output Cable/On Load
(CT LOCATION) Cable
Page | 25
GC2100 SEDEMAC
Level 1 (On
screen)
Current Monitoring ERTH Curr Mon/
(FAN / EARTH MOMN) Fan Curr Mon
Current CT Ratio
0 – 8000 / 5
(CT RATIO)
High Current Action None/Warning/Electrical
Earth Current (HIGH CURR ACTION) Trip/Shutdown/Notification
Monitoring
High Current Threshold
(EARTH CURR 0.1 – 10.0 A
MON) (HIGH CURR THRESH)
Current Delay
5 – 60 sec
(CURR DELAY)
Low Current Action None/Warning/Electrical
(LOW CURR ACTION) Trip/Shutdown/Notification
Low Current Threshold
0.1 – 9.9 A
(LOW CURR THRESH)
Generator Rating
0 – 8000 kW
(GEN RATING)
Over-load Action None/Warning/Electrical
(OVERLOAD ACTION) Trip/Shutdown/Notification
Over-load Threshold
50 – 150 %
(OVERLOAD THRESHOLD)
Load Monitoring Over-load Monitoring Delay
1 – 600 sec
(LOAD (OVERLOAD MON DELAY)
MONITOR)
Unbalanced Load Action None/Warning/Electrical
(UNBAL LOAD ACTION) Trip/Shutdown/Notification
Unbalanced Load Threshold
(UNBAL LOAD 5 – 200 %
THRESHOLD)
Unbalanced Load Delay
1 – 600 sec
(UNBAL LOAD DELAY)
Mains Monitoring
Enable/Disable
(MAINS MONITORING)
Mains AC System
1 Phase/3 Phase
(MAINS AC SYSTEM)
Phase Reversal Detection
Configuration (PHASE REVERSAL Enable/Disable
(MAINS CONFIG) DETECT)
Mains Phase Reversal Action
(Mains) (PHASE REVERSAL None/Notification
ACTION)
Partial Healthy Detection
Enable/Disable
(MAINS PARTIAL HEALTHY)
Under Voltage Under-voltage
Enable/Disable
Monitoring (UV ENABLE)
(UNDER VOLT (UV) Trip
MON) 50 – 298 V Ph - N
(UV TRIP)
Page | 26
GC2100 SEDEMAC
Level 1 (On
screen)
(UV) Return
52 – 300 V Ph - N
(UV RETURN)
Over-voltage
Enable/Disable
Over Voltage (OV ENABLE)
Monitoring (OV) Trip
102 – 350 V Ph - N
(OVER VOLT (OV TRIP)
MON) (OV) Return
100 – 348 V Ph - N
(OV RETURN)
Under-frequency
Enable/Disable
Under Frequency (UF ENABLE)
Monitoring (UF) Trip
10.0 – 59.0 Hz
(UNDER FREQ (UF TRIP)
MON) (UF) Return
11.0 – 60.0 Hz
(UF RETURN)
Over-frequency
Enable/Disable
Over Frequency (OF ENABLE)
Monitoring (OF) Trip
26.0 – 75.0 Hz
(OVER FREQ (OF TRIP)
MON) (OF) Return
25.0 – 74.0 Hz
(OF RETURN)
Start Attempts
1–9
(START ATTEMPTS)
Disconnect on Oil Pressure
Sensor Enable/Disable
(DISCONN ON LOP SENS)
Pressure Sensor Monitoring
Threshold 0.5 – 10.0 bar
(DISCONN LOP SENS)
Monitor Pressure Sensor
Before Crank Enable/Disable
(MON LLOP BEF CRANK)
Monitor Pressure Switch
Crank Disconnect
Engine Before Crank Enable/Disable
(CRANK
(ENGINE) (MON LOP BEF CRANK)
DISCONN)
Disconnect on Oil Pressure
Switch Enable/Disable
(DISCONN ON LLOP SW)
Pressure Switch Transient
Time 0.0 – 3.0 Sec
(LLOP SW TRANS TIME)
Crank Disconnect At Alt
Frequency 10 – 70 Hz
(ALT FREQUENCY)
Crank Disconnect At Engine
Speed 150 – 4000 RPM
(ENGINE SPEED)
Page | 27
GC2100 SEDEMAC
Level 1 (On
screen)
Disconnect On Charging Alt
Voltage Enable/Disable
(DISC ON CHG ALT VOLT)
Charging Alt Disconnect Volt
Threshold 5.0 – 30.0 V
(CHG ALT THRESHOLD)
Engine Speed Sense Source
Alternator frequency
(SPEED SENSE SOURCE)
Under-speed Shutdown
(UNDER SPEED Enable/Disable
SHUTDOWN)
Under-speed Threshold
0 – 3600 RPM
(UNDER SPEED THRESH)
Speed Monitoring
(SPEED Under-speed Delay
1 – 60 Sec
MONITOR) (UNDER SPEED DELAY)
Over-speed Threshold
700 – 4000 RPM
(OVER SPEED THRESH)
Over-speed Delay
1 – 20 Sec
(OVER SPEED DELAY)
Gross Over-speed Threshold
100% – 200%
(GROSS OS THRESHOLD)
Low Battery Voltage Action None/Warning/Electrical
(LOW VOLT ACTION) Trip/Shutdown/Notification
Low Battery Voltage
(LOW VOLT THRESHOLD)
Battery Low Battery Voltage Delay
5 – 1800 Sec
Monitoring (LOW VOLT DELAY)
(BATTERY High Battery Voltage Action None/Warning/Electrical
MONITOR) (HIGH VOLT ACTION) Trip/Shutdown/Notification
High Battery Voltage
(HIGH VOLT THRESHOLD)
High Battery Voltage Delay
5 – 1800 Sec
(HIGH VOLT DELAY)
Charging Alternator Fail
Charging (FAIL ACTION)
Alternator Charging Alternator Fail
Monitoring Threshold 0.0 – 35.0 V
(CHARGE ALT (FAIL THRESHOLD)
MON) Charging Alternator Fail
Delay 5 – 60 sec
(FAIL DELAY)
Preheating Preheat Timer
1 – 900 sec
(PREHEAT) (PREHEAT TIMER)
Page | 28
GC2100 SEDEMAC
Level 1 (On
screen)
Engine Temperature
Enable/Disable
(ENG TEMP EN)
Engine Temperature
Threshold 10 – 300 °C
(ENG TEMP LIMIT)
Alarm Action
Notification/Warning
Maint Alarm (ACTION)
(MAINT ALARM) Due At Engine Hours
Maintenance 10 – 65000 Hrs
(MAINTENANCE) (DUE AT ENGINE HOURS)
Alarm Due Date
Alarm Due Date
(ALARM DUE 1-31/Jan-Dec/2016-75
(ALARM DUE DATE)
DATE)
0 – 9 for each digit and A – Z
Id (ENG SR NO) ############
for each alphabet
(ID)
(PASSWORD 1) #### 0 – 9 for each digit
(PASSWORD 2) #### 0 – 9 for each digit
(RUN HOURS) (In Numbers) Hrs
(NO OF STARTS) (In Numbers)
NO OF TRIPS (In Numbers)
(GENERATOR)
kWh (In Numbers) kWh
RESET kVAh (In Numbers) kVAh
PARAMETERS kVArh (In Numbers) kVArh
(RUN HOURS) (In Numbers) Hrs
kWh (In Numbers) kWh
(MAINS)
kVAh (In Numbers) kVAh
kVArh (In Numbers) kVArh
Table 18: Digital input source selection

# Source (On screen)
1 Not used
2 User Configured
3 Low fuel level switch (Low Fuel LVL switch)
4 Low Lube Oil Pressure Switch
5 High engine temperature switch (High Engine Temp Switch)
6 Low water level switch (Low Water LVL Switch)
7 Emergency Stop
8 Remote Start / Stop
9 Simulate Start
10 Simulate Stop
11 Simulate Auto
12 Close genset/open mains contactor (Close Gen/Open Mains Switch)
13 Close mains/ open genset contactor (Close Mains/Open Gen Switch)
14 Simulate Mains
Page | 29
GC2100 SEDEMAC
# Source (On screen)
15 V-Belt Broken Switch
16 Mains Contactor Latched
17 Genset Contactor Latched
18 Battery Charger Fail
19 Smoke Fire
20 Remote Alarm Mute
21 Remote Alarm Acknowledge
22 Stop and Panel Lock
23 External Panel Lock
24 Generator Load Inhibit
25 Mains Load Inhibit
Table 19: LOP (Resistive) sensor calibration

Resistance(Ω) Pressure (Bar)
0 – 5000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)
Table 20: Fuel level sensor calibration

Resistance(Ω) Fuel level (%)
0 – 5000 (R1 - R10) 0 - 100% (L1-L10)
Table 21: Engine / shelter temperature sensor calibration

Resistance(Ω) Temperature° C
0 – 5000 (R1 - R10) -25 - 300° C (T1-T10)
Table 22: Auxiliary (S1/S2) resistive sensor calibration

Resistance(Ω) Monitoring Parameter (User configuration)
0 – 5000 (R1 - R10) 0 – 1000 (V1-V10)
Table 23: Auxiliary (S3/S4) current sensor calibration

Current(mA) Monitoring Parameter (User configuration)
4 – 20 (I1 - I10) 0 – 1000 (V1 – V10)
Table 24: LOP sensor calibration

Current(mA) Pressure (Bar)
4 – 20 (I1 - I10) 0.0 – 10.0 Bar (V1-V10)
Table 25: Auxiliary (S3/S4) (0 – 5V) voltage sensor calibration

Voltage(V) Monitoring Parameter (User configuration)
0 – 5 V (V1 - V10) 0 – 1000 (V1 – V10)
Table 26: Digital output source selection

# Output source (On screen)
1 Disable
2 Sounder Alarm
3 Battery Over Voltage (Battery Over Volt)
Page | 30
GC2100 SEDEMAC
4 Battery Under Voltage (Battery Under Volt)
5 Charging Alternator Shutdown (Charge Alt Shutdown)
6 Charging Alternator Warning (Charge Alt Warning)
7 Close Genset Contactor (Close Gen Contactor)
8 Close Mains Contactor (Close Mains Contactor)
9 Mains Failure
10 Common Alarm
11 Common Electrical Trip
12 Common Shutdown
13 Common Warning
14 Cooling Down
15 Digital Input A (Dig In A)
16 Digital Input B (Dig In B)
17 Digital Input C (Dig In C)
18 Digital Input D (Dig In D)
19 Digital Input E ((Dig In E)
20 Digital Input F (Dig In F)
21 Digital Input G (Dig In G)
22 Digital Input H (Dig In H)
23 Digital Input I (Dig In I)
24 Digital Input J (LOP Resistive)
25 Digital Input K (Anlg In Fuel LVL)
26 Digital Input L (Anlg In Eng Temp)
27 Digital Input M (Aux Sensor 1)
28 Digital Input N (Aux Sensor 2)
29 Digital Input O (Aux Sensor 3)
30 Digital Input P (Aux Sensor 4)
31 Emergency Stop
32 Stop Solenoid
33 Fail To Start
34 Fail To Stop
35 Fuel Relay
36 Generator Available (Gen Available)
37 R Phase Over Voltage Shutdown (R Phase OV Shutdown)
38 R Phase Under Voltage Shutdown (R Phase UV Shutdown)
39 Y Phase Over Voltage Shutdown (Y Phase OV Shutdown)
40 Y Phase Under Voltage Shutdown (Y Phase UV Shutdown)
41 B Phase Over Voltage Shutdown (B Phase OV Shutdown)
42 B Phase Under Voltage Shutdown (B Phase UV Shutdown)
43 Gen Over Current
44 High Temperature (High Engine Temp)
45 Low Fuel Level (Low Fuel LVL)
Page | 31
GC2100 SEDEMAC
46 Low Lube Oil Pressure (Low LOP)
47 Main High Voltage (Mains High Volt)
48 Mains Low Voltage (Mains Low Volt)
49 Oil Pressure Open Circuit
50 Open Generator Contactor (Open Gen Contactor)
51 Open Mains Contactor
52 Over Frequency Shutdown (Over Freq Shutdown)
53 Over Speed Shutdown
54 Gross Over Speed Shutdown
55 Start Relay
56 Temp Sensor Open Circuit
57 Under Frequency Shutdown (Under Freq Shutdown)
58 Under Speed Shutdown
59 Maintenance Due
60 Stop Mode
61 Auto Mode
62 Manual Mode
63 Preheat Output
64 Calling For Scheduler Run
65 Stop and Panel Lock
66 External Panel Lock
67 Fail To Close Generator
68 Fail To Close Mains
69 Loading Volt Not Reached
70 Loading Freq Not Reached
71 MPU Loss
Page | 32
GC2100 SEDEMAC
Modes selection in GC2100
Figure 14: Mode selection screen
Page | 33
GC2100 SEDEMAC
Start and Stop Sequence
The following is the mechanism which explains the behaviour of the controller when it receives start
and stop command.
Start Sequence
Figure 15: Flow chart of start sequence

Once the start command is received by the controller/controller enters Start Wait State. After Start
Delay (Manual or Auto Start Delay) is over, if Preheat Output is configured then controller will enter
Preheating State. If Preheat output is not configured, then controller will directly enter Crank Hold State
and will activate Start Relay output. In case of Preheat output configured, controller will enter Crank
Hold State after Preheat time is over or Preheat temperature threshold is reached. If Crank is not
disconnected and Crank Hold time is over, then controller enters Crank Rest State. In Crank Rest, also
if Crank is not disconnected and Crank Rest time is over, then controller enters Crank Hold State for
next cranking attempt. If Crank is disconnected by any means in the Crank Hold OR Crank Rest States,
then controller will enter ENGINE ON state. If Maximum cranking attempts are done, then controller will
raise the Fail to Start alarm.
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GC2100 SEDEMAC
Stop Sequence
Figure 16: Flow chart of stop sequence

Once the Stop command is received, controller enters Stopping State where it starts the Stop Action
Time and activates Stop Solenoid output. If controller detects engine OFF by all the means even before
Stop action time is over, then controller will enter by skipping stop action time. Once Additional Stopping
Time is over, controller will enter ENGINE OFF State and will deactivate Stop Solenoid output. If Engine
is not detected OFF before Stop Action Time, then Fail to Stop alarm will be raised.
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GC2100 SEDEMAC
Operation modes
• Auto mode
• Manual mode
• Test mode
Auto mode
To enter Auto mode press “AUTO” key.
• Site Battery Monitoring mode (fuel saving mode)
• Cyclic mode
• Auto Mains Failure (AMF)
• Remote start/stop
• Exerciser mode
Site Battery Monitoring mode
Figure 17: Flow chart of Site monitoring mode

This mode enables the controller to monitor the health of the Site battery and Shelter temperature and
accordingly control the power sources (Mains / Genset) to keep the battery charge within the specified
threshold.
In this mode if the Site battery condition is healthy, Shelter temperature is below “High Shelter Temp
threshold” and mains is unhealthy, the controller keeps both the contactors (Genset and Mains) open
Page | 36
GC2100 SEDEMAC
and waits till the Site battery gets discharged. Once the Site battery becomes unhealthy or Shelter temp
is detected high, the controller then gives a start command to the genset. Then Genset will Start
according to Start Sequence. When genset loading voltage and frequency are above the Minimum
Healthy thresholds, Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. Then genset will run for DG run
Duration. According to the factor which triggered DG start (Site battery voltage Low OR Shelter Temp
High), Run duration (Site low Run duration OR High Shelter Temp run duration) will be taken. After the
duration is over or mains becomes healthy during the DG Run duration, controller will open genset
contactor. If shelter temp run duration is over and the temp is not below Low Temp Threshold, then
genset will continue to run for the set duration. After opening genset contactor, Engine Cooling Time
starts. Then at the end of Engine Cooling Time, controller initiates the stopping sequence by giving
Stop command.
This mode also supports partial healthy condition of mains source. Partial healthy is a state in which
mains is not considered as failed even if one or two-phases are unhealthy. The mains keep supplying
power through the available phase/s. Mains failure occurs only when all the three phases fail. Upon
Mains failure genset shall receive start command only if either of following conditions occur
a) Site Battery voltage level has reached below its lower limits.
b) Shelter temperature has exceeded its upper threshold limits.
c) If either of a) or b) occur when source is partially healthy.
It is recommended to keep mains monitoring enable in this mode. Also, it is

recommended to use shelter temperature only when Site monitoring is enabled.
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GC2100 SEDEMAC
Cyclic mode
Figure 18: Flow chart of cyclic mode

This mode is used for running the genset for a pre-specified time for a cycle of max 12 hours each. The
time of genset to be kept ON & OFF is configurable.
Mains is being monitored in this mode. Load is on mains when mains is healthy. If mains is detected
unhealthy, controller gives a start command to the genset. Then Genset will Start according to Start
sequence. When genset loading voltage and frequency are above the Minimum Healthy thresholds,
then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get latched after taking
Load Transfer Delay. Engine run hours will start incrementing as long as the genset is in running
condition till the stop command is received. After completion of the ON time or if mains become healthy
during ON time, controller will open the genset contactor. After opening genset contactor, Engine
Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping
sequence by giving Stop command. When genset is off, controller will start DG off time.
After completion of DG OFF time, DG ON time will start and this cycle will continue until mains is
detected healthy. During any of the times, if mains is detected healthy both the timers are reset to zero
and load will shift to mains after taking return delay. This process continues in cyclic mode.
If genset is shut down or is unable to start because of any alarm present, then after clearing alarms if
mains is unhealthy, DG ON time will be taken first followed by DG OFF time.
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GC2100 SEDEMAC
Auto Mains Failure (AMF)
Figure 19: Flow chart of Auto Mains Failure (AMF) mode

The AMF mode is activated when Site monitoring, Cyclic and exerciser modes are disabled, and Mains
Monitoring is enabled.
In this mode, if the mains is healthy then the genset remains in Stop condition. If after the Mains Detect
Delay, mains is found unhealthy, then controller will issue Start command and Genset will start
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched after taking Load Transfer Delay. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received. During genset running condition, if the
mains is found healthy, Return To Mains Delay timer starts. If mains is found unhealthy during the
Return To Mains Delay, then Genset continues to run. At the end of this delay if mains is still healthy,
then genset contactor gets opened and mains contactor gets latched after the completion of Load
Transfer Delay. After opening genset contactor, Engine Cooling Time starts. Then at the end of
Engine cooling Time, controller initiates the stopping sequence by giving Stop command.
During start sequence, if the mains voltage recovers or any stop command or shutdown / warning alarm
occurs controller will not issue start command to genset. To start the genset it is necessary to clear all
the alarms manually and put the controller in Auto mode.
The AMF mode is only valid when site monitoring, Cyclic and exercise modes are
disabled, and Mains Monitoring is enabled.
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GC2100 SEDEMAC
Remote start/stop
Figure 20: Flow chart of remote start/stop mode

To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote
start/stop (Latched type input) and put the controller in the Auto mode. Also disable both Site monitoring
and Cyclic mode.
In this mode, the genset can be commanded to start and stop by activating the preconfigured Remote
start/stop input. If Remote Start command is received, then controller will issue Start command and
Genset will start according to Start Sequence. When genset loading voltage and frequency are above
the Minimum Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset
contactor will get latched after taking Load Transfer Delay. Engine run hours will start incrementing as
long as the genset is in running condition till the stop command is received. When Remote Stop
command is received the controller will open the genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine cooling Time, controller initiates the stopping
sequence by giving Stop command.
It is recommended not to enable Mains Monitoring and Remote Start/Stop configuration simultaneously.
The Remote start/stop mode is only valid when Site monitoring, Cyclic, exerciser
modes and Mains Monitoring are disabled.
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GC2100 SEDEMAC
Exercise Mode
The GC2100 allows to configure two scheduled sequences to start and stop the genset on preconfigured
time.
The Exercise will occur when the controller is in the Auto mode with no shutdown or warning alarms. The
genset will run for pre-set duration. In this mode, load transfer on mains/genset is configurable.
Scheduled sequences can be configured to repeat daily, weekly or monthly.
• If the controller is in Auto mode, Exercise will run at scheduled time for pre-set duration. Controller
will exit from Exercise mode, if the pre-set duration is expired or if Stop key is pressed while
scheduled sequence is running.
• If the controller is in Manual mode when the scheduled sequence begins, genset will not be
started. If the controller is switched to Auto mode during Exercise is running, genset will start and
run for remaining scheduled duration.
• The genset controller will not respond to Remote start command in Exercise mode.
• In AMF mode, if the mains is unhealthy or cut off or when the genset is running in Exercise mode,
genset will first run Exercise and then genset will continues to run in AMF mode. Load will be
transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF
mode when the mains become healthy.
• If both exercises are scheduled at the same time, then Start time for second exercise will be
incremented by 1 min.
The Exerciser mode is only valid when Site monitoring and Cyclic modes are
disabled, and Mains Monitoring is enabled.
Manual mode
Module Operation in Manual Mode
Figure 21: Flow chart of manual mode
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GC2100 SEDEMAC
Starting the Engine
Then, press the START

key
First press STOP key to crank the engine.
Figure 22: Pictorial reference for starting the engine

If Start Key is pressed in this mode, then controller will issue Start command and Genset will start
Healthy thresholds, then Warm-Up Delay timer starts. At the end of this delay, genset contactor will get
latched if Auto Load Transfer is enabled. Engine run hours will start incrementing as long as the
genset is in running condition till the stop command is received.
When Stop key is pressed, controller will open genset contactor. After opening genset contactor,
Engine Cooling Time starts. Then at the end of Engine Cooling Time, controller initiates the stopping
sequence by giving Stop command. If Stop key is pressed during Engine Cooling Time, controller skips
the Cooling Time and issues the stop command immediately.
Stopping the Engine
While engine is running,

press STOP key to stop
engine. To stop engine
immediately press STOP
key twice.
Figure 23: Pictorial reference for stopping the engine
Test mode
In manual mode (while genset is OFF) if auto key is long pressed then controller goes in Test mode.
Test mode is almost same as manual mode. Only in test mode, irrespective of auto load transfer option
enabled or disabled, Genset contactor will not get latched. If Genset contactor latching key is pressed,
then only genset contactor will get latched. Once the genset starts in test mode, Test mode timer
starts. After Stop key is pressed or this timer is over, controller will send the Stop command and genset
will stop according to stop sequence.
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GC2100 SEDEMAC
Acknowledging & Clearing the Alarms
Press the “Ack” key to acknowledge the alarm in any mode.
Ack
key
Figure 24: Pictorial reference to acknowledge the alarm in any mode
In case, if engine ON is detected without any start command given to GCU, it will
allow engine to stay ON and further act according to operating mode and
configuration.
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GC2100 SEDEMAC
Load sensing
Load Sensing in Manual mode
In Manual mode, the load sensing is done with following configuration:
The GCU senses the load (on Mains / Genset) depending upon “Generator Contactor Latched” and
“Mains Contactor latched” inputs (if configured) and their real-time status.
In case if the inputs are not configured, the GCU will sense the load depending upon the outputs ‘’Close
Genset Contactor’’ and ‘’Close Mains Contactor’’ or ‘’Open Mains Contactor’’ and ‘’Open Genset
Contactor” being configured and depending upon their real-time status. These outputs are set through
facial keys or Contactor controlling inputs (such as ‘’Close Genset/Open Mains’’ or ‘’Close Mains/Open
Genset’’).
In case of MCP Panels, since the “Genset & Mains” contactors are not
configured, the load sensed will be treated as load on the genset only
Load Sensing in Auto mode

The GCU will sense the load (on Mains / Genset) when contactors outputs, i.e. ‘’Close Genset
Contactor’’ and ‘’Close Mains Contactor’’ or ‘’Open Mains Contactor’’ and ‘’Open Genset Contactor” are
being configured and depending upon their real-time status. These outputs will intelligently be set
considering different types of Auto operating modes and configuration.
Contactor Status inputs are not considered for load sensing in any type of
auto modes.
For Mains load sensing, two configurations are mandatory.
1. Mains monitoring must be enabled.

2. CT location in panel and in GCU configuration must be “On Load
Cable”.
Features
There are some silent features that helps in saving power and other monitoring purpose.
Auto Config Exit Mode

In this mode, the controller comes out of Configuration Mode automatically when there is no user
interaction for the pre-set Auto Config Exit Mode Delay.
Controller saves all configuration parameter changes and exit the configuration mode.
Load Histogram
Load Histogram displays an engine run hour spent in different regimes. This mode helps user to
monitor the duration of genset running on specific percentage of load.
The load percentage is calculated based on following parameters:
1. Generator rating
2. CT ratio
Page | 44
GC2100 SEDEMAC
Alarms
When Shutdown alarm occurs controller commands genset to stop. The controller will not issue the
start command if the Shutdown alarm left unacknowledged.
When an electrical trip alarm occurs, the controller opens the genset contactor first and then it
commands the genset to stop. The controller will not issue the start command if the Electrical trip
alarm left unacknowledged.
If the warning alarm occurs in between the genset running condition, then the controller will not
issue the stop command. But if the warning alarm left unacknowledged when the genset is in stop
condition, then the genset cannot be started. Warning alarm gets auto cleared when condition gets
cleared only if auto warning clear is enabled in config file or through UI.
Notification alarms get auto cleared.
Table 27: Types of alarms actions and their descriptions
Alarm
# Description
Actions
Load is taken off from the genset and the genset is immediately stopped by
1 Shutdown
skipping Engine Cooling Time.
Electrical Load is taken off from the genset, engine cooling timer begins, after which
2
trip genset is stopped.
Warning alarms serves to draw operator's attention to an undesirable condition
3 Warning without affecting genset's operation.
The genset cannot be started without acknowledging the warning alarms
Controller will display message on the display screen and will not affect genset
4 Notification
start stop operation.
Table 28: Alarms and their causes

Sr.
Alarms Causes / Indication Actions
No.
1 Low Oil Pressure Indicates that the oil pressure measured is below None/
(Sensor) the pre-set threshold Shutdown/
Warning
Low Oil Pressure Indicates that the oil pressure measured is low None/
(Switch) through switch Shutdown/
Warning/
Electrical Trip/
Notification
2 LOP Res Sensor- The oil pressure sensor is detected as not being None/
Ckt Open present Shutdown/
Warning/
Electrical Trip/
Notification
3 High Eng Temp Indicates that the engine temperature is above the None/
(sensor) pre-set threshold. This condition is detected only Shutdown/
when engine is on. Warning
High Eng Temp Indicates that the engine temperature measured is None/
(Switch) high through switch Shutdown/
Warning/
Electrical Trip/
Notification
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GC2100 SEDEMAC
Sr.
No.
4 Eng Temp - Ckt Opn The temperature sensor is detected as not being None/
present Shutdown/
Warning/
Electrical Trip/
Notification
5 Low Fuel level Indicates that the amount of fuel level is below the None/
(Sensor) pre-set threshold. This condition is detected only Shutdown/
when engine is on. Warning
Low Fuel level Indicates that the amount of fuel level measured is None/
(Switch) low through switch Shutdown/
Warning/
Electrical Trip/
Notification
Fuel level - Ckt Fuel level sensor is detected as not being present None/
Open Shutdown/
Warning/
Electrical Trip/
Notification
6 Fuel Theft The fuel consumption has exceeded the pre-set
Warning
threshold
7 Low Water Level Indicates that radiator water level is below the pre- None/
Switch set threshold Shutdown/
Warning/
Electrical Trip/
Notification
8 Shelter Temp - Ckt Shelter Temperature sensor is detected as not
Notification
Open being present
9 Aux S2 - Ckt Open Auxiliary sensor S2 is detected as not being None/
present Shutdown/
Warning/
Electrical Trip/
Notification
10 Auxiliary Input (for Configured auxiliary input has triggered longer than None/
e.g. Aux_A - P) pre-set duration Shutdown/
/user defined name Warning/
Electrical Trip/
Notification
11 Emergency Stop When emergency stop switch is pressed and
Shutdown
immediate shutdown is required.
12 Fail To Stop It is detected that genset is still running after
Shutdown
sending stop command
13 Fail To Start Indicates that genset has not started after the pre-
Shutdown
set number of Start Attempts
14 R Phase Over Indicates that genset (R) Phase voltage has Warning/
Voltage exceeded the pre-set over voltage threshold. Shutdown
15 Y Phase Over Indicates that genset (Y) Phase voltage has Warning/
Voltage exceeded the pre-set over voltage threshold Shutdown
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GC2100 SEDEMAC
Sr.
No.
16 B Phase Over Indicates that genset (B) Phase voltage has Warning/
Voltage exceeded the pre-set over voltage threshold Shutdown
17 R Phase Under Indicates that genset (R) Phase voltage has fallen Warning/
Voltage below pre-set under voltage threshold. Shutdown
18 Y Phase Under Indicates that genset (Y) Phase voltage has fallen Warning/
Voltage below pre-set under voltage threshold Shutdown
19 B Phase Under Indicates that genset (B) Phase voltage has fallen Warning/
Voltage below pre-set under voltage threshold Shutdown
20 DG Phase Alternator phase sequence (R-Y-B) is not correct None/
Reversed Warning/
Electric trip/
Shutdown/
Notification
21 Mains Phase Mains is in unhealthy condition None/
Reversed Notification
22 Over Frequency Indicates that genset output frequency has Warning/
exceeded the pre-set threshold Shutdown
23 Under Frequency Indicates that genset output frequency has fallen Warning/
below the pre-set threshold Shutdown
24 Over Current Indicates that genset current has exceeded the None/
pre-set shutdown threshold Shutdown/
Warning/
Electrical Trip/
Notification
25 Over Load Indicates that the measured kW load rating has None/
exceeded the pre-set threshold Shutdown/
Warning/
Electrical Trip/
Notification
26 Unbalanced Load Load on any phase is greater or less than other None/
phases by a threshold value Shutdown/
Warning/
Electrical Trip/
Notification
27 Over Speed Indicates that genset speed has exceeded the pre-
set over speed threshold. Genset will shut down Shutdown
after Over Speed Delay.
28 Gross Over Speed Indicates that genset speed has exceeded the pre-
set Gross Over Speed Threshold. Genset will shut Shutdown
down immediately without any delay.
29 Under Speed The engine speed has fallen below the pre-set
Shutdown
RPM
30 Charge Fail The charge alternator voltage has dropped below None/
the pre-set threshold Shutdown/
Warning/
Electrical Trip/
Page | 47
GC2100 SEDEMAC
Sr.
No.
Notification
31 Over Speed Indicates that genset speed has exceeded the pre-
set over speed threshold. Genset will shut down Shutdown
after Over Speed Delay.
32 Gross Over Speed Indicates that genset speed has exceeded the pre-
set Gross Over Speed Threshold. Genset will shut Shutdown
down immediately without any delay.
33 Under Speed The engine speed has fallen below the pre-set
Shutdown
RPM
34 Charge Fail The charge alternator voltage has dropped below Warning/
the pre-set threshold Electrical Trip/
Shutdown
35 Battery Under The battery voltage has fallen below the pre-set None/
Voltage threshold Shutdown/
Warning/
Electrical Trip/
Notification
36 Battery Over The battery voltage has exceeded the pre-set None/
Voltage threshold Shutdown/
Warning/
Electrical Trip/
Notification
37 High Oil Press Lube oil pressure is detected above the crank
Warning
Detected disconnect threshold when the engine is off.
38 Maintenance Due Indicates that engine running hours has exceeded Notification/
the pre-set hours limit or maintenance due date
has occurred and filter servicing is required. Warning
39 Battery Charger Fail Indicates the battery is not getting charged by the None/
charger Shutdown/
Warning/
Electrical Trip/
Notification
40 Smoke Fire Controller has detected smoke / fire through its None/
digital input Shutdown/
Warning/
Electrical Trip/
Notification
41 Aux S2 / user Auxiliary sensor S2’s threshold being crossed None/
defined name Warning/
Electrical Trip/
Shutdown
Page | 48
GC2100 SEDEMAC
Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Table 29: Troubleshooting
Sr. No. Fault Possible Causes / Remedial Actions
1 The controller does not • Check the battery voltage.
power ON. • Check the fuse on the battery supply.
• Check continuity between battery +ve and controller
terminal # 2.
• Check continuity between battery ground and controller
terminal # 1.
2 The controller screen • Reset the controller power.
freezes or hangs up.
3 The controller fails to • Check the battery voltage.
crank-start the engine. • Enter the “configuration mode” in controller and verify the
configuration for the “START” output. Also, check that
“START” output is working correctly by measuring its
voltage o/p.
• Enter the “configuration mode” in controller and verify the
configuration of “CRANK DISCONNECT” method. Verify
the configuration of “LLOP SWITCH” polarity. Also, ensure
that the lube oil pressure switch & sensor are working OK.
Check their wiring.
4 The “Emergency Stop” • Check if the “Emergency Stop” switch is working OK.
alarm comes up even Check its wiring also.
when the “Emergency • Enter the “configuration mode” in controller and verify the
Stop” is not pressed. configuration of “EMERGENCY STOP” polarity.
5 The controller generates • Check the respective switch/sensor and wiring.
unnecessary “Shutdown • Enter the “configuration mode” in the controller and verify
Alarms” or “Warning the respective threshold configuration.
Alarms”
6 The controller reports • To check if the controller's charging alternator terminal is
“Charging Alt Fail” alarm. working or not: disconnect the charging alternator wiring to
the controller's terminal # 10. Short the terminal # 10 to the
ground through a DC ammeter. Crank-start the engine. The
DC ammeter should indicate the current in the range 200 -
400 mA for ~30 seconds. If yes, the controller's chg
alternator terminal is working OK.
• Disconnect and re-connect the charging alternator ind
connection to the controller's terminal # 10.
• Check if the charging alternator is working OK or not.
7 A) The controller shows • Enter the “configuration mode” in the controller and verify
genset “ON” while the configuration for the LLOP and LOP. Check their wiring
genset is at rest. also.
B) “Fail To Stop” alarm • Ensure that the mains voltage wiring is not connected by
when genset is at mistake to the controller's genset voltage terminals.
rest.
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GC2100 SEDEMAC
8 The controller issues • Ensure that the controller's o/p terminal is not directly
unnecessary “crank- connected to the starter relay. The controller's o/p should
start” command be given to an intermediate relay which should in-turn
immediately after power power the starter relay. The controller can get permanently
on. damaged and will need to be replaced if this precaution is
not taken.
• Check start-relay connection with the suitable controller
terminal.
• Enter the “configuration mode” in the controller and verify
the configuration for “START MODE” and the “START
RELAY” o/p polarity.
9 The engine runs, but the • Check for alternator voltage signal (R phase) is received by
controller shows genset the controller terminal.
to be “OFF”. • Check if the LOP and LLOP are working OK. Also check
their wiring to the controller.
10 The controller displays • Check wiring of the respective alternator phase voltage
incorrect PF value or kW and the CT to the controller.
or load current. • Check the CT ratio (if kW or current reading is faulty).
11 The controller displays • Check the wiring of the respective phase to the controller.
incorrect mains voltage
or incorrect main
alternator voltage.
12 Controller displays • Check respective sensor and its wiring.
incorrect reading for any • Check SCP wiring.
of LOP, Fuel Level, • Enter the “configuration mode” in the controller and verify
Engine Temp sensors. the calibration for the respective
• sensor in configuration.
• Possible Issues in AUTO Mode
13 The controller displays • Check wiring of the main alternator’s R-phase and neutral
incorrect engine RPM. to the controller.
14 The controller does not • Check the wiring of the “Remote Start” signal to the
start the engine even controller's respective digital i/p terminal.
when a “Remote Start” • Enter the “configuration mode” in the controller and verify
command is sent from the configuration for the “Remote Start” digital i/p terminal.
an external device such
• Check that the controller is in “Auto” mode.
as a telecom PIU.
• check for mains monitoring disabled & Site mode disabled.
15 Controller does not stop • Check the wiring of the “Remote Stop” signal to the
engine even when a controller's respective digital i/p terminal.
“Remote Stop” • Enter the “configuration mode” in the controller and verify
command is sent from the configuration for the “Remote Stop” digital i/p terminal.
an external device such
• Check that the controller is in “Auto” mode.
as a telecom PIU.
16 While in Auto mode, • Check the wiring of the mains R, Y and B phase to the
controller issues “Start” controller's respective i/p terminal.
command even if the • Enter the “configuration mode” in the controller and verify
mains present. the configuration for the “MAINS MONITORING”.
• Possible issues with Site monitoring
17 Site voltage is observed • Check if earthing is proper for panel and Site
continuously varying • Check if the connections are done properly for the
differential input (pin # 24 & 25)
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GC2100 SEDEMAC
• Possible issues with MODBUS communication
18 GCU is not sending data • Check if the MODBUS communication is enabled in GCU
over MODBUS • Check if the MODBUS communication settings of slave
communication (GCU) match with the master
• Check if the connections are done properly for the
MODBUS input (pin # 31 & 32)
• Check if the connections are interchanged
• Check the 120 Ω resistance between terminal A (pin # 31)
& terminal B (pin # 32)
Communication protocol
The GC2100 genset controller supports a custom protocol based on MODBUS over a RS485 layer. The
GC2100 genset controller implement a custom protocol based on the standard MODBUS protocol. It
operates in a slave mode and responds to commands received from an external MODBUS master.
Connection Details
The transmission mode used by GC2100 series genset or Diesel Genset (DG) controllers is
MODBUS RTU (not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits,
no parity bits and 1 stop bit, Cyclic Redundancy Check (CRC).
The following section describe the connection details of RS485 MODBUS to SMPS MODBUS module.
On the GCU Pin 31 is represented as A, Pin 32 is represented as B and Pin 30 is represented as
ground.
Figure 25: RS485 MODBUS connection with the help of two core shielded twisted pair cable
Precautions
• Keep the slave ID of the GCU controller and the SMPS controller same, take the slave ID from
the SMPS and configure the same ID in GCU.
• Enable the GCU in the configuration of the SMPS after hardware connections are made, so the
SMPS can communicate with the GCU.
• Connect the Pin # 31 & 32 (A & B) of the GCU to the pin # A & B of the SMPS respectively and
not with any other pin.
• Connect the ground of the RS485 MODBUS module of the controller to the ground of SMPS. If
ground of the SMPS is not present, leave the ground terminal (Pin 30) of the controller open.
• Use two core shielded cable for connection.
• Use different colour wires for Pin # 31 & 32 (A & B) for easy detection and connection.
• Route the Pin # 31 & 32 (A & B) wires properly ensuring they do not get short with any other
wires.
• Do not use multi strand wires for the connection.
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GC2100 SEDEMAC
Supported Functions
This genset controller operates as a MODBUS slave that responds to certain commands (or
functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate
format. Supported functions and respective command-response structure is as shown below. If the
command received from the MODBUS master is other than the three functions mentioned below,
an exception message is generated.
Table 30: Details of function codes
Function Code MODBUS Name Description
03 Read holding register Reads one or more 16-bit from the slave device of
read/write location
04 Read input register Reads one or more 16-bit from the slave device of
read/write location
16 Write holding register Writes one or more 16-bit registers to the slave device
Communication settings
Table 31: RS485 MODBUS communication configuration setting
RS485 Communication
Slave ID 1-247
Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/115200
Parity None/Even/Odd
Stop Bit 1, 2
Recommended polling frequency: 50Hz
No response timeout: 250ms
Function 04 is used to read measurement parameters and status from the GC2100 controller.
Function code is a part of MODBUS message that defines the action to be taken by the Slave.
SEDEMAC GC2K supports following functions and the command-response format is as shown in the
following table.
Table 32: Command from MODBUS master for Function 4
Byte Field Remarks
0 Slave address As configured in GC2100
1 Function code (0x04)
2 First register address – high byte 16-bit register address, register address map
3 First register address – low byte is described in Table 34
4 Number of registers to read – high byte Number of registers to read must be between
5 Number of registers to read – low byte 1 to 255
6/7 Error check CRC
Query response format for Function 4 is as follows:
Table 33: Normal response from GC2100 slave for Function 4
Byte Field Remarks
0 Slave address As configured in GC2100
1 Function code (0x04)
Equals to number of registers to be read times
2 Byte count (n)
two. 8-bit even number between 2 to 250
3 First register – high byte
Page | 52
GC2100 SEDEMAC
Byte Field Remarks
4 First register – low byte
...
1+n Last register – high byte
2+n Last register – low byte
3+n/4+n Error check CRC
Table 34: Register map

Register Scale Unit /
Parameter Bits/ Sign
Address Factor Interpretation
Protocol revision 0 - - Unsigned
Generator L1-N voltage 1 0.1 V Unsigned
Generator L1-L2 voltage 4 0.1 V Unsigned
Generator R frequency 7 0.1 Hz Unsigned
Generator Y frequency 8 0.1 Hz Unsigned
Generator B frequency 9 0.1 Hz Unsigned
Generator power factor L1 10 0.01 -- Unsigned
Generator average power factor 13 0.01 -- Unsigned
Mains L1-N voltage 14 0.1 V Unsigned
Mains L1-L2 voltage 17 0.1 V Unsigned
Mains R frequency 20 0.1 Hz Unsigned
Mains Y frequency 21 0.1 Hz Unsigned
Mains B frequency 22 0.1 Hz Unsigned
Load L1 current 23 0.1 A Unsigned
Load L1 watts 26 0.1 kW Unsigned
Load total watts 29 0.1 kW Unsigned
Percentage Load 30 0.1 kW Unsigned
Load L1 VA 31 0.1 kVA Unsigned
Page | 53
GC2100 SEDEMAC
Load total VA 34 0.1 kVA Unsigned
Load L1 VAR 35 0.1 kVAR Unsigned
Load total VAR 38 0.1 kVAR Unsigned
Generator cumulative energy 39-40 0.1 kW Unsigned
Generator cumulative apparent
41-42 0.1 kVA Unsigned
energy
Generator cumulative reactive
43-44 0.1 kVAR Unsigned
energy
Mains cumulative energy 45-46 0.1 kW Unsigned
Mains cumulative apparent energy 47-48 0.1 kVA Unsigned
Mains cumulative reactive energy 49-50 0.1 kVAR Unsigned
Oil pressure 51 0.1 Bar Unsigned
Coolant temperature 52 0.1 Deg C Unsigned
Fuel level 53 1 % Unsigned
Fuel Level in lit 54 0.1 lit Unsigned
Charge alternator voltage 55 0.1 V Unsigned
Battery voltage 56 0.1 V Unsigned
Engine speed 57 1 RPM Unsigned
No of starts 58 1 -- Unsigned
No of trips 59 1 -- Unsigned
Eng run hrs 60 1 Hrs Unsigned
Eng run min 61 1 Min Unsigned
Mains run hrs 62 1 Hrs Unsigned
Mains run min 63 1 Min Unsigned
Auxiliary Input S1 value 64 0.1 Unsigned
Site Voltage 68 0.1 Unsigned
Site Run time hrs 69 1 Unsigned
Site Tun time mins 70 1 Unsigned
Alarm Status
Alarm 1 71
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Radiator water level / low fuel level -- -- 5/16-8/16
Reserved / Radiator water level
-- -- 1/16-4/16
switch
Alarm 2 72
Page | 54
GC2100 SEDEMAC
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
Alarm 3 73
Generator low voltage/ reserved -- -- 13/16-16/16
Generator high voltage/ reserved -- -- 9/16-12/16
Generator low frequency -- -- 5/16-8/16
Generator high -- -- 1/16-4/16
Alarm 4 74
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
Alarm 5 75
Charge alternator failure -- -- 13/16-16/16
Oil filter maintenance / filter
-- -- 9/16-12/16
maintenance
Fuel filter maintenance / reserved -- -- 5/16-8/16
Air filter maintenance / reserved -- -- 1/16-4/16
Alarm 6 76
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- -- 9/16-12/16
Oil pressure circuit open engine
-- -- 5/16-8/16
Temperature Circuit open
Reserved -- -- 1/16-4/16
Alarm 7 77
Fuel theft -- -- 13/16-16/16
Magnetic pick up fault -- -- 9/16-12/16
Extended over load trip / oil pressure
-- -- 5/16-8/16
circuit
Reserved -- -- 1/16-4/16
Alarm 8 78
Digital input A -- -- 13/16-16/16
Digital input B -- -- 9/16-12/16
Digital input C -- -- 5/16-8/16
Digital input D -- -- 1/16-4/16
Alarm 9 79
Digital input E -- -- 13/16-16/16
Digital input F -- -- 9/16-12/16
Digital input G -- -- 5/16-8/16
Digital input H -- -- 1/16-4/16
Page | 55
GC2100 SEDEMAC
Alarm 10 80
Digital input I -- -- 13/16-16/16
Analog input J -- -- 9/16-12/16
Analog input K -- -- 5/16-8/16
Analog input L -- -- 1/16-4/16
Alarm 11 81
Auxiliary input M -- -- 13/16-16/16
Auxiliary input N -- -- 9/16-12/16
Auxiliary input O -- -- 5/16-8/16
Auxiliary input P -- -- 1/16-4/16
Alarm 12 82
Gen L1 phase low volt -- -- 13/16-16/16
Gen L1 phase high volt -- -- 9/16-12/16
Alarm 13 83
Dg phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
Alarm 14 84 --
Open fuel level -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Extended over load trip/Reserved -- -- 5/16-8/16
High oil pressure detected -- -- 1/16-4/16
Alarm 15 85 --
Auxiliary Input S1 13/16-16/16
Alarm 16 86
Auxiliary S1 open ckt alarm 13/16-16/16
Alarm 17 87
Auxiliary S3 overcurrent/overvoltage
13/16-16/16
alarm
Auxiliary S4 overcurrent/overvoltage
9/16-12/16
alarm
Auxiliary S3 short to ground alarm 5/16-8/16
Auxiliary S4 short to ground alarm 1/16-4/16
Page | 56
GC2100 SEDEMAC
Input and output status
Input diagnostics 88
Digital input A -- -- 16/16
Digital input B -- -- 15/16
Digital input C -- -- 14/16
Digital input D -- -- 13/16
Digital input E -- -- 12/16
Digital input F -- -- 11/16
Digital input G -- -- 10/16
Digital input H -- -- 9/16
Digital input I -- -- 8/16
Analog input J -- -- 7/16
Analog input K -- -- 6/16
Analog input L -- -- 5/16
Auxiliary input M -- -- 4/16
Auxiliary input N -- -- 3/16
Auxiliary input O -- -- 2/16
Auxiliary input P -- -- 1/16
Output Diagnostic 89
Digital output A -- -- 16/16
Digital output B -- -- 15/16
Digital output C -- -- 14/16
Digital output D -- -- 13/16
Digital output E -- -- 12/16
Digital output F -- -- 11/16
Digital output G -- -- 10/16
Unimplemented -- -- 9/16
Dg status 90
GCU Mode Config /Run 16/16
Mains Healthy / unhealthy -- True (1) / False (0) 15/16
Scheduler/cyclic/A
DG operation mode -- 14-12/16
uto / Manual
Load on Mains True (1) / False (0) 11/16
Page | 57
GC2100 SEDEMAC
Load on DG -- True (1) / False (0) 10/16
Current DG status -- Running / stopped 9/16
DG stopped normally -- True (1) / False (0) 8/16
DG stopped with fault True (1) / False (0) 7/16
DG fail to start -- True (1) / False (0) 6/16
Gen available True (1) / False (0) 5/16
Common shut down -- True (1) / False (0) 4/16
Common electric trip -- True (1) / False (0) 3/16
Common warning -- True (1) / False (0) 2/16
Common notification -- True (1) / False (0) 1/16
Current EPOCH
Current time stamp 88-89 --
time
Page | 58
GC2100 SEDEMAC
Notes
Page | 59
GC2100 SEDEMAC
Disclaimer: Due to continuous development, the details provided in this document are subject
to change without any prior notice.
SEDEMAC Mechatronics Pvt Ltd

Technical Centre
C9-10, C Block, MIDC Bhosari
Pune 411026, India
Manufacturing Plant
G-1, MIDC, Phase-III Chakan
Industrial Area, Nighoje
Pune 410501, India
Manufacturing Plant
Survey No. 64/5, Off Sinhagad Road
Vadgaon Budruk, Narhe
Pune 411041, India
Page | 60

Sed Man Gc2100 002 Manual For Gc2100 Controller

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Sed Man Gc2100 002 Manual For Gc2100 Controller

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ABSTRACT

This manual is intended as

MANUAL FOR Doc #SED-MAN-GC2100-002

SEDEMAC Mechatronics Pvt. Ltd.

• Highlights an essential element of a procedure to ensure correctness

• Indicates a procedure or practice, which could result in damage or

• Indicates a procedure or practice, which could result in injuring

Key highlights of the product

Figure 1: GC2100 genset controller's front fascia

Figure 2: Connectors of 5.08 mm pitch

Figure 3: Connectors of 10.16 mm pitch

Power Supply Specifications

Genset Voltages and Frequency Measurements

Genset Current Measurements

Earth leak Measurements

Follow the recommended phase sequence while connecting the Current

Mains Voltages and Frequency Measurements

Analog Resistive Sensor Inputs

Figure 4: SCP connection

Site Battery Inputs

1) Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID”

Sensor common point

Deep Sleep Mode Feature

• Pin 30 should be connected to master’s isolated ground only

• Keep pin 30 connection open if shielded cable is not available

Figure 5: Dimensions of the GC2100 genset controller

Figure 6: Fixing clip and screw supplied along with controller

Figure 7: Controller mounting on the panel using the fixing clips

Over tightening of the screws may damage the controller casing.

Terminal Pin Details

Figure 8: Rear view of the controller for terminal detail

Typical Wiring Diagram

MANUAL MODE AUTO MODE

DG AND MAINS LOAD STATUS*

LOAD KVA LOAD KW

*These 3 screens are common for DG and Mains

Generator Voltage Shelter temperature

ENGINE LUBE OIL PRESSURE ENGINE FUEL LEVEL

ENGINE SPEED ENGINE TEMPERATURE

HISTOGRAM AUXILIARY SENSOR

ENGINE BATTERY / SITE BATTERY

Figure 10: Control keys function

Figure 11: Configuration mode screen

Figure 12: Configuration mode authentication page screen

Figure 13: Saving setting screen

Use Input As Not used/Dig In O/Dig In P/

Table 18: Digital input source selection

Table 19: LOP (Resistive) sensor calibration

Table 20: Fuel level sensor calibration

Table 21: Engine / shelter temperature sensor calibration

Table 22: Auxiliary (S1/S2) resistive sensor calibration

Table 23: Auxiliary (S3/S4) current sensor calibration

Table 24: LOP sensor calibration

Table 25: Auxiliary (S3/S4) (0 – 5V) voltage sensor calibration

Table 26: Digital output source selection

Figure 14: Mode selection screen

Figure 15: Flow chart of start sequence

Figure 16: Flow chart of stop sequence

Site Battery Monitoring mode

Figure 17: Flow chart of Site monitoring mode

It is recommended to keep mains monitoring enable in this mode. Also, it is

Figure 18: Flow chart of cyclic mode

Figure 19: Flow chart of Auto Mains Failure (AMF) mode