G-545 User Manual Rev_01 Firmware V-6.

G-545
ADVANCED
GENSET
CONTROLLER

DESCRIPTION COMMUNICATIONS
The G-545 is a next generation genset controller *Ethernet port (10/100Mb)
combining multi-functionality and wide communication *GSM-GPRS
capabilities together with a reliable and modular *Embedded web server
design. *Web monitoring
The same controller provides synchronization, load *Web programming
share, AMF, ATS, Remote Start, Engine Control and *Central Monitoring through internet
Remote Display Panel functionalities. *SMS message sending
*E-mail sending
The module comes ready for remote monitoring over
PC software: Rainbow Plus
GSM or Ethernet with plug-in communication modules.
*Central monitoring
Various plug-in modules provide unlimited expansion *Modbus RTU through RS-485
capabilities allowing to meet any special requirement. *Modbus TCP/IP
The unit complies and mostly exceeds world’s tightest *SNMP
safety, vibration and environmental standards for the *USB Host
industrial category. USB Device
Software features are complete with easy firmware RS-485 port, adjustable baud rate
upgrade process through USB port. J1939-CANBUS for electronic engines
*CANBUS-2 for inter-module
The Windows based PC software allows monitoring
communication
and programming through USB, RS-485, Ethernet and
GPRS. The Rainbow Scada web monitoring service *Optional with plug-in module
allows monitoring and control of an unlimited number
of gensets through any web browser. TOPOLOGIES
FUNCTIONALITIES 3 phases 4 wires, star
3 phases 4 wires, delta
*Multi-genset synchronizer and load share unit
3 phases 3 wires, delta, 3 CTs
AMF unit with uninterrupted transfer
3 phases 3 wires, delta, 2 CTs (L1-L2)
ATS unit with uninterrupted transfer
3 phases 3 wires, delta,2 CTs (L1-L3)
Remote start controller
2 phases 3 wires, L1-L2
Manual start controller
2 phases 3 wires, L1-L3
Engine controller
1 phase 2 wires
Remote display & control unit
Waveform display of V & I
Harmonic analysis of V & I

*Optional with plug-in module

G-545 User Manual Rev_01 Firmware V-6.0

COPYRIGHT NOTICE

Any unauthorized use or copying of the contents or any part of this document is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

ABOUT THIS DOCUMENT

This document describes minimum requirements and necessary steps for the successful installation of
the G-545 family units.
Follow carefully advices given in the document. These are often good practices for the installation of
genset control units which reduce future issues.
For all technical queries please contact Grupel.

QUERRIES
If additional information to this manual is required, please contact Grupel.

Please provide following information in order to get answers to any question:

- Device model name (see the back panel of the unit),
- Complete serial number (see the back panel of the unit),
- Firmware version (read from the display screen),
- Measuring-circuit voltage and power supply voltage,
- Precise description of the query.

RELATED DOCUMENTS

FILENAME DESCRIPTION
545-Rainbow Installation Rainbow Plus Installation Guide
545-Rainbow Usage Rainbow Plus Usage Guide
545-DYNdns account setting Dynamic DNS Account Setting
545-Ethernet Configuration Ethernet Configuration Guide
545-GSM Configuration GSM Configuration Guide
545-Firmware Update Firmware Update Guide
545-MODBUS Modbus Application Manual
545-snmp_E_34076 MIB file for SNMP Application
545-Rainbow Scada Installation Rainbow Scada Installation Guide
545-Rainbow Scada Usage Rainbow Scada Usage Guide

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G-545 User Manual Rev_01 Firmware V-6.0

REVISION HISTORY

REVISION DATE AUTHOR DESCRIPTION

01 01.01.2018 MK First release, firmware version 6.0

TERMINOLOGY

CAUTION: Potential risk of injury or death.

WARNING: Potential risk of malfunction or material damage.

ATTENTION: Useful hints for the understanding of device operation.

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 G-545 User Manual Rev_01 Firmware V-6.0

ORDERING CODES

The G-545 family units are available in various options and peripheral features. Please use below
information for ordering the correct version:

G545 -S -E -M -C -G -T -00
Family Code
Variant
00: standard unit
01...99: customer
Synchronization specific products
slot
GSM-GPRS With Conformal
Modem slot Coating
I/O Extension
slot With Sealing
USB-Host,
RS-485, gasket
Ethernet slot

SPARE PARTS

Screw type bracket Self-Retaining type bracket

Stock Code=J10P01 (per unit) Stock Code=K16P01 (per unit)

Sealing Gasket, Stock Code= L043P01

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G-545 User Manual Rev_01 Firmware V-6.0

SAFETY NOTICE
Failure to follow below instructions
will result in death or serious injury

▪ Electrical equipment should be installed only by qualified

specialist. No responsibility is assured by the manufacturer or
any of its subsidiaries for any consequences resulting from the
non-compliance to these instructions.
▪ Check the unit for cracks and damages due to transportation. Do
not install damaged equipment.

▪ Do not open the unit. There are no serviceable parts inside.

▪ Fuses must be connected to the power supply and phase voltage

inputs, in close proximity of the unit.
▪ Fuses must be of fast type (FF) with a maximum rating of 6A.

▪ Disconnect all power before working on equipment.

▪ When the unit is connected to the network do not touch

terminals.

▪ Short circuit terminals of unused current transformers.

▪ Any electrical parameter applied to the device must be in the

range specified in the user manual. Although the unit is designed
with a wide safety margin, over-range parameters may reduce
lifetime, alter operational precision or even damage the unit.
▪ Do not try to clean the device with solvent or the like. Only clean
with a dump cloth.

▪ Verify correct terminal connections before applying power.

▪ Only for front panel mounting.

Current Transformers must be used for current measurement.

No direct connection allowed.

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G-545 User Manual Rev_01 Firmware V-6.0

TABLE OF CONTENTS

1. INSTALLATION INSTRUCTIONS
2. MOUNTING
2.1 DIMENSIONS
2.2 SEALING, GASKET
2.3 ELECTRICAL INSTALLATION
3. TERMINAL DESCRIPTIONS
3.1. BATTERY VOLTAGE INPUT
3.2. AC VOLTAGE INPUTS
3.3. AC CURRENT INPUTS
3.4. DIGITAL INPUTS
3.5. ANALOG SENDER INPUTS AND SENDER GROUND
3.6. ANALOG I/O EXTENSION (plug-in module)
3.7. CHARGE INPUT TERMINAL
3.8. MAGNETIC PICKUP INPUT
3.9. DIGITAL OUTPUTS
3.10. MAINS CONTACTOR OUTPUT
3.11. GENERATOR CONTACTOR OUTPUT
3.12. INPUT/OUTPUT EXTENSION
3.13. RS-485 PORT
3.14. J1939-CANBUS PORT
3.15. DATALINK-CANBUS PORT (plug-in module)
3.16. ANALOG AVR CONTROL OUTPUT (plug-in module)
3.17. ANALOG GOVERNOR CONTROL OUTPUT (plug-in module)
3.18. ANALOG LOAD SHARE SIGNAL (plug-in module)
3.19. ETHERNET PORT (plug-in module)
3.20. USB DEVICE PORT
3.21. USB HOST PORT (plug-in module)
3.22. GSM MODEM (plug-in module)
4. TOPOLOGIES
4.1. SELECTING THE TOPOLOGY
4.2. 3 PHASE, 4 WIRE, STAR
4.3. 3 PHASE, 3 WIRE, DELTA
4.4. 3 PHASE, 4 WIRE, DELTA
4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)
4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)
4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)
4.9. 1 PHASE, 2 WIRE

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G-545 User Manual Rev_01 Firmware V-6.0

5. FUNCTIONALITIES
5.1. CT LOCATION SELECTION
5.2. SYNCHRONIZATION FUNCTIONALITY
5.3 MAINS SYNCHRONIZATION FUNCTIONALITY
5.4 SINGLE GENSET PARALLEL WITH MAINS
5.5. AMF FUNCTIONALITY
5.6. ATS FUNCTIONALITY
5.7. REMOTE START FUNCTIONALITY
5.8 ENGINE CONTROLLER FUNCTIONALITY
5.9. REMOTE DISPLAY UNIT FUNCTIONALITY
5.10. 400HZ OPERATION
6. CONNECTION DIAGRAMS
6.1. GENSET SYNCHRONIZATION FUNCTIONALITY
6.2. MAINS SYNCHRONIZATION FUNCTIONALITY
6.3. SINGLE GENSET PARALLEL WITH MAINS FUNCTIONALITY
6.4. AMF FUNCTIONALITY
6.5. ATS FUNCTIONALITY
6.6. REMOTE START FUNCTIONALITY
6.7. ENGINE CONTROL FUNCTIONALITY
6.8. REMOTE DISPLAY PANEL FUNCTIONALITY
7. TERMINAL DESCRIPTION
8. TECHNICAL SPECIFICATIONS
9. DESCRIPTION OF CONTROLS
9.1. FRONT PANEL FUNCTIONALITY
9.2. PUSHBUTTON FUNCTIONS
9.3. DISPLAY SCREEN ORGANIZATION
9.4. AUTOMATIC DISPLAY SCROLL
9.5. MEASURED PARAMETERS
9.6. LED LAMPS
10. WAVEFORM DISPLAY & HARMONIC ANALYSIS
11. DISPLAYING EVENT LOGS
12. STATISTICAL COUNTERS
12.1. FUEL FILLING COUNTER
12.2. FUEL CONSUMPTION MONITORING

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G-545 User Manual Rev_01 Firmware V-6.0

13. OPERATION OF THE UNIT

13.1. QUICK START GUIDE
13.2. STOP MODE
13.3. AUTO MODE
13.4. RUN MODE, MANUAL CONTROL
13.5. TEST MODE
14. PROTECTIONS AND ALARMS
14.1. DISABLING ALL PROTECTIONS
14.2. SERVICE REQUEST ALARM
14.3. SHUTDOWN ALARMS
14.4. LOADDUMP ALARMS
14.5. WARNINGS
14.6. NON-VISUAL WARNINGS
15. PROGRAMMING
15.1. RESETTING TO FACTORY DEFAULTS
15.2. ENTERING THE PROGRAMMING MODE
15.3. NAVIGATING BETWEEN MENUS
15.4. MODIFYING PARAMETER VALUE
15.5. PROGRAMMING MODE EXIT
16. PROGRAM PARAMETER LIST
16.1. CONTROLLER CONFIGURATION GROUP
16.2. ELECTRICAL PARAMETERS GROUP
16.3. ENGINE PARAMETERS GROUP
16.4. ADJUST DATE AND TIME
16.5. WEEKLY OPERATION SCHEDULE
16.6. EXERCISER SCHEDULE
16.7. SENDER CONFIGURATION
16.8. DIGITAL INPUT CONFIGURATION
16.9. OUTPUT CONFIGURATION
16.10. SITE ID STRING
16.11. ENGINE SERIAL NUMBER
16.12. MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS
16.13. GSM MODEM PARAMETERS
16.14. ETHERNET PARAMETERS
16.15. SNTP PARAMETERS
16.16. SYNCHRONIZATION PARAMETERS
17. CRANK CUTTING
18. OVERCURRENT PROTECTION (IDMT)
19. MOTORIZED CIRCUIT BREAKER CONTROL
20. AUTO LEARNING

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G-545 User Manual Rev_01 Firmware V-6.0

21. SPEED & VOLTAGE UP/DOWN RELAY OUTPUTS

21.1. SPEED UP/DOWN CONTROL
21.2. VOLTAGE UP/DOWN CONTROL
22. J1939 CANBUS ENGINE SUPPORT
23. GPS SUPPORT
24. ETHERNET CONFIGURATION
25. GSM CONFIGURATION
26. DYNAMIC DNS FEATURE
27. ACCESSING THE EMBEDDED WEB SERVER
28. WEB MONITORING AND CONTROL OF GENSETS
29. CENTRAL MONITORING OF GENSETS
30. E-MAIL SENDING
31. SMS COMMANDS
32. LOAD TRANSFER MODES
32.1. TRANSFER WITH INTERRUPTION
32.2. UNINTERRUPTED TRANSFER
32.3. SOFT TRANSFER
33. LOAD SHARING
33.1. DIGITAL LOAD SHARING (DATALINK)
33.2. ANALOG LOAD SHARING
33.3. DROOP MODE OPERATION
34. PARALLELING WITH MAINS OPERATION
34.1. PEAK LOPPING
34.2. POWER EXPORT TO MAINS
34.3. DISTRIBUTED POWER EXPORT TO MAINS
34.4. PEAK LOPPING WITH GENSET PRIORITY
35. PROTECTION FUNCTIONS PARALLELING WITH MAINS
35.1. ROCOF FUNCTION (rate of change of frequency)
35.2. VECTOR SHIFT FUNCTION
35.3. OVER/UNDER FREQUENCY FUNCTION
35.4. OVER/UNDER VOLTAGE FUNCTION
35.5. MAINS REVERSE POWER FUNCTION
35.6. NO FREQUENCY FUNCTION
36. DATA RECORDING
36.1. DATA RECORDING MEDIA
36.2. DIRECTORY STRUCTURE
36.3. UNDERSTANDING THE CSV FORMAT
36.4. RECORDED DATA LIST, RECORD PERIOD

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G-545 User Manual Rev_01 Firmware V-6.0

37. SOFTWARE FEATURES

37.1. LOAD SHEDDING / DUMMY LOAD
37.2. LOAD ADD / SUBSTRACT
37.3. FIVE STEP LOAD MANAGEMENT
37.4. REMOTE START OPERATION
37.5. DISABLE AUTO START, SIMULATE MAINS
37.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS
37.7. DUAL GENSET MUTUAL STANDBY OPERATION
37.8. MULTIPLE VOLTAGE AND FREQUENCY
37.9. SINGLE PHASE OPERATION
37.10. EXTERNAL CONTROL OF THE UNIT
37.11. AUTOMATIC EXERCISER
37.12. WEEKLY OPERATION SCHEDULER
37.13. ENGINE HEATING OPERATION
37.14. ENGİNE IDLE SPEED OPERATİON
37.15. ENGINE BLOCK HEATER
37.16. FUEL PUMP CONTROL
37.17. GAS ENGINE FUEL SOLENOID CONTROL
37.18. PRE-TRANSFER SIGNAL
37.19. CHARGING THE ENGINE BATTERY
37.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
37.21. COMBAT MODE
37.22. RESETTING THE CONTROLLER
37.23. AUTOMATIC CONNECTION TOPOLOGY DETERMINATION
37.24. ZERO POWER AT REST
38. MODBUS COMMUNICATIONS
38.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION
38.2. PARAMETERS REQUIRED FOR MODBUS-TCP/IP VIA ETHERNET
38.3. DATA FORMATS
39. SNMP COMMUNICATIONS
39.1. PARAMETERS REQUIRED FOR SNMP VIA ETHERNET
39.2. SNMP TRAP MESSAGES
40. DECLARATION OF CONFORMITY
41. MAINTENANCE
42. DISPOSAL OF THE UNIT
43. ROHS COMPLIANCE
44. TROUBLESHOOTING GUIDE

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G-545 User Manual Rev_01 Firmware V-6.0

1. INSTALLATION INSTRUCTIONS

Before installation:
▪ Read the user manual carefully, determine the correct connection diagram.
▪ Remove all connectors and mounting brackets from the unit, then pass the unit through the
mounting opening.
▪ Put mounting brackets and tighten. Do not tighten too much, this can break the enclosure.
▪ Make electrical connections with plugs removed from sockets, then place plugs to their sockets.
▪ Be sure that adequate cooling is provided.
▪ Be sure that the temperature of the environment will not exceed the maximum operating
temperature in any case.

Below conditions may damage the device:

▪ Incorrect connections.
▪ Incorrect power supply voltage.
▪ Voltage at measuring terminals beyond specified range.
▪ Voltage applied to digital inputs over specified range.
▪ Current at measuring terminals beyond specified range.
▪ Overload or short circuit at relay outputs
▪ Connecting or removing data terminals when the unit is powered-up.
▪ High voltage applied to communication ports.
▪ Ground potential differences at non-isolated communication ports.
▪ Excessive vibration, direct installation on vibrating parts.

Current Transformers must be used for current

measurement.
No direct connection allowed.

Below conditions may cause abnormal operation:

▪ Power supply voltage below minimum acceptable level.
▪ Power supply frequency out of specified limits
▪ Phase order of voltage inputs not correct.
▪ Current transformers not matching related phases.
▪ Current transformer polarity incorrect.
▪ Missing grounding.

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G-545 User Manual Rev_01 Firmware V-6.0

2. MOUNTING

2.1. DIMENSIONS

Dimensions: 211x162x42mm
Panel Cutout: 183x134mm minimum
Weight: 500gr (approx.)

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G-545 User Manual Rev_01 Firmware V-6.0

The unit is designed for panel mounting. The user should not be able to access parts of the unit other
than the front panel.

Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors
from the unit, then pass the unit through the mounting opening.

Place and tighten mounting brackets.

Panel Cutout

Required Panel Depth

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G-545 User Manual Rev_01 Firmware V-6.0

Two different types of brackets are provided:

Screw type bracket Self retaining type bracket

Installation of screw type bracket Installation of self-retaining type bracket

Do not tighten too much, this may break the unit.

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G-545 User Manual Rev_01 Firmware V-6.0

2.2. SEALING, GASKET

Panel

Gasket

Module

The rubber gasket provides a watertight means of mounting the module to the genset panel. Together
with the gasket, IEC 60529-IP65 protection can be reached from the front panel. A short definition of IP
protection levels is given below.

1st Digit Description of Protection Level

0 Not protected
1 Protected against solid foreign objects of 50 mm diameter and greater
2 Protected against solid foreign objects of 12,5 mm diameter and greater
3 Protected against solid foreign objects of 2,5 mm diameter and greater
4 Protected against solid foreign objects of 1,0 mm diameter and greater
5 Protected from the amount of dust that would interfere with normal operation
6 Dust tight

2nd Digit Description of Protection Level

0 Not protected
1 Protected against vertically falling water drops
2 Protected against vertically falling water drops when enclosure is tilted up to 15 °
3 Protected against water sprayed at an angle up to 60 ° on either side of the vertical
4 Protected against water splashed against the component from any direction
5 Protected against water projected in jets from any direction
6 Protected against water projected in powerful jets from any direction
7 Protected against temporary immersion in water
8 Protected against continuous immersion in water, or as specified by the user

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G-545 User Manual Rev_01 Firmware V-6.0

2.3. ELECTRICAL INSTALLATION

Do not install the unit close to high electromagnetic

noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.

Although the unit is protected against electromagnetic disturbance, excessive

disturbance can affect the operation, measurement precision and data communication
quality.
▪ ALWAYS remove plug connectors when inserting wires with a screwdriver.

▪ Fuses must be connected to the power supply and phase voltage inputs, in
close proximity of the unit.

▪ Fuses must be of fast type (FF) with a maximum rating of 6A.

▪ Use cables of appropriate temperature range.

▪ Use adequate cable section, at least 0.75mm2 (AWG18).

▪ Follow national rules for electrical installation.

▪ Current transformers must have 5A output.

▪ For current transformer inputs, use at least 1.5mm2 section (AWG15) cable.

▪ The current transformer cable length should not exceed 1.5 meters. If
longer cable is used, increase the cable section proportionally.

Current Transformers must be used for current

measurement.
No direct connection allowed.

The engine body must be grounded. Otherwise faulty

voltage and frequency measurements may occur.

For the correct operation of the exerciser and

weekly schedule programs, adjust the real time
clock of the unit through programming menu.

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G-545 User Manual Rev_01 Firmware V-6.0

3. TERMINAL DESCRIPTIONS

3.1. BATTERY VOLTAGE INPUT

Supply voltage: 9 to 36VDC

Cranking dropouts: Survives 0VDC during 100ms. The voltage before surge should be
9VDC minimum
Overvoltage protection: Withstands 150VDC continuously.
Reverse voltage: -36VDC continuous
Maximum operating 600mA @ 12VDC. (All options included, digital outputs open.)
current: 300mA @ 24VDC. (All options included, digital outputs open.)
Typical operating current: 300mA @ 12VDC. (all options passive, digital outputs open)
150mA @ 24VDC. (all options passive, digital outputs open)
Measurement range: 0 to 36VDC
Display resolution: 0.1VDC
Accuracy: 0.5% + 1 digit @ 24VDC

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G-545 User Manual Rev_01 Firmware V-6.0

3.2. AC VOLTAGE INPUTS

Measurement method: True RMS

Sampling rate: 8000 Hz
Harmonic analysis: up to 31th harmonic
Input voltage range: 0 to 300 VAC
Minimum voltage for 15 VAC (Ph-N)
frequency detection:
Supported topologies: 3 ph 4 wires star
3 ph 4 wires delta
3 ph 3 wires delta
3 ph 3 wires delta L1-L2
3 ph 3 wires delta L2-L3
2ph 3 wires L1-L2
2ph 3 wires L1-L3
1 ph 2 wires
Measurement range: 0 to 330VAC Ph-N (0 to 570VAC Ph-Ph)
Common mode offset: max 100V between neutral and BAT-
Input impedance: 4.5M-ohms
Display resolution: 1VDC
Accuracy: 0.5% + 1 digit @ 230VAC Ph-N (±2VAC Ph-N)
0.5% + 1 digit @ 400VAC Ph-Ph (±3VAC Ph-Ph)

Frequency range: DC to 500Hz

Frequency display 0.1 Hz
resolution:
Frequency accuracy: 0.2% + 1 digit (±0.1 Hz @ 50Hz)

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3.3. AC CURRENT INPUTS

Measurement method: True RMS

Sampling rate: 8000 Hz
Harmonic analysis: up to 31th harmonic
Supported topologies: 3 ph 4 wires star, 3 ph 4 wires delta,
3 ph 3 wires delta
3 ph 3 wires delta L1-L2
3 ph 3 wires delta L2-L3
2ph 3 wires L1-L2
2ph 3 wires L1-L3
1 ph 2 wires
CT secondary rating: 5A
Measurement range: 5/5 to 5000/5A minimum
Input impedance: 15 milliohm
Burden: 0.375W
Maximum continuous 6A
current:
Measurement range: 0.1 to 7.5A
Common mode offset: Max 5VAC between BAT- and any CT terminal.
Display resolution: 1A
Accuracy: 0.5% + 1 digit @ 5A (± 4.5A @ 5/500A full range)

SELECTING THE CT RATING AND CABLE SECTION:

The load on a CT should be kept minimum in

order to minimize phase shift effect of the
current transformer. Phase shift in a CT will
cause erroneous power and power factor
readings, although amp readings are correct.
Grupel advises CT rating to be selected
following this table for the best measurement
accuracy.

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G-545 User Manual Rev_01 Firmware V-6.0

SELECTING THE CT ACCURACY CLASS:

The CT accuracy class should be selected in accordance with the required measurement precision. The
accuracy class of controller is 0.5%. Thus 0.5% class CTs are advised for the best result.

➢ Current Transformers must be used for current

measurement. No direct connection allowed.
➢ No common terminals or grounding allowed.

CONNECTING CTs:
Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs between
phases will cause faulty power and pf readings.
Many combinations of incorrect CTs connections are possible, so check both order of CTs and their
polarity. Reactive power measurement is affected by incorrect CTs connection in similar way as active
power measurement.

CORRECT CT CONNECTIONS

Let’s suppose that the genset is loaded with 100 kW on each phase. The load Power Factor (PF) is 1.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 100.0 0.0 100 1.00
Phase L3 100.0 0.0 100 1.00
Total 300.0 0.0 300 1.00

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G-545 User Manual Rev_01 Firmware V-6.0

EFFECT OF POLARITY REVERSAL

The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1.
PF in phase L2 will show -1.00 due to reverse CT polarity. The result is that total generator power
displayed by the controller is 100 kW.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 -100.0 0.0 100 -1.00
Phase L3 100.0 0.0 100 1.00
Total 100.0 0.0 300 0.33

EFFECT OF PHASE SWAPPING

The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1.
PF in phases L2 and L3 will show -0.50 due to phase shift between voltages and currents which is
caused by CT swapping. The result is that total generator power displayed by controller is 0 kW.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 -50.0 86.6 100 -0.50
Phase L3 -50.0 -86.6 100 -0.50
Total 0.0 0.0 300 0.0

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3.4. DIGITAL INPUTS

Number of inputs: 6 inputs, all configurable

Function selection: from list
Contact type: Normally open or normally closed (programmable)
Switching: Battery negative or battery positive (programmable)
Structure: 47 k-ohms resistor to battery positive, 110k-ohms to battery negative.
Measurement: Analog voltage measurement.
Open circuit voltage: 70% of battery voltage
Low level threshold: 35% of battery voltage
High level threshold: 85% of battery voltage
Maximum input voltage: +100VDC with respect to battery negative
Minimum input voltage: -70VDC with respect to battery negative
Noise filtering: Yes, both analog and digital filtering

3.5. ANALOG SENDER INPUTS & SENDER GROUND

Number of inputs: 5 inputs, all configurable, additional sender ground input

Function selection: from list
Structure: 667 ohms resistor polarizing to 3.3VDC
Measurement: Analog resistor measurement.
Open circuit voltage: +3.3VDC
Short circuit current: 5mA
Measurement range: 0 to 5000 ohms.
Open circuit threshold: 5000 ohms.
Resolution: 1 ohms @ 300 ohms or lower
Accuracy: 2 %+1 ohm (±7 ohms @300 ohms)
Common mode voltage ± 3VDC
range:
Noise filtering: Yes, both analog and digital filtering

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3.6. ANALOG I/O EXTENSION (plug-in module)

Analog I/O extension plug-in module with 3 analog inputs. Each analog input can be switched by DIP
switches for:
-Resistive,
-4 to 20 mA
-0 to 10 Vdc

Analog I/O
Extension slot

The main configuration of the inputs is done

with DIP switches located on slot.

SND 8 cannot be switched to resistive input. The

configuration can be 4-20 mA or 0-10 VDC.

Analog outputs will be functional with further

firmware version.

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3.7. CHARGE INPUT TERMINAL

The Charge terminal is both an input and output.

When the engine is ready to run, this terminal supplies the excitation current to the charge alternator.
The excitation circuit is equivalent to a 2W lamp.
The threshold voltages for warning and shutdown alarm are adjustable through program parameter.

Structure: • battery voltage output through 20 ohm PTC

• voltage measurement input
Output current: 160mA @12VDC
80mA @24VDC
Voltage measurement 0.1VDC
resolution:
Voltage measurement 2% + 0.1V (0.9V @30VDC)
accuracy:
Charge Fail Warning adjustable
Threshold:
Charge Fail Shutdown adjustable
Alarm Threshold:
Open circuit voltage: battery positive
Overvoltage protection: > 500VDC continuous, with respect to battery negative
Reverse voltage -30VDC with respect to battery negative
protection:

3.8. MAGNETIC PICKUP INPUT

Structure: Differential frequency measurement input

Input impedance: 50 k-ohms
Input voltage: 0.5VAC-RMS to 30VAC-RMS
Max common mode ± 5VDC
voltage:
Frequency range: 10Hz to 10 kHz
Resolution: 1 rpm
Accuracy: 0.2% + 1 rpm (±3rpm @1500 rpm)
Flywheel teeth range: 1 to 500

Do not share MPU with other devices.

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3.9. DIGITAL OUTPUTS

The unit offers 6 digital outputs with programmable function, selectable from list.

Structure: Negative pulling protected semiconductor output. One terminal is

connected to battery negative.
Max continuous current: 1.0 ADC
Max switching voltage: 33 VDC
Overvoltage protection: 40 VDC
Short circuit protection: > 1.7 ADC
Reverse voltage 500 VDC
protection:

3.10. MAINS CONTACTOR OUTPUT

Structure: Relay output, normally closed contact. One terminal is internally

connected to mains phase L1 input.
Max switching current: 12A @250VAC
Max switching voltage: 440VAC
Max switching power: 3000VA

3.11. GENERATOR CONTACTOR OUTPUT

Structure: Relay output, normally open contact. One terminal is internally

connected to genset phase L1 input.
Max switching current: 16A @250VAC
Max switching voltage: 440VAC
Max switching power: 4000VA

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3.12. INPUT/OUTPUT EXTENSION

The module provides resources for 32 additional digital inputs and 32 additional digital outputs.
Digital inputs can be extended using G-188 Digital Input Extension modules, each one providing 8
inputs. Digital inputs are programmable through the main controller. The switching characteristic is not
programmable and must be battery negative. Any function can be assigned to digital inputs.
Digital outputs can be extended using G-186 Fet Extension modules, each one providing 8 outputs.
Digital outputs have the same electrical characteristics as on board outputs. They have programmable
functions through the main controller. Any function can be assigned to any output.
Input and output extension modules are connected to the main controller in a cascade structure, in any
order. The connection cable is provided with each extension module.

I/O Extension
Connector

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3.13. RS-485 PORT

Structure: RS-485, non-isolated in AMF versions, isolated in synch versions.

Connection: 3 wires (A-B-GND). Half duplex.
Baud rate: 2400-115200 bauds, selectable
Data type: 8 bit data, no parity, 1 bit stop
Termination: External 120 ohms required
Isolation voltage: 1000 VAC, 1 minute (in isolated versions only)
Common mode voltage: -0.5 VDC to +7VDC, internally clamped by transient suppressors.
Max distance: 1200m @ 9600 bauds (with 120 ohms balanced cable)
200m @ 115200 bauds (with 120 ohms balanced cable)

The RS-485 port features MODBUS-RTU protocol. Multiple modules (up to 128) can be paralleled on the
same RS-485 bus for data transfer to automation or building management systems.

The Modbus register list is available at Grupel.

The RS-485 port provides also a good solution for distant PC connection where RainbowPlus program
will enable programming, control and monitoring.

For more details about programming, control and

monitoring through RS-485 port please refer to
RainbowPlus user manual.

3.14. J1939-CANBUS PORT

Structure: CANBUS, non-isolated.

Connection: 3 wires (CANH-CANL-GND).
Data rate: 250 kbps
Termination: Internal 120 ohms provided
Common mode voltage: -0.5 VDC to +15 VDC, internally clamped by transient suppressors.
Max distance: 200m with 120 ohm balanced cable

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3.15. DATALINK-CANBUS PORT ( plug-in module )

Structure: CANBUS, isolated.

Connection: 4 wires (DATALINK-H, DATALINK-L, GND, TERMINATION).
Data rate: 250 kbps standard (adjustable between 50 and 500 kbps)
Termination: 120 ohms resistor internally connected to DATALINK-H.
The TERMINATION is to be connected to DATALINK-L in order to
terminate the Datalink bus.
Isolation voltage: 1000 VAC, 1 minute
Common mode voltage: -0.5 VDC to +15 VDC, internally clamped by transient suppressors.
Max distance: 200m with 120 ohm balanced cable

The Datalink bus should be terminated from both

ends.

The Datalink cable shield should be grounded from

one end only.

Termination Termination

Figure illustrating the Datalink termination from two ends

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3.16. ANALOG AVR CONTROL OUTPUT ( plug-in module )

Structure: Isolated analog output, ±3 VDC

Connection: 2 wires
Output Impedance: 270 ohms
Isolation Voltage: 1000 VAC, 1 minute
Precision: 12 bits
Rest point: Adjustable through program parameter
Sweep Range: Adjustable through program parameter

3.17. ANALOG GOVERNOR CONTROL OUTPUT ( plug-in

module )

Structure: Non-isolated analog output, 0-10 VDC

Reference: Battery negative
Output Impedance: 1000 ohms
Precision: 12 bits
Rest point: Adjustable through program parameter
Sweep Range: Adjustable through program parameter

3.18. ANALOG LOAD SHARE SIGNAL ( plug-in module )

Structure: Non-isolated analog input & output, 0-10 VDC

Reference: Battery negative
Output Impedance: 1000 ohms
Precision: 12 bits
Rest point: Adjustable through program parameter
Sweep Range: Adjustable through program parameter

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3.19. ETHERNET PORT ( plug-in module )

Description: IEEE802.3 compliant, 10/100 Base-TX RJ45 ethernet port with

indicating leds
Data rate: 10/100 Mbits/s, auto detecting
Connector: RJ45
Cable type: CAT5 or CAT6
Isolation: 1500 VAC, 1 minute
Max distance: 100m with CAT5 or CAT6 cable
Functionality: Embedded TCP/IP, Web Server, Web Client, SMTP, e-mail, SNMP,
Modbus TCP_IP

Ethernet
Connector

STANDARD ETHERNET CABLE

LED FUNCTIONS:
GREEN: This led turns on when the ethernet link is established (connector inserted)
YELLOW: This led blinks when data transfer occurs inwards or outwards. Periodic blinking will witness
data flow.

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3.20. USB DEVICE PORT

USB Device
Connector

USB A to B
Cable

Description: USB 2.0, not isolated, HID mode

Data rate: Full Speed 1.5/12 Mbits/s, auto detecting
Connector: USB-B (printer connector)
Cable length: Max 6m
Functionality: Modbus, FAT32 for firmware upgrade (boot loader mode only)

The USB-Device port is designed to connect the module to a PC. Using the RainbowPlus software,
programming, control of the genset and monitoring of measured parameters are achieved.
The RainbowPlus software can be downloaded from Grupel website.
The connector on the module is of USB-B type. Thus, A to B type USB cable should be used. This is the
same cable used for USB printers.
For more details about programming, control and monitoring please refer to RainbowPlus user manual.

If USB-Device is plugged then USB-Host port will not

function.

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3.21. USB HOST PORT ( plug-in module )

USB HOST
Port

USB FLASH MEMORY

The USB-Host port is available in units with COMM option.

Description: USB 2.0, not isolated

Power Supply 5V, 300mA max
Output:
Data rate: Full Speed 1.5/12 Mbits/s, auto detecting
Connector: USB-A (PC type connector)
Cable length: Max 1.5m
Functionality: USB memory, FAT32, data recording

Memory capacity: All USB flash memories.

The USB-Host port is designed for detailed data recording. The period of recording is adjustable through
program parameter.
As soon as a USB flash memory is inserted, the unit will start data recording and continue until the
memory is removed.
For more details about data recording please review chapter “Data Recording”.

If USB-Device is plugged then USB-Host port will not

function.

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3.22. GSM MODEM ( plug-in module )

The optional GSM modem offers the advantage of being internally powered and is fully compatible with
the unit. It does not require any special setup.
The 1800/1900 MHz magnetic antenna together with its 2-meter cable is supplied with the internal
modem option. The antenna is intended to be placed outside of the genset panel for the best signal
reception.

SIM card slot

Antenna
connector

The module requires a GPRS enabled SIM card for full functionality. Voice-only type SIM cards will
usually not function properly.
Please refer to GSM Modem Configuration Guide for more details.

Description: Quad-band GSM/GPRS 850/900/1800/1900MHz module.

GPRS multi-slot class 12/12
GPRS mobile station class B
Compliant to GSM phase 2/2+.
– Class 4 (2 W @850/ 900 MHz)
– Class 1 (1 W @ 1800/1900MHz)
Functionality: Web Client, SMTP, Modbus TCP/IP (client), SMS, e-mail
Operating temp range: -40°C to +85 °C
Data speed: Max. 85.6 kbps (download), 42.8 kbps (upload)
SIM card type: external SIM 3V/1.8V, GPRS enabled
Antenna: Quad band, magnetic, with 2m cable
Module certificates: CE, FCC, ROHS, GCF, REACH

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LOCATION DETERMINATION VIA GSM

The unit determines automatically the geographical position through the GSM network. No settings are
necessary for this.
This feature is especially useful for the remote monitoring where the controller will appear automatically at
its geo-position or for mobile gensets.
Although the controller supports also GPS location determination for more precise positioning, the GSM
based location is free of charge, available everywhere, even where GPS signal is not available.

The location precision will depend of the GSM

system. In highly populated areas, the precision is
good (a few hundred meters), but rural areas may
lead to errors of a many kilometers.

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4. TOPOLOGIES

Various topologies are selectable through program parameter.

The topology is independently selectable for both genset and mains sections.
In following drawings, the connections are shown for the alternator. Current transformers are supposed
connected to the alternator side.
Similar topologies are available for the mains side as well.

4.1. SELECTING THE TOPOLOGY

Generator
Parameters
s

Topology
Selection

Mains
Parameters
s
Topology
Selection

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4.2. 3 PHASE, 4 WIRE, STAR

4.3. 3 PHASE, 3 WIRE, DELTA

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4.4. 3 PHASE, 4 WIRE, DELTA

4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)

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4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)

4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)

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4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)

4.9. 1 PHASE, 2 WIRE

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5. FUNCTIONALITIES
The same unit provides different functionalities through parameter setting. Thus a single stock item will
fulfill various duties, minimizing stock cost.
The selection of the functionality is done through Controller Parameter, as shown in below picture.

Controller Selection of
Configuration Functionality
Parameters
CT Location
Selection

5.1. CT LOCATION SELECTION

CTs may be placed at alternator or load sides. The CT location selection is configured with Controller
Configuration > CT Location parameter. When CTs are located at the alternator side, then mains
current and power parameters will not be displayed. When CTs are located at load side, then both mains
and genset currents and power parameters will be displayed, based on contactor positions. Please review
AMF functionality connection diagrams for CT connection details.

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5.2 SYNCHRONIZATION FUNCTIONALITY

The synchronization functionality is used to parallel 2 or more gensets on the same busbar, in order to
increase the total genset power rating or in order to have redundancy/reserve power for a more reliable
operation.
A maximum of 48 gensets can be paralleled on the same busbar using G-545 units. Always one of the
gensets will become the MASTER one. It will determine the voltage and frequency of the busbar. When
more than one genset start together, the master genset will always feed the busbar first. Other gensets
will synchronize to the busbar, get in parallel and share the load.

TO LOAD

Genset
Busbar

Datalink
Bus
Max 48 To mains
controllers
gensets
Genset
Contactor

When SYNCH mode is selected, the controller will monitor its REMOTE START input. If the remote start
input is active, it will run the genset (depending on settings). The remote start signal is usually provided
by a Mains Synchronization unit or an ATS controller. It can be a manually controlled signal as well.
If the Genset busbar is not energized, when the engine runs, the controller will immediately close the
genset contactor and feed the busbar. It will also become the MASTER.
If the genset Busbar is already energized, then the controller will synchronize the genset to the Busbar,
then close the genset contactor. After this, it will start to share the load.
Ramping for soft loading and unloading is provided as an inherent feature.

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5.3 MAINS SYNCHRONIZATION FUNCTIONALITY

It is not currently available for this version.

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5.4. AMF FUNCTIONALITY

When AMF functionality is selected, the unit will monitor mains voltages, provide mains and genset
contactor control, run the engine and provide engine and alternator instrumentation and fault monitoring.

The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines
are supported.
The unit provides control outputs for both contactors and motorized circuit breakers.

5.5. ATS FUNCTIONALITY

When ATS functionality is selected, the unit will monitor mains voltages, provide mains and genset
contactor control and issue a Remote Start signal to the engine controller. It will provide alternator
instrumentation and fault monitoring.

Engine instrumentation and protection will be insured by the engine controller.

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5.6. REMOTE START FUNCTIONALITY

When the Remote Start functionality is selected, the unit will wait for a Remote Start signal from external
controller. Upon reception of this signal, it will run the engine, and provide engine and alternator
instrumentation and fault monitoring. The genset contactor/MCB control functionality will be available.

The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines
are supported.

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5.7. ENGINE CONTROLLER FUNCTIONALITY

When the Engine Controller functionality is selected, genset electrical measurements and protections will
be disabled. The unit is supposed to control an engine without alternator.

When the Engine Control Mode is activated:

-the unit will not display genset AC parameters (volts, amps, kW and pf).
-genset voltage and frequency protections are disabled. However engine rpm protections will be
active.
Note that the engine controller functionality is compatible with both AMF and Remote Start modes.
When AMF and Engine controller modes are selected, the unit will monitor the mains and will run the
engine upon mains failure. This functionality is useful for the backup electric motor driven systems during
mains failures, like fire pump or irrigation systems.
When Remote Start and Engine controller modes are selected, the unit will start and stop the engine with
external signal only.
The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines
are supported.

It is strongly recommended to wire speed detection

through MPU or J1939-CANBUS and enter correct
low and high rpm limit values in order to preserve
engine speed protection.

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5.8. REMOTE DISPLAY UNIT FUNCTIONALITY

The unit is able to become the remote display and control panel of another identical module.

Remote
Control Unit Display Unit

The connection between two modules is done through RS-485 ports. For the best results, a 120 ohms
balanced, low capacitance cable should be used.
The data rate between modules is selectable between 2400 and 115200 bauds.
A high data rate offers better synchronization between modules, but the distance will be limited.
Typically at 115200 bauds and with adequate cable, the distance will be 200m maximum.
At 9600 bauds and adequate cable the distance can go up to 1200m.
Below settings are necessary:

PARAMETER MAIN UNIT REMOTE DISPLAY UNIT

Annunciator Mode 0 1
RS-485 Enable 1 1
RS-485 Baud Rate any same as main unit
Modbus Slave Address any same as main unit

The remote display panel should be powered up

with an isolated voltage source, like a wall adapter.
Otherwise damages due to ground potential
differences may occur.

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5.9. 400HZ OPERATION

The standard unit is also 400Hz enabled. The nominal frequency setting accepts up to 500Hz. Usual low
and high limits will apply without any special setting.
The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely.
However the display is limited to 650Hz. Frequencies over 650Hz will be displayed as 650Hz.
The bandwidth of the harmonic analyzer is limited to 1800Hz. Thus in case of a 400Hz system, only the
3rd harmonic will be displayed.
The waveform display of a 400Hz signal will be represented with 10 points. It will not be as accurate as
50/60Hz signals.
For more details please read chapter: “Waveform Display & Harmonic Analysis”.

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6. CONNECTION DIAGRAMS

6.1. GENSET SYNCHRONIZATION FUNCTIONALITY

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6.2. MAINS SYNCHRONIZATION FUNCTIONALITY

It is not currently available for this version.

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6.3. SINGLE GENSET PARALLEL WITH MAINS FUNCT.

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6.4. AMF FUNCTIONALITY

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6.5. ATS FUNCTIONALITY

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6.6. REMOTE START FUNCTIONALITY

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6.7. ENGINE CONTROL FUNCTIONALITY

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6.8. REMOTE DISPLAY PANEL FUNCTIONALITY

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7. TERMINAL DESCRIPTION
Term Function Technical data Description
01 BATTERY POSITIVE +12 or 24VDC The positive terminal of the DC Supply.
02 BATTERY NEGATIVE O VDC Power supply negative connection.
03 DIGITAL OUTPUT 1 Protected This relay has programmable function,
Semiconductor selectable from a list. Factory set as CRANK
Outputs, 1A/28VDC output.
04 DIGITAL OUTPUT 2 This relay has programmable function,
selectable from a list. Factory set as FUEL
output.
05 DIGITAL OUTPUT 3 This relay has programmable function,
selectable from a list. Factory set as ALARM
output.
06 DIGITAL OUTPUT 4 This relay has programmable function,
selectable from a list. Factory set as PREHEAT
output.
07 DIGITAL OUTPUT 5 This relay has programmable function,
selectable from a list. Factory set as STOP
output.
08 DIGITAL OUTPUT 6 This relay has programmable function,
selectable from a list. Factory set as IDLE
SPEED output.
09 CHARGE Connect the charge alternator’s D+/WL terminal
to this terminal. This terminal will supply the
excitation current and measure the voltage of
the charge alternator.

Term Function Technical data Description

10 SENDER GROUND Analog inputs, Ground potential for analog senders. Connect
0-5000 ohms to the engine body, close to senders.
11 ANALOG SENDER 1 The input has programmable function. Factory
set as OIL PRESSURE SENDER.
12 ANALOG SENDER 2 The input has programmable function. Factory
set as ENGINE TEMPERATURE SENDER.
13 ANALOG SENDER 3 The input has programmable function. Factory
set as FUEL LEVEL SENDER.
14 ANALOG SENDER 4 The input has programmable function. Factory
set as OIL PRESSURE SENDER.
15 ANALOG SENDER 5 The input has programmable function. Factory
set as CANOPY TEMPERETURE SENDER.
16 DIGITAL INPUT 1 Digital Inputs, The input has programmable function. Factory
0-30Vdc set as LOW OIL PRESSURE SWITCH.
17 DIGITAL INPUT 2 The input has programmable function. Factory
set as HIGH TEMP SWITCH.
18 DIGITAL INPUT 3 The input has programmable function. Factory
set as EMERGENCY STOP.
19 DIGITAL INPUT 4 The input has programmable function. Factory
set as LOW COOLANT LEVEL SWITCH.
20 DIGITAL INPUT 5 The input has programmable function. Factory
set as SPARE INPUT-1.
21 DIGITAL INPUT 6 The input has programmable function. Factory
set as SPARE INPUT-2.

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Term Function Technical data Description

22 CANBUS-H Digital communication Connect the J1939 port of an electronic
port engine to these terminals.
The 120 ohm terminating resistor is
installed inside the unit. Please do not use
23 CANBUS-L
external resistors.
Use a balanced 120 ohms low
capacitance shielded data cable for the
best result.
24 CAN GROUND Output 0Vdc Connect the protective shield of the J1939
and MPU cables to this terminal, from one
end only.
25 MPU + Analog input, 0.5 to Connect the MPU unit to these inputs
30V-AC Use a twisted cable pair or coaxial cable
26 MPU -
for the best result.

Term Function Technical data Description

27 RS-485 A Digital communication Connect the A-B data lines of the RS-485
28 RS-485 B port link to these terminals.
29 RS-485 TERMINATION 120 ohm resistor This terminal is used to enable the 120
RESISTOR ohms termination resistor of the RS-485.
The RS-485 should be terminated at 2
ends only. Thus the termination resistor
will be enabled in only 2 units. In order to
enable the termination resistor, this
terminal should be connected to the RS-
485 B (terminal 28).

Term Function Technical data Description

61 GEN I-L1 Generator current Connect the generator current transformer
transformer inputs, terminals to these inputs.
63 GEN I-L2 5A-AC Do not connect the same current
transformer to other instruments otherwise
this may damage the unit.
65 GEN I-L3 Connect each terminal of the transformer
to the unit’s related terminal.
66 GEN I-COM Do not use common terminals. Do not use
grounding.
Correct polarity of connection is vital.
The rating of the transformers should be
identical for each of the 3 phases.
The secondary winding rating shall be 5
Amperes. (ex: 200/5 Amps).
67 GEN I-GND + Current transformer Connect the earth current transformer
inputs, 5A-AC terminals to these inputs.
68 GEN I-GND-

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Term Function Technical data Description

51 GENERATOR CONTACTOR Relay output, 16A-AC This output provides energy to the
generator contactor. If the generator
phases do not have acceptable voltage or
frequency values, the generator contactor
will be de-energized. In order to provide
extra security, the normally closed contact
of the mains contactor should be serially
connected to this output.
52 GEN-L1 Generator phase Connect the generator phases to these
54 GEN-L2 inputs, 0-300V-AC inputs. The generator phase voltages
56 GEN-L3 upper and lower limits are programmable.
58 GENERATOR NEUTRAL Input, 0-300V-AC Neutral terminal for the generator phases.

Term Function Technical data Description

71 MAINS NEUTRAL Input, 0-300V-AC Neutral terminal for the mains phases.
73 MAINS-L3 Mains phase inputs, Connect the mains phases to these inputs.
75 MAINS-L2 0-300V-AC The mains voltages upper and lower limits
77 MAINS-L1 are programmable.
78 MAINS CONTACTOR Relay output, 16A-AC This output provides energy to the mains
contactor. If the mains phases do not have
acceptable voltages, the mains contactor
will be de-energized. In order to provide
extra security, the normally closed contact
of the generator contactor should be
serially connected to this output.

SYNCH PLUG-IN MODULE:

Term Function Technical data Description

01 DATA LINK TERMINATION 120 ohm resistor This terminal is used to enable the 120
RESISTOR ohms termination resistor of the Data Link.
The Data Link bus should be terminated at
2 ends only. Thus the termination resistor
will be enabled in only 2 units. In order to
enable the termination resistor, this
terminal should be connected to the DATA
LINK_L (terminal 03).
02 DATA LINK-H Digital communication Connect these terminals to the same Data
03 DATA LINK_L port, CANBUS, Link terminals of the next unit. All units are
250kbps connected in parallel on the same Datalink
bus.
The bus should be terminated at two ends
only. Termination resistors are provided
inside the unit.
Use a balanced 120 ohms low
capacitance shielded data cable for the
best result.
04 DATA LINK_GROUND 0 VDC Connect this terminal to the shield of the
Datalink from one end only.

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Term Function Technical data Description

05 AVR - Isolated Output, AVR voltage control outputs. The output
±3VDC has adjustable polarity, restpoint and gain
06 AVR + through parameter setting.
The isolation is 1000 VAC for 1 minute..
07 GOV OUT Isolated Output, Governor control outputs. The output has
0 to 10 VDC adjustable polarity, restpoint and gain
08 GOV GND through parameter setting.

09 LOAD SHARE Output 0 to 10 VDC When ANALOG LOAD SHARE terminals

of all synchronization units are connected
together, they will be able to share the
active load through this analog line, even
without Datalink communication. This
signal is designed as a backup of the
Datalink bus for emergency purposes.

ANALOG I/O EXTENSION PLUG-IN MODULE:

Term Function Technical data Description

01 SND 6 Analog inputs, These inputs have programmable function.
0-5000 ohms
02 SND 7 0 to 10 VDC
4 to 20 mA
03 SND 8

04 A1 + Analog output, This output will be functional with further

4 to 20 mA firmware version.
05 GND 0 VDC Ground potential for analog senders.

06 A2 + Analog output, This output will be functional with further

4 to 20 mA firmware version.
07 GND 0 VDC Ground potential for analog senders.

SND 8 cannot be switched to resistive input. The

configuration can be 4-20 mA or 0-10 VDC.

Analog outputs will be functional with further

firmware version.

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8. TECHNICAL SPECIFICATIONS

Alternator voltage: 0 to 300 V-AC (Ph-N)

Alternator frequency: 0-600 Hz.
Mains (Busbar) voltage: 0 to 300 V-AC (Ph-N)
Mains (Busbar) frequency: 0-600 Hz.
Topology: 1-2-3 phases, with or without neutral
DC Supply Range: 8.0 to 36.0 V-DC.
DC power consumption:
300 mA-DC typical @12V-DC
150 mA-DC typical @24V-DC
600 mA-DC max. @12V-DC
300 mA-DC max. @24V-DC
V-A-cos Accuracy: 0.5% + 1 digit
KW-kVA-kVAr Accuracy: 1.0% + 1 digit
CT Range: 5/5A to 5000/5A
VT Range: 0.1/1 to 6500 / 1
kW Range: 0.1kW to 65000 kW
Current Inputs: from current transformers. ../5A.
Digital inputs: input voltage 0 to 36 V-DC.
Analog input range: 0-5000 ohms.
Digital Outputs: Protected mosfet semiconductor outputs, rated 1Amp@28V-DC
Cranking dropouts: survives 0V for 100ms.
Magnetic pickup voltage: 0.5 to 30VAC.
Magnetic pickup frequency: 0 to 10000 Hz.
GOV Control Output: 0-10V-DC
AVR Control Output: ±3V-DC, fully isolated
Charge Alternator Excitation: 2W.
Display Screen: 2.9”, 128x64 pixels
Ethernet Port: 10/100 Mbits
USB Device: USB 2.0 Full speed
USB Host: USB 2.0 Full speed
RS-485 Port: selectable baud rate
Data Link Port: Fully Isolated CANBUS
Operating temperature: -20°C to 70°C (-4 to +158 °F)
Storage temperature: -40°C to 80°C (-40 to +176°F)
Maximum humidity: 95% non-condensing.
IP Protection: IP54 from front panel, IP30 from the rear.
Dimensions: 211 x 162 x 42mm (WxHxD)
Panel Cut-out Dimensions: 183 x 134 mm minimum.
Weight: 500gr (approx.)
Case Material: High Temperature, non-flammable ABS/PC
Mounting: Front panel mounted with rear retaining plastic brackets.
EU Directives Conformity
-2006/95/EC (low voltage)
-2004/108/EC (electro-magnetic compatibility)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)
UL / CSA Conformity:
-UL 6200, Controls for Stationary Engine Driven Assemblies (Certificate # - 20140725-E314374)
CSA Compatibility:
-CAN/CSA C22.2 No. 14-13 – Industrial Control Equipment

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9. DESCRIPTION OF CONTROLS

9.1. FRONT PANEL FUNCTIONALITY

AUTO READY LCD screen Mains Contactor Mimic Diagram

indicator control in RUN (sysem status)
mode
Genset
Fault condition Contactor
indicators control in
RUN mode
Programmable
LED indicators Previous
screen in the
Next screen in same group.
the same group. ALARM Mute
LAMP TEST if
held pressed
Next display
Previous group
display group

TEST mode AUTO mode MANUAL STOP mode RUN mode

button button mode button button button

When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the
service request output function will be active. The service request can also create a fault condition of any
level following parameter setting.
The service request output function may be assigned to any digital output using Relay Definition
program parameters. Also relays on an extension module may be assigned to this function.

To turn off the SERVICE REQUEST led, and reset the service
period, press together the ALARM MUTE and LAMP TEST keys
for 5 seconds.

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9.2. PUSHBUTTON FUNCTIONS

BUTTON FUNCTION

Selects TEST mode. The genset runs and takes the load.

Selects MANUAL mode. The RUN pushbutton is enabled. The genset will run when
RUN mode is selected. It can be stopped anytime by depressing the OFF button.

Runs the genset off load. Applicable only in MANUAL mode.

Selects AUTO mode. The genset runs when necessary and takes the load.

Selects OFF mode. The genset stops after cooldown. If depressed again, the genset
will immediately stop.

Selects next display screen in the same display group.

LAMP TEST when held pressed.

Selects previous display group.

Selects next display group.

Selects previous display screen in the same display group.

Resets the ALARM RELAY.

Manual MAINS CONTACTOR (or BUSBAR CONTACTOR) control in RUN mode.

Manual GENSET CONTACTOR (or BUSBAR CONTACTOR) control in RUN mode.

When held pressed for 5 seconds, enters PROGRAMMING mode.

Makes factory reset. Please review chapter RESETTING TO FACTORY

DEFAULTS for more details.

When held pressed for 5 seconds, resets service request counters. Please review
chapter SERVICE REQUEST ALARM for more details.

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When held pressed for 5 seconds, switches to MANUAL ADJUST mode

When held pressed for 1 seconds, switches to next PID ADJUST group in MANUAL
ADJUST mode

When held pressed for 5 seconds, exits the annunciator mode if enabled

When held pressed for 5 seconds, switch to AUTO LEARN mode (only in Manual
mode)

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9.3. DISPLAY SCREEN ORGANIZATION

The unit measures a large number of electrical and engine parameters. The display of the parameters is
organized as PARAMETER GROUPS and items in a group.

Navigation between different groups are made with and buttons.

Each depression of the button will cause the display to switch to the next group of parameters. After
the last group the display will switch to the first group.

Each depression of the button will cause the display to switch to the previous group of parameters.
After the first group the display will switch to the last group.

Navigation inside a group is made with and buttons.

Each depression of the button will cause the display to switch to the next parameter in the same
group. After the last parameter the display will switch to the first parameter.

Each depression of the button will cause the display to switch to the previous parameter in the same
group. After the first parameter the display will switch to the last parameter.
Below is a basic list of parameter groups:
Genset (Bus bar) Parameters: Genset voltages, currents, kW, kVA, kVAr, pf etc...
Engine Parameters: Analog sender readings, rpm, battery voltage, engine hours, etc...
J1939 Parameters: Opens only if the J1939 port is enabled. The unit is able to display a long list of
parameters, under the condition that the engine sends this information. A complete list of available
readings is found at chapter J1939 CANBUS ENGINE SUPPORT.
Mains Parameters: Mains voltages, currents, kW, kVA, kVAr, pf etc...
Synchronization / Load Share Display: A graphical synchroscope updated 10 times a second, target
and actual power levels, AVR and governor output positions, bus total power measurements and a mimic
diagram about the system is available.
Scopemeter Display: This group display waveforms of voltages and currents as an oscilloscope. All Ph-
N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to
investigate waveform distortions and harmonic loads.
Graphical Harmonic Analysis Results: This group displays harmonic composition of voltages and
currents. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially
useful to investigate the harmonic caused by complex loads. Only harmonics above 2% are represented
in the graphics because of the display resolution. In order to see all harmonic levels please use the
Alphanumerical Harmonic Analysis Results.
Alphanumerical Harmonic Analysis Results: This group displays harmonic composition of voltages
and currents with 0.1% resolution. All Ph-N and Ph-Ph voltages as well as phase currents are available.
This feature is especially useful to investigate the harmonic caused by complex loads.
Alarm Display: This group displays all existing alarms, one screen per alarm. When there is no more
alarm to display it will show “END OF ALARM LIST”.
GSM Modem Parameters: Signal strength, counters, communication status, IP addresses etc...
Ethernet Parameters: Ethernet connection status, counters, IP addresses etc...
Status & Counters Groups: This group includes various parameters like genset status, service
counters, date-time, firmware version etc...

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9.4. AUTOMATIC DISPLAY SCROLL

The unit will automatically scroll all Mains, Genset and Engine measurements with programmable
interval. The scroll period setting can be performed using the RainbowPlus program through Module >
Screen options.

Screen Scroll
Timer

Eventually the same parameter can be modified through the front panel programming menu. The related
parameter is Controller Configuration > Screen Scroll Timer.

If the Screen Scroll Timer is set to zero, then scrolling will be

disabled.

When a front panel button is pressed, the scrolling is

suspended during 2 minutes.

If a fault condition occurs, the display will automatically

switch to the ALARM LIST page.

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9.5. MEASURED PARAMETERS

The unit performs a detailed set of AC measurements.

The list of measured AC parameters is below:
Mains voltage phase L1 to neutral Gen voltage phase L1 to neutral
Mains voltage phase L2 to neutral Gen voltage phase L2 to neutral
Mains voltage phase L3 to neutral Gen voltage phase L3 to neutral
Mains average voltage phase to neutral Gen average voltage phase to neutral
Mains voltage phase L1-L2 Gen voltage phase L1-L2
Mains voltage phase L2-L3 Gen voltage phase L2-L3
Mains voltage phase L3-L1 Gen voltage phase L3-L1
Mains frequency Gen frequency
Mains current phase L1 Gen current phase L1
Mains current phase L2 Gen current phase L2
Mains current phase L3 Gen current phase L3
Mains average current Gen average current
Mains kW phase L1 Gen kW phase L1
Mains kW phase L2 Gen kW phase L2
Mains kW phase L3 Gen kW phase L3
Mains total kW Gen total kW
Mains kVA phase L1 Gen kVA phase L1
Mains kVA phase L2 Gen kVA phase L2
Mains kVA phase L3 Gen kVA phase L3
Mains kVAr phase L1 Gen kVAr phase L1
Mains kVAr phase L2 Gen kVAr phase L2
Mains kVAr phase L3 Gen kVAr phase L3
Mains pf phase L1 Gen total kVAr
Mains pf phase L2 Gen pf phase L1
Mains pf phase L3 Gen pf phase L2
Mains total pf Gen pf phase L3
Mains neutral current Gen total pf
Mains kWh - energy meter Gen Neutral current
Mains kVAr cap&ind - energy meter Gen kWh - energy meter
Mains exported power – kWh energy meter Gen kVArh cap&ind - energy meter

Below engine parameters are always measured:

Engine speed (rpm)
Battery voltage,
Charge voltage

The unit features 5 analog senders, fully configurable for the name and function.
Below is a typical list of analog senders, capable of changing following configuration:
Coolant temperature
Oil pressure (bar, Psi)
Fuel level (%, liters)
Oil temperature (°C, °F)
Canopy temperature (°C, °F)

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9.6. LED LAMPS

AUTO READY
indicator
Mains
available led
Shutdown
alarm indicator Mains
Contactor
Warning On led
indicator
Genset
Service Contactor
request on led
indicator
Programmable Genset
LED indicators available led

TEST mode
AUTO mode MANUAL STOP mode RUN mode
indicator
indicator mode indicator indicator indicator

STATUS LEDS:
AUTO READY: Turns on when the AUTO mode is selected and there is no condition preventing
engine start.
ALARM: Turns on when a shutdown alarm or loaddump condition exists.
WARNING: Turns on when a warning condition exists
SERVICE REQUEST: Turns on when at least one of the service counters has expired.
PROGRAMMABLE LEDS: 2 leds reserved for customer specific use. Any alarm condition or input
function can be freely assigned to each led.
MODE LEDS: Each led turns on when the related mode is selected, either locally or remotely.
MIMIC DIAGRAM LEDS:
MAINS AVAILABLE: This led turns on when all mains phase voltages and the mains frequency
are within limits. If enabled, the mains phase rotation order must be also right. When any digital
input is defined as Remote Start, this led will reflect the status of the input. When a Simulate
Mains signal is present, then mains status will become “available”. When a Force to Start signal is
present, then the mains status will become “not available”.
MAINS CONTACTOR ON: Turns on when the mains contactor is activated.
GENSET CONTACTOR ON: Turns on when the genset contactor is activated.
GENSET AVAILABLE: This led turns on when all genset phase voltages and the genset
frequency are within limits. If enabled, the genset phase rotation order must be also right.

If a Remote Start input is defined, then the Mains led will

reflect the input status.
Simulate Mains and Force to Start signals will also affect this
led.

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10. WAVEFORM DISPLAY & HARMONIC ANALYSIS

The unit features waveform display together with a precision harmonic analyzer for both mains and
genset voltages and currents. Both phase to neutral and phase to phase voltages are available for
analysis, thus 18 channels in total are possible.

In order to enable display and analysis of mains currents, current

transformers must be placed at load side.

Available channels are:

Mains volts: V1, V2, V3, U12, U23, U31
Mains currents: I1, I2, I3
Genset volts: V1, V2, V3, U12, U23, U31
Genset currents: I1, I2, I3

Scopemeter Display

The waveform display memory is of 100 samples (320 samples in color version) length and 13 bit
resolution, with a sampling rate of 4096 s/s. Thus one cycle of a a 50Hz signal is represented with 82
points (164 points in color version). The vertical scale is automatically adjusted in order to avoid clipping
of the signal.
The waveform is displayed on the device screen, and with more resolution, on PC screen through the
RainbowPlus program.
The display memory is also available in the Modbus register area for third party applications. For more
details please check chapter “MODBUS Communications”.

The waveform display is updated twice a second. All channels may be scrolled using buttons.

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The harmonic analyzer consists on a Fast Fourier Transform (FFT) algorithm which run twice a second
on the selected channel.
The sample memory is of 1024 samples length and 13 bits resolution with a sampling rate of 4096 s/s.
The theory says that a periodic signal may have only odd multiples of the main frequency. Thus in a 50Hz
network, harmonics will be found only at 150, 250, 350, 450 Hz etc...
The unit is able to analyze up to 1800Hz and up to 31th harmonic, whichever is smaller. Thus in a 50Hz
system all 31 harmonics will be displayed, but in a 60Hz system only 29 harmonics will come to the
screen.
In case of a 400Hz system, only the 3rd harmonic will be displayed.

Graphical Harmonic Table

Alphanumeric Harmonics Table

Harmonic are represented by 2 different ways on the device display. The first one is a graphical
representation allowing one sight perception of the harmonic structure. Because of the display resolution,
only harmonics above 2% are displayed on the B&W display models.
The second display is alphanumeric, thus all harmonics are displayed with 0.1% resolution in order to
provide more detailed information.
On RainbowPlus program, harmonics and waveform are displayed on a single screen with more
resolution.

RainbowPlus Scada section: Harmonic Analysis and Waveform Display

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11. DISPLAYING EVENT LOGS

The unit features more than 400 event logs with date-time stamp and full snapshot of measured values at
the moment that the event has occurred.
Stored values in an event record are listed below:
-event number
-event type / fault definition (see below for various event sources)
-date and time
-operation mode
-operation status (on-load, on-mains, cranking, etc...)
-engine hours run
-mains phase voltages: L1-L2-L3
-mains frequency
-genset phase voltages: L1-L2-L3
-genset phase currents: L1-L2-L3
-genset frequency
-genset total active power (kW)
-genset total power factor
-oil pressure
-engine temperature
-fuel level
-oil temperature
-canopy temperature
-ambient temperature
-engine rpm
-battery voltage
-charge voltage

Possible event sources are various. Every source can be individually enabled or disabled:

Event enable
selection tab

Program mode entrance event: recorded with the password level when program mode is entered.
Periodic event: recorded every 30 minutes when the engine is running, and every 60 minutes anyway.
Mode change event: recorded when the operation mode is changed.
Shutdown/loaddump/warning events: recorded when the related fault condition occurs.
Mains fail/restore events: recorded when mains status is changed
Engine started/stopped events: recorded when engine status is changed
Genset on_load/off_load events: recorded when the genset loading status is changed

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Event logs are displayed within the program mode menu. This is designed in order to reduce the
interference of event logs with other measurement screens.

To enter the event display, press together and buttons for 5 seconds.
When the program mode is entered, below password entry screen will be displayed.

Press 2
buttons
for 5
seconds

Skip the password entry screen by pressing the button 4 times. The screen below left will come.

Press again the button. The last stored event will open, as in the below-right picture.
The first page will display the event number, event type, fault type and date-time information.

When displaying event logs:

button will display the next information in the same event

button will display the previous information in the same event

button will display the same information of the previous event

button will display the same information of the next event.

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12. STATISTICAL COUNTERS

The unit provides a set of non-resettable incremental counters for statistical purposes.

The counters consist on:

-total genset kWh
-total genset kVArh inductive
-total genset kVArh capacitive
-total genset export kWh

-total mains kWh

-total mains kVArh
-total mains kVAh

-total engine hours

-total engine starts
-total fuel filled in the tank

-engine hours to service-1

-time to service-1
-engine hours to service-2
-time to service-2
-engine hours to service-3
-time to service-3

These counters are kept in a non-volatile memory and are not affected from power failures.

12.1. FUEL FILLING COUNTER

The unit offers a temper-proof incremental counter for fuel filling.

Related parameters are:
Factory Description
Parameter Definition Unit Min Max
Set
0: MPU input is used for engine speed
Fuel Pulses from MPU detection
- 0 1 0
input 1: MPU input is used for reading the
flowmeter pulses during fuel filling.
This is the number of pulses produced
by the flowmeter for the unit volume.
Fuel Pulses per Volume - 0 65000 1000 This parameter is characteristic of the
flowmeter used and should be set
according to the flowmeter data.
Fuel Counter Unit Lt/gal - - liters This is the unit for the fuel counter

The quantity of the fuel filled in the tank is read from pulses generated by a flowmeter installed at the tank
filling hose. Flowmeter pulse outputs will be connected to the MPU input of the controller. The controller
will count pulses and convert them in liters (or gallons) then increment the fuel filling counter by the
calculated amount.
The fuel filling counter is visible through Scada and Central Monitoring. Thus the genset operator can
confirm fuel invoices with the real amount of fuel filled in the tank, preventing corruption.

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12.2. FUEL CONSUMPTION MONITORING

The unit is capable to display the actual fuel consumption of the engine by two different ways:
▪ Through J1939 fuel consumption information
▪ By counting fuel consumption pulses.
If the engine is sending the fuel rate through J1939 messaging, then the unit will directly display the fuel
consumption information coming from the ECU.
If a flowmeter is installed at the fuel suction hose of the engine, then the unit is also capable of counting
these pulses, calculating and displaying the fuel consumption.
Related parameters are:
Required Description
Parameter Definition Unit Min Max
Value
0: MPU input is used for engine speed
Fuel Pulses from MPU detection
- 0 1 1
input 1: MPU input is used for reading the
flowmeter pulses during fuel filling.
This is the number of pulses produced
by the flowmeter for the unit volume.
Fuel Pulses per Volume - 0 65000 any This parameter is characteristic of the
flowmeter used and should be set
according to the flowmeter data.
Fuel Counter Unit Lt/gal - - any This is the unit for the fuel counter
This parameter determines the purpose
of fuel pulses
0: Fuel filling pulses, increment fuel
Fuel Counter Type - 0 1 1
counter
1: Fuel consumption pulses, display
consumption.

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13. OPERATION OF THE UNIT

13.1. QUICK START GUIDE

STOPPING THE ENGINE: Press STOP button

STARTING THE ENGINE: Press MAN and then RUN button

MANUAL LOAD TRANSFER: Use MAINS and GENSET buttons.

LOAD TEST: Press TEST button. The genset will run and take the load.

AUTOMATIC OPERATION: Press AUTO button. Check that AUTO READY led is illuminated.

Mode can be changed anytime without negative effect.

Changing the operation mode while the genset is running will
result into a behavior suitable for the new operating mode.

13.2. STOP MODE

The STOP mode is entered by pressing the button.

In this mode, the genset will be in a rest state. If it is running, then it will be stopped.
If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur.
If a Remote Start or Force to Start signal arrives in STOP mode, the genset will not start until AUTO mode
is selected.

▪ AMF Mode: If the genset is running under load, then it will ramp out (if applicable) then the genset
contactor will open. The engine will continue to run during Cooldown Timer and will stop afterwards.
If the STOP button is pressed during cooldown, then the engine will immediately stop. The mains
contactor will be energized only if mains phase voltages and frequency are within the programmed
limits. If enabled, the mains phase order is also checked.
▪ Synchronizing & Load Sharing Mode: If the genset is running under load, then it will ramp out then
the genset contactor will open. The engine will continue to run during Cooldown Timer and will stop
afterwards. If the STOP button is pressed during cooldown, then the engine will immediately stop.
▪ ATS Mode: The controller will clear the REMOTE START signal output and open immediately the
genset contactor. The mains contactor will be energized only if mains phase voltages and frequency
are within the programmed limits. If enabled, the mains phase order is also checked.

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13.3. AUTO MODE

The AUTO mode is entered by pressing the button.

The AUTO mode is used for the automatic operation of the genset system.

▪ AMF Mode: The controller will constantly monitor the mains availability. It will run the engine and
transfer the load when a mains failure occurs.

▪ Synchronizing & Load Sharing Mode: The controller will monitor the REMOTE START signal.
When the signal arrives, it will run the genset, synchronize to the busbar, get in parallel, ramp up and
start sharing the load. Depending on settings, the controller may decide to stop the genset, or restart
it anytime in order to achieve the necessary available power on the busbar.

▪ ATS Mode: The controller will constantly monitor the mains availability. When a mains failure occurs,
it will activate its REMOTE START output, thus the genset group will run and the controller will
transfer the load. When the mains is back again, it will open the genset contactor and it will close the
mains contactor.

If a panel lock input is defined and signal is applied, then mode

change with pushbuttons will not occur. However, display
navigation buttons are still enabled and parameters may be
visualized.

The mains availability evaluation sequence is below:

• If at least one of the mains phase voltages or the mains frequency is outside limits, the mains will be
supposed failing. Otherwise mains is available.
• If a Simulate Mains signal is present, then mains are made available
• If a Force to Start signal is present, then mains are unavailable
• If a Remote Start input is defined, then this signal decides of mains availability.
When mains are evaluated as “unavailable” then an engine start sequence begins:
• The unit waits during Engine Start Delay for skipping short mains failures. If the mains is restored
before the end of this timer, the genset will not start.
• The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
• The engine will be cranked for programmed times during crank timer. When the engine fires, the
crank relay will be immediately deactivated. See section Crank Cutting for more details.
• The engine will run at idle speed during Idle Speed Timer.
• The engine will run unloaded during engine heating timer.
• If alternator phase voltages, frequency and phase order are correct, the unit will wait for the
generator contactor period and the generator contactor will be energized.

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When mains are evaluated as “available” again then an engine stop sequence begins:
• The engine will continue to run for the mains waiting period to allow mains voltages to stabilize.
• Then the generator contactor is deactivated and the mains contactor will be energized after mains
contactor timer.
• If a cooldown period is given, the generator will continue to run during the cooldown period.
• Before the end of cooldown, the unit will reduce the engine speed to idle speed.
• At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for
Stop Solenoid timer and the diesel will stop.
• The unit will be ready for the next mains failure.

If the operation of the genset is disabled by the weekly

schedule, then the AUTO led will flash, and the operation of the
genset will be as in the STOP mode.

13.4. RUN MODE, MANUAL CONTROL

The RUN mode is entered by pressing the MAN and then the RUN buttons.
When the RUN mode is selected, the engine will be started regardless of the mains availability.
The starting sequence is as described below:
• The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
• The engine will be cranked for programmed times during crank timer. When the engine fires, the
crank relay will be immediately deactivated. See section Crank Cutting for more details.
• The engine will run at idle speed during Idle Speed Timer.
• The engine will run unloaded until another mode is selected.

The RUN mode allows also manual contactor control through MC and GC buttons.
When a contactor button is pressed, the related contactor will change position. Thus if it was on, then it
will turn off. If it was off then it will turn on.
If the other contactor was on, then it will turn off, the controller will wait for the related contactor timer and
the contactor will turn on. This will prevent manual closure of both contactors.

If Emergency Backup mode is enabled and if the mains are

off, then the mains contactor will be deactivated and the
generator contactor will be activated.
When the mains are on again, a reverse changeover to the
mains will be performed, but the engine will be kept running
unless another mode is selected.

In order to stop the engine press button or select another mode of operation.

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13.5. TEST MODE

The TEST mode is entered by pressing the button.

The TEST mode is used in order to test the genset under load.
Once this mode is selected, the engine will run as described in the AUTO mode, regardless of the mains
availability and the load will be transferred to the genset.
The genset will feed the load indefinitely unless another mode is selected.

▪ AMF Mode: The controller will run the engine and make an interrupted transfer.

▪ Synchronizing & Load Sharing Mode: The controller will run the genset. If the busbar is not
energized, it will simply close its genset contactor. If the busbar was energized then it will
synchronize to the busbar, get in parallel, ramp up and start sharing the load.

▪ ATS Mode: The controller will activate its REMOTE START output, thus the genset group will run,
synchronize and close to the busbar. When sufficient power is ready on the busbar, the controller will
transfer the load.

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14. PROTECTIONS AND ALARMS

The unit provides 3 different protection levels, being warnings, loaddumps and shutdown alarms.
1- SHUTDOWN ALARMS: These are the most important fault conditions and cause:
- The ALARM led to turn on steadily,
- The genset contactor to be released immediately,
- The engine to be stopped immediately,
- The Alarm digital output to operate.
2- LOAD_DUMPS: These fault conditions come from electrical trips and cause:
- The ALARM led to turn on steadily,
- The genset contactor to be released immediately,
- The engine to be stopped after Cooldown period,
- The Alarm digital output to operate.
3- WARNINGS: These conditions cause:
- The WARNING led to turn on steadily,
- The Alarm digital output to operate.

If a fault condition occurs, the display will automatically

switch to the ALARM LIST page.

Alarms operate in a first occurring basis:

-If a shutdown alarm is present, following shutdown alarms, loaddumps and warnings will not be accepted,
-If a loaddump is present, following loaddumps and warnings will not be accepted,
-If a warning is present, following warnings will not be accepted.

If the ALARM MUTE button is pressed, the Alarm

output will be deactivated; however the existing
alarms will persist and disable the operation of the
genset.

Alarms may be of LATCHING type following programming.

For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation
of the genset.

Existing alarms may be canceled by pressing one of the

operating mode buttons:

Most of the alarms have programmable trip levels. See the programming chapter for adjustable alarm limits.

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G-545 User Manual Rev_01 Firmware V-6.0

14.1. DISABLING ALL PROTECTIONS

The unit allows any digital input to be configured as “Disable Protections”.

This input configuration is used in cases where the engine is required to run until destruction. This may be
the case under critical conditions like firefighting or other emergency cases.
This input should be configured as a “Warning”. Thus when protections are disabled, a warning message
will immediately appear on the screen.
When protections are disabled, all shutdown alarms and loaddumps will become warnings. They will
appear on the screen, but will not affect genset operation.
The input may be constantly activated, or preferably it may be activated by an external key activated
switch in order to prevent unauthorized activation.

Disabling protections will allow the genset run until destruction.

Place written warnings about this situation in the genset room.

14.2. SERVICE REQUEST ALARM

The SERVICE REQUEST led is designed to help the periodic maintenance of the genset to be made
consistently.
The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but
even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12
months).
The unit offers 3 independent service counter sets in order to enable different service periods with different
priorities.
The fault level created upon expiration of service timers may be set as Warning, Loaddump or Shutdown.
Thus different levels of fault conditions may be generated at different overrun levels.
Each service counter set has both programmable engine hours and maintenance time limit. If any of the
programmed values is zero, this means that the parameter will not be used. For example a maintenance
period of 0 months indicates that the unit will request maintenance only based on engine hours, there will be
no time limit. If the engine hours is also selected as 0 hours this will mean that this service counter set is not
operative.
When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the
service request output function will be active. The service request can also create a fault condition of any
level following parameter setting.
The service request output function may be assigned to any digital output using Relay Definition
program parameters. Also relays on an extension module may be assigned to this function.

To turn off the SERVICE REQUEST led, and reset the service
period, press together the ALARM MUTE and LAMP TEST keys
for 5 seconds.

The remaining engine hours and the remaining time limits are kept stored in a non-volatile memory and are
not affected from power supply failures.
The time and engine hours to service are displayed in the GENSET STATUS menu group.

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14.3. SHUTDOWN ALARMS

Digital input and analog sender alarms are fully programmable

for the alarm name, sampling and action.
Only internal alarms are explained in this section.

GENSET LOW / HIGH Set if the generator frequency is outside programmed limits. These faults will
FREQUENCY be monitored with Fault Holdoff Timer delay after the engine is running.
Low and high limits are separately programmable. The detection delay is
also programmable. Another high frequency shutdown limit which is 12%
above the high limit is always monitored and stops the engine immediately.
GENSET LOW / HIGH Set if the generator rpm is outside programmed limits. These faults will be
RPM monitored with Fault Holdoff Timer delay after the engine is running. Low
and high limits are separately programmable. The detection delay is also
programmable. The high rpm overshoot limit is always monitored and stops
the engine immediately.
GENSET LOW / HIGH Set if any of the generator phase voltages goes outside programmed limits
VOLTAGE for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer
delay after the engine is running.
LOW / HIGH BATTERY Set if the genset battery voltage is outside programmed limits. Low and high
VOLTAGE limits are separately programmable. The detection delay is also
programmable.
FAIL TO START Set if the engine is not running after programmed number of start attempts.
FAIL TO STOP Set if the engine is not stopped before the expiration of the Stop Timer.
LOW CHARGE VOLTAGE Set if the charge alternator voltage is below the programmed limit. This fault
will be monitored with Fault Holdoff Timer delay after the engine is running.
J1939 ECU FAIL Set if no information has been received during 3 seconds from the ECU of
the electronic engine. This fault condition is only controlled when fuel is on.
VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running.
CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running. The
action taken at fault condition is programmable.
OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent
Limit for the period allowed by the IDMT curve setting. The allowed timer is
dependent of the overcurrent level. If currents go below the limit before
expiration of the timer then no alarm will be set. Please check chapter
Overcurrent Protection (IDMT) for more details. The action taken at fault
condition is programmable.
PICKUP SIGNAL LOST Set if the rpm measured from the magnetic pickup input falls below the
Crank Cut RPM level during Loss of Speed Signal Timer. The action of
signal loss is programmable.
SERVICE REQUEST Set if at least one of the service counters has expired. In order to reset the
service counters please hold pressed both with and buttons during 5
seconds. The screen will display “Completed!”
J1939 ECU Alarm Set if the communication between the unit and the ECU is lost.

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14.4. LOADDUMP ALARMS

Digital input and analog sender alarms are fully programmable

for the alarm name, sampling and action.
Only internal alarms are explained in this section.

VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running.
CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running. The
action taken at fault condition is programmable.
OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent
Limit for the period allowed by the IDMT curve setting. The allowed timer is
dependent of the overcurrent level. If currents go below the limit before
expiration of the timer then no alarm will be set. Please check chapter
Overcurrent Protection (IDMT) for more details. The action taken at fault
condition is programmable.
OVERLOAD Set if the genset power (kW) supplied to the load goes over the Overload
Load Dump limit for Overload Timer. If the power goes below the limit
before expiration of the timer then no alarm will be set.
REVERSE POWER Set if the genset power (kW) is negative and goes over the Reverse Power
limit for Reverse Power Timer. If the power goes below the limit before
expiration of the timer then no alarm will be set.
GENSET PHASE ORDER Set if the fault is enabled and the genset phase order is reverse.
FAIL

MAINS CB FAIL TO Set if the feedback input is defined and the related contactor block
OPEN feedback signal is not detected after the expiration of Contactor
Open/Close Fail Timer.
GENSET CB FAIL TO Set if the feedback input is defined and the related contactor block
CLOSE feedback signal is not detected after the expiration of Contactor
Open/Close Fail Timer.
PICKUP SIGNAL LOST Set if the rpm measured from the magnetic pickup input falls below the
Crank Cut RPM level during Loss of Speed Signal Timer. The action of
signal loss is programmable.
SERVICE REQUEST Set if at least one of the service counters has expired. In order to reset the
service counters please hold pressed both with and buttons during
5 seconds. The screen will display “Completed!”
UNIT LOCKED Set if the controller is remotely locked.
UNKNOWN TOPOLOGY Set if the automatic topology determination is active, and the topology
cannot be determined during “holdoff timer” after the engine runs.
Excitation Lost Set if the AVR control output has gone to the low or high limit when the
genset is on load.

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Synchronization Fail Set if the AVR control output has gone to the low or high limit when the
genset is on load.
Synchronization Fail Set if the phase and voltage synchronization is not successful before the
expiration of Synchronization Fail Timeout
Busbar Voltage Fail Set if busbar voltages are not within limits and busbar voltage above Dead
Bus Limit during 5 seconds, when the master requests the slave to close
the genset contactor to the busbar.
Busbar Freq. Fail Set if busbar frequency is not within limits and busbar voltage above Dead
Bus Limit during 5 seconds, when the master requests the slave to close
the genset contactor to the busbar.

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14.5. WARNINGS

Digital input and analog sender alarms are fully programmable

for the alarm name, sampling and action.
Only internal alarms are explained in this section.

All warnings can be made latching by enabling a single program

parameter: Controller Configuration >Latch All Warnings

Latch All Warnings

GENSET LOW / HIGH Set if the generator frequency is outside programmed limits. These faults will
FREQUENCY be monitored with Fault Holdoff Timer delay after the engine is running.
Low and high limits are separately programmable. The detection delay is
also programmable. Another high frequency shutdown limit which is 12%
above the high limit is always monitored and stops the engine immediately.
GENSET LOW / HIGH Set if the generator rpm is outside programmed limits. These faults will be
RPM monitored with Fault Holdoff Timer delay after the engine is running. Low
and high limits are separately programmable. The detection delay is also
programmable. The high rpm overshoot limit is always monitored and stops
the engine immediately.
GENSET LOW / HIGH Set if any of the generator phase voltages goes outside programmed limits
VOLTAGE for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer
delay after the engine is running.
LOW / HIGH BATTERY Set if the genset battery voltage is outside programmed limits. Low and high
VOLTAGE limits are separately programmable. The detection delay is also
programmable.
FAIL TO STOP Set if the engine has not stopped before the expiration of the Stop Timer.
LOW CHARGE VOLTAGE Set if the charge alternator voltage is below the programmed limit. This fault
will be monitored with Fault Holdoff Timer delay after the engine is running.

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J1939 ECU FAIL Set when an engine fault code is received from the ECU of the electronic
engine. This fault will not cause an engine stop. If necessary, the engine will
be stopped by the ECU.
VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running.
CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more
than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine is running. The
action taken at fault condition is programmable.
OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent
Limit for the period allowed by the IDMT curve setting. The allowed timer is
dependent of the overcurrent level. If currents go below the limit before
expiration of the timer then no alarm will be set. Please check chapter
Overcurrent Protection (IDMT) for more details. The action taken at fault
condition is programmable.
OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent
Limit.
REVERSE POWER Set if the genset power (kW) is negative and goes over the Reverse Power
limit for Reverse Power Timer. If the power goes below the limit before
expiration of the timer then no alarm will be set.
MAINS PHASE ORDER Set if the mains phase order checking is enabled, mains phases are present
FAIL and mains phase order is reversed. This fault prevents the Mains Contactor
to close.
GENSET CB FAIL TO Set if the feedback input is defined and the related contactor block
CLOSE / OPEN feedback signal is not detected after the expiration of Contactor
Open/Close Fail Timer.
MAINS CB FAIL TO Set if the feedback input is defined and the related contactor block
CLOSE feedback signal is not detected after the expiration of Contactor
Open/Close Fail Timer.
SYNCHRONIZATION Set if the uninterrupted transfer is enabled and voltage, frequency and
FAIL phase matching is not found before the expiration of the Synchronization
Fail Timer
PICKUP SIGNAL LOST Set if the rpm measured from the magnetic pickup input falls below the
Crank Cut RPM level during Loss of Speed Signal Timer. The action of
signal loss is programmable.
SERVICE REQUEST Set if at least one of the service counters has expired. In order to reset the
service counters please hold pressed both with and buttons during
5 seconds. The screen will display “Completed!”
EEPROM WRITE FAULT Set if the internal non-volatile memory cannot be written.
ENGINE RUNNING Set if the engine is running while the fuel output is not energized.
AUTO NOT READY Set if the genset is not in AUTO mode or a fault condition or the weekly
schedule prevents the automatic starting of the genset.
GPS DISCONNECTED Set if the serial communication with the GPS is lost.
GPS SIGNAL LOST Set if the communication with the GPS module is functional, but the GPS
signal level is insufficient to determine the geo-location.

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14.6. NON-VISUAL WARNINGS

These warnings are not announced at the device front panel,

however they appear in event logs, transferred to the Scada
and cause SMS and e-mail sending.
Only internal alarms are explained in this section.

FUEL THEFT Engine is not running:

If the fuel level measured from the sender input falls by 20% or more in
one hour, then Fuel Theft warning occurs (the detection delay is 10 sec,
not adjustable).
Engine is running:
If the fuel level measured from the sender input falls by 2x”hourly fuel
consumption percentage” or more, then Fuel Theft warning occurs.
FUEL FILLING If the fuel level measured from the sender input is increased by 20% or
more in one hour, then Fuel Filling non-visual warning occurs (the
detection delay is 10 seconds, not adjustable).
MAINTENANCE DONE Sent when the periodic maintenance counters are manually reset.

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15. PROGRAMMING

15.1. RESETTING TO FACTORY DEFAULTS

In order to resume to the factory set parameter values:

-hold pressed the OFF, LAMP TEST and ALARM MUTE buttons for 5 seconds,
-“RETURN TO FACTORY SET” will be displayed
-immediately press and hold pressed the RIGHT ARROW button for 5 seconds
-factory set values will be reprogrammed to the parameter memory.

Hold pressed OFF, LAMP TEST and ALARM MUTE

Hold pressed RIGHT ARROW

The program mode is used to adjust timers, operational limits and the configuration of the unit.
Although a free PC program is provided for programming, every parameter may be modified through the front
panel, regardless of the operating mode.
When modified, program parameters are automatically recorded into a non-erasable memory and take effect
immediately.
The program mode will not affect the operation of the unit. Thus programs may be modified anytime, even
while the genset is running.

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15.2. ENTERING THE PROGRAMMING MODE

To enter the program mode, press together ◄MENU and MENU►buttons for 5 seconds.
When the program mode is entered, below password entry screen will be displayed.

Press 2
buttons
for 5
seconds

A 4 digit password must be entered using ▼, ▲ , MENU► and ◄MENU buttons.

The ▼, ▲buttons modify the value of the current digit. The MENU►, ◄MENU buttons navigate
between digits.
The unit supports 3 password levels. The level_1 is designed for field adjustable parameters. The level_2
is designed for factory adjustable parameters. The level_3 is reserved. It allows recalibration of the unit.
The password level-1 is factory set to ‘1234’ and the password level-2 is factory set to ‘9876’.

Passwords are not front panel adjustable.

If a wrong password is entered, the unit will still allow access to the program parameters, but in read-only
mode.
If password “0000” is entered, only EVENT LOG file will be available.

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15.3. NAVIGATING BETWEEN MENUS

The program mode is driven with a two level menu system. The top menu consists on program groups
and each group consists on various program parameters.
When program mode is entered, a list of available groups will be displayed. Navigation between different
groups are made with ▼and ▲buttons. Selected group is shown in reverse video (blue on white). In
order to enter inside a group, please press MENU►button. In order to exit from the group to the main list
please press ◄MENU button.

If inside the
group then
exit to main
Enter inside
PGM menu
the group

Next group Previous

group
Navigation inside a group is made also with ▼and ▲buttons. A list of available parameters will
be displayed. Selected parameter is shown in reverse video (blue on white). In order display/change the
value of this parameter, please press MENU► button. Parameter value may be increased and
decreased with ▼and ▲buttons. If these keys are hold pressed, the program value will be
increased/decreased by steps of 10. When a program parameter is modified, it is automatically saved in
memory. If MENU► button is pressed, next parameter will be displayed. If ◄MENU button is pressed,
then the list of parameters in this group will be displayed.

Return to the Edit

main menu parameter
value

Next Previous
parameter parameter
inside the inside the
same group same group

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15.4. MODIFYING PARAMETER VALUE

Decrease
Increase
parameter
parameter
value
value

Previous
parameter
Long Press: Next
Return to the parameter
upper menu

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15.5. PROGRAMMING MODE EXIT

To exit the program mode press one of the mode selection keys. If no button is pressed during 2
minutes the program mode will be cancelled automatically.

Press any
mode button

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16. PROGRAM PARAMETER LIST

16.1. CONTROLLER CONFIGURATION GROUP

Parameter Definition Unit Min Max Factory Description

Set
This parameter is used to set LCD
LCD Contrast - 30 50 31contrast. Adjust for the best viewing
angle.
The screen will scroll between different
measurements with this interval. If set
Screen Scroll Timer sec 0 250 0
to zero, the screen scroll will be
disabled.
0: English language selected.
1: Local language selected. This
Language - 0 1 0
language may depend on the country
where the unit is intended to be used.
This parameter selects the screen
which is displayed during genset on
load operation.
0: genset voltages table
Genset Default Display - 0 4 0
1: genset currents and freq. table
2: genset kW and pf table
3: genset kVA and kVAr table
4: genset average measurements
Status Prompt Window 0: Status prompts disabled
- 0 1 0
Enable 1: Status prompts enabled
This parameter defines the delay after
Fault Holdoff Timer sec 0 120 12 the engine runs and before the fault
monitoring is enabled.
This is the period during which the
ALARM relay is active. If the period is
Alarm Relay Timer sec 0 120 60
set to 0, this will mean that the period is
unlimited.
0: continuous
Intermittent Alarm Relay - 0 1 0 1: intermittent (turns on and off every
second)
0: In RUN mode, the load will not be
transferred to the genset even if the
Emergency Backup mains fails.
- 0 1 0
Operation 1: In RUN mode, the load will be
transferred to the genset if the mains
fails.
0: automatic exerciser disabled
Exerciser Enable - 0 1 0
1: automatic exerciser enabled
Weekly: exercise once per week
Monthly: exercise once per month
Exercise Period - Weekly Monthly Weekly The exact exerciser day and time is
adjusted within the EXERCISE
SCHEDULE section.
0: Exercise at RUN mode
Exercise Off/On Load - 0 1 1
1: Exercise at TEST mode

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16.1. CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
0: delayed simulate mains disabled
Delayed Simulate Mains - 0 1 0
1: delayed simulate mains enabled
0: no MODEM / no GPS
1: Internal MODEM, no GPS
2: External MODEM, no GPS
Modem / GPS Selection - 0 5 0
3: External generic MODEM, no GPS
4: no MODEM, RS-232 GPS
5: Internal MODEM, RS-232 GPS
External Modem / GPS This is the data rate of the RS-232 port
bps 2400 115200 115200
Baud Rate for the external modem / GPS.
If the GSM SIM card uses pin number,
enter the pin number here. If incorrect
GSM Sim Card Pin - 0 9999 0
pin number is entered, then the SIM
card will not operate.
0: SMS messages disabled
SMS Enable - 0 1 0
1: SMS messages enabled
GPRS Connection 0: GPRS disabled
- 0 1 0
Enable 1: GPRS enabled
Web Programming 0: Web programming disabled
- 0 1 0
Enable 1: Web programming enabled
0: Web control disabled
Web Control Enable - 0 1 0
1: Web control enabled
The unit will refresh the web page with
Web Refresh Rate sec 0 240 10
this interval.
The unit will check the availability of the
Ping Period sec 30 900 120
internet connection with this interval.
Rainbow Scada Refresh The unit will update the distant
sec 0 65535 60
Rate monitoring terminal with this rate.
Rainbow Scada This is the port number of the first
- 0 65535 90
Address-1 Port monitoring terminal address.
Rainbow Scada This is the port number of the second
- 0 65535 90
Address-2 Port monitoring terminal address.
This is the port number of the internal
Web Server Port - 0 65535 80 web server. The unit will answer queries
to this port only.
Internal Modbus TCP/IP server’s port
Modbus TCP/IP Port - 0 65535 502 number. The unit answers Modbus
requests to this port only.
This is the port number used for e-mail
SMTP Port - 0 65535 587
sending.
0: ethernet-modbus gateway function
disabled.
Ethernet to RS-485 1: ethernet-modbus gateway function
- 0 1 0
Modbus Gateway Enable enabled. The unit will redirect Modbus
requests from ethernet to the RS-485
port.
0: gprs-modbus gateway function
disabled.
GPRS to RS-485 1: gprs-modbus gateway function
- 0 1 0
Modbus Gateway Enable enabled. The unit will redirect Modbus
requests from GPRS to the RS-485
port.

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16.1. CONTROLLER CONFIGURATION GROUP (continued)

Factory Description
Parameter Definition Unit Min Max
Set
0: RS-485 port disabled
RS-485 Enable - 0 1 1
1: RS-485 port enabled
This is the modbus controller identity
Modbus Address - 0 240 1
used in Modbus communication.
This is the data rate of the RS-485
RS-485 Baud Rate bps 2400 115200 9600
Modbus port.
0: ethernet port disabled
Ethernet Enable - 0 1 1
1: ethernet port enabled
0: crank cut is performed through oil
pressure switch and oil pressure sender
Oil Pressure Switch
- 0 1 0 reading
Priority
1: crank cut is performed only through
oil pressure switch
Delayed Simulate Mains Operation:
max genset running time after Simulate
Flashing Relay ON Timer min 0 1200 0 Mains signal disappears.
Dual Genset Systems: flashing relay
ON state duration timer.
Flashing Relay OFF Dual Genset Systems: flashing relay
min 0 1200 0
Timer OFF state duration.
This parameter trims precisely the real
time clock circuit. Values from 0 to 63
Real Time Clock Adjust - 0 255 117 speed up the clock with 0.25sec/day
steps. Values from 127 to 64 slow down
the clock with 0.25sec/day steps.
This parameter provides the mains and
genset voltage limits with a hysteresis
feature in order to prevent faulty
decisions.
For example, when the mains are
Hysteresis Voltage V-AC 0 30 8
present, the mains voltage low limit will
be used as the programmed low limit.
When the mains fail, the low limit will be
incremented by this value. It is advised
to set this value to 8 volts.
0: Genset control
Engine Control Only - 0 1 0
1: Engine control (no alternator)
This parameter is used for frequency to
rpm conversion. For a 1500/1800 rpm
Alternator Pole Pairs - 1 8 2
engine select 2. For a 3000/3600 rpm
engine select 1.
0: read rpm from the MPU input
RPM from genset
- 0 1 1 1: convert frequency to rpm (using
frequency
Alternator Pole Pairs)
This is the number of pulses generated
Crank Teeth Count - 1 244 30 by the magnetic pickup sensing unit in
one turn of the flywheel.
This parameter controls SMS sending
when mains voltages status is changed.
SMS on Mains Change - 0 1 0 No warnings generated.
0: no SMS on mains failed or restored
1: SMS sent on mains failed or restored

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16.1. CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
This parameter controls SMS sending
when IP address of GPRS connection is
SMS on IP Change - 0 1 0 changed. No warnings generated.
0: no SMS on IP change
1: SMS sent on IP change
This parameter controls e-mail sending
when IP address of GPRS or ethernet
connection is changed. No warnings
E-mail on IP Change - 0 1 0
generated.
0: no e-mail on IP change
1: e-mail sent on IP change
If the fuel level measured from the
sender input falls below this level, then
Fuel Pump Low Limit % 0 100 20
the FUEL PUMP function will become
active.
If the fuel level measured from the
sender input goes above this level, then
Fuel Pump High Limit % 0 100 80
the FUEL PUMP function will become
passive.
This parameter controls the activation of
the ALARM output during “Engine Start
Warning Before Start - 0 1 1 Delay” timer before engine run.
0: no warning before start
1: warning before start
0: warnings are latching/non-latching on
parameter control
Latch all Warnings - 0 1 0 1: all warnings are latched. Even if the
fault source is removed, warnings will
persist until manually reset.
This parameter controls remote control
of the unit through Rainbow, Modbus
Remote Control Enable - 0 1 1 and Modbus TCP/IP.
0: remote control disabled
1: remote control enabled
0: normal operation
1: the unit becomes an annunciator of
Annunciator Mode - 0 1 0
the remote unit. Engine/genset control
functions are disabled.
0: CTs are at the genset side. Mains
currents are not measured.
CT Location - Genset Load Genset 1: CTs are at load side. Both mains and
genset currents are monitored following
contactor status.
This parameter is useful to invert all CT
polarities at the same time.
Reverse CT Direction - 0 1 0
0: normal CT polarity assumed.
1: reverse CT polarity assumed.
Internal buzzer control
Buzzer Enable - 0 1 0 0: buzzer disabled
1: buzzer enabled

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16.1. CONTROLLER CONFIGURATION GROUP (continued)

Factory Description
Parameter Definition Unit Min Max
Set
0: AMF functionality. The unit controls
both engine and load transfer. The
genset starts based on mains status.
1: ATS functionality. The unit controls
the load transfer and issues REMOTE
START signal based on mains status.
2: REMOTE START functionality. The
Unit Functionality - 0 3 SYNCH unit controls engine and alternator. The
genset starts with external signal.
3: SYNCH functionality. The unit
controls the synchronization and load
sharing. The genset starts with remote
start signal coming from a mains
synchronizer or ATS module
4: RESERVED: Not used
This parameter adjusts the data logging
frequency to micro-SD or USB Flash
memories. Frequent recording will
require more memory capacity.
Log Record Period sec 5 3600 5
With a period of 2 seconds, 4GB per
year of memory is necessary.
With a period of 1 minute, 133MB is
consumed per year.
If no button is pressed during this
period, then the unit will reduce the LCD
LCD Backlight Timer min 0 1440 60
screen backlight intensity in for
economy.
After activation of the fuel pump
function, if the Fuel Pump High Limit
level is not reached, then the fuel pump
Fuel Filling Timer sec 0 36000 0
will stop for safety.
If this parameter is set to zero, then the
timer is unlimited.
0: SMS commands not accepted
SMS Commands
- 0 1 0 1: SMS commands are accepted but
Enabled
from listed telephone numbers only.
0: The unit powers up in STOP mode
Open with Last Mode - 0 1 0 1: The unit powers up in the same
operating mode before power down.
If this parameter is not zero, the unit will
activate the Wait Before Transfer output
function during this timer, before
Pre-Transfer Delay sec 0 60 0 initiating a load transfer.
This function is designed for elevator
systems, in order to bring the cabin to a
floor and open doors before transfer.
0: No e-mail at mains status changes
E-mail on mains change - 0 1 0
1: E-mails sent at mains status change
Enable Auto not Ready 0: Auto not Ready Warning disabled
- 0 1 0
Warning 1: Auto not Ready Warning enabled
0: MPU input is used for engine speed
Fuel Pulses from MPU detection
- 0 1 0
input 1: MPU input is used for reading the
flowmeter pulses during fuel filling.

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16.1. CONTROLLER CONFIGURATION GROUP (continued)

Factory Description
Parameter Definition Unit Min Max
Set
This is the number of pulses produced
by the flowmeter for the unit volume.
Fuel Pulses per Volume - 0 65000 1000 This parameter is characteristic of the
flowmeter used and should be set
according to the flowmeter data.
Fuel Counter Unit - Liter Gallon Liter This is the unit for the fuel counter
This parameter controls SMS sending
when the engine runs or stops. No
SMS on Engine
- 0 1 0 warnings generated.
Run/Stop
0: no SMS on engine run/stop
1: SMS sent on engine run/stop
This parameter controls e-mail sending
when the engine runs or stops. No
E-mail on Engine
- 0 1 0 warnings generated.
Run/Stop
0: no e-mail on engine run/stop
1: e-mail sent on engine run/stop
This parameter determines the purpose
of fuel pulses
0: Fuel filling pulses, increment fuel
Fuel Counter Type - 0 1 0
counter
1: Fuel consumption pulses, display
consumption.
Dual Genset Equal Aging 0: Equal aging not enabled
- 0 1 0
Enabled 1: Equal aging enabled
0: xxx/5A
CT Secondary Rating - 0 1 0
1: xxx/1A
If this parameter is enabled, when the
engine runs, the controller will detect
Automatic Topology the connection topology automatically
- 0 1 0
Detection and will select alarm levels accordingly.
0: auto detect not enabled
1: auto detect enabled
If enabled, the unit will generate a non-
visual warning when maintenance
counters are reset. In consequence,
Maintenance Done SMS and e-mails will be sent, the
- 0 1 0
Warning Enable warning will be visible on the central
monitoring system.
0: maintenance warning disabled
1: maintenance warning enabled
0: Enable status screens
Stop Status Screens - 0 1 0
1: Disable status screens
This parameter adjusts the time zone of
the controller, in order to allow internal
Time Zone min -720 +720 0
real time clock to be synchronized to
the UTC time.
0: no location information from GSM
GSM Location
- 0 1 0 1: location information read from GSM
Information
system.
0: When Loaddump alarm occurs,
genset contactor opens and genset
Disable STOP at runs until the end of the cooldown
- 0 1 0
Loaddump 1: When Loaddump alarm occurs,
genset contactor opens but the genset
continues running without timeout.

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16.2. ELECTRICAL PARAMETERS GROUP

Parameter Definition Unit Min Max Factory Description

Set
This is the rated value of current
transformers at the genset CT inputs.
Genset Current
Amp 1 5000 500 All transformers must have the same
Transformer Primary
rating. The secondary of the
transformer will be 5 Amps.
This is the rated value of current
transformers at the mains CT inputs.
Mains Current
Amp 1 5000 500 All transformers must have the same
Transformer Primary
rating. The secondary of the
transformer will be 5 Amps.
This is the voltage transformer ratio.
Voltage Transformer This value will multiply all voltage and
- 0 5000 1.0
Ratio power readings. If transformers are not
used, the ratio should be set to 1.0
The nominal value of genset and mains
Nominal Voltage V-AC 0 300 230 voltages. Voltage limits are defined by
reference to this value.
The nominal value of genset and mains
Nominal Frequency Hz 0 500 50 frequency. Frequency limits are defined
by reference to this value.
When secondary voltage is selected,
this is the nominal value of genset and
Nominal Voltage-2 V-AC 0 300 120
mains voltages. Voltage limits are
defined by reference to this value.
When secondary frequency is selected,
this is nominal value of genset and
Nominal Frequency-2 Hz 0 500 60
mains frequency. Frequency limits are
defined by reference to this value.
When tertiary voltage is selected, this is
the nominal value of genset and mains
Nominal Voltage-3 V-AC 0 300 120
voltages. Voltage limits are defined by
reference to this value.
When tertiary frequency is selected, this
is nominal value of genset and mains
Nominal Frequency-3 Hz 0 500 60
frequency. Frequency limits are defined
by reference to this value.
If one of the mains phases goes under
this limit, it means that the mains are off
Mains Voltage Low Limit % V-100 V+100 V-20% and starts the transfer to the genset in
AUTO mode. The value is defined with
reference to Nominal Voltage.
If one of the mains phases goes over
this limit, it means that the mains are off
Mains Voltage High Limit % V-100 V+100 V+20% and starts the transfer to the genset in
AUTO mode. The value is defined with
reference to Nominal Voltage.
If at least one of the mains phase
voltages goes outside of the limits
Mains Voltage Fail Timer sec 0 10 1 during this timer, it means that the
mains are off and it starts the transfer to
the genset in AUTO mode.

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If the mains phase voltages are outside
limits, but not more than this parameter
(with reference to nominal voltage),
then the genset will run without
releasing the mains contactor. When
Instant Mains Dropout % 0 50 0
the genset is ready to take the load, the
load will be transferred.
If this parameter is set to zero then the
mains contactor is immediately released
at mains failure.
If the mains frequency goes under this
limit, it means that the mains are off and
Mains Frequency Low
% F-100 F+100 F-10% starts the transfer to the genset in
Limit
AUTO mode. The value is defined with
reference to Nominal Frequency.
If the mains frequency goes over this
limit, it means that the mains are off and
Mains Frequency High
% F-100 F+100 F+10% starts the transfer to the genset in
Limit
AUTO mode. The value is defined with
reference to Nominal Frequency.
If the mains frequency goes outside of
Mains Frequency Fail the limits during this timer, it means that
sec 0 10 1
Timer the mains are off and starts the transfer
to the genset in AUTO mode.
If one of the genset phase voltages goes
Genset Low Voltage under this limit when feeding the load,
% V-100 V+100 V-15%
Warning Limit this will generate a GENSET LOW
VOLTAGE warning.
If one of the genset phase voltages goes
under this limit when feeding the load,
Genset Low Voltage
% V-100 V+100 V-20% this will generate a GENSET LOW
Shutdown Limit
VOLTAGE shutdown alarm and the
engine will stop.
If one of the genset phase voltages goes
Genset High Voltage over this limit when feeding the load, this
% V-100 V+100 V+15%
Warning Limit will generate a GENSET HIGH
VOLTAGE warning.
If one of the genset phase voltages goes
over this limit when feeding the load, this
Genset High Voltage
% V-100 V+100 V+20% will generate a GENSET HIGH
Shutdown Limit
VOLTAGE shutdown alarm and the
engine will stop.
If at least one of the genset phase
Genset Voltage Fail voltages goes outside of the limits
sec 0 10 1
Timer during this timer, a genset voltage fault
will occur.

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If the genset frequency goes under this
Genset Low Frequency limit when feeding the load, this will
% F-100 F+100 V-15%
Warning Limit generate a GENSET LOW
FREQUENCY warning.
If the genset frequency goes under this
limit when feeding the load, this will
Genset Low Frequency
% F-100 F+100 F-20% generate a GENSET LOW
Shutdown Limit
FREQUENCY shutdown alarm and the
engine will stop.
If the genset frequency goes over this
Genset High Frequency limit when feeding the load, this will
% F-100 F+100 F+15%
Warning Limit generate a GENSET HIGH
FREQUENCY warning.
If the genset frequency goes over this
limit when feeding the load, this will
Genset High Frequency
% F-100 F+100 F+20% generate a GENSET HIGH
Shutdown Limit
FREQUENCY shutdown alarm and the
engine will stop.
If the genset frequency goes outside of
Genset Frequency Fail
sec 0 10 1 the limits during this timer, a genset
Timer
frequency fault will occur.
If the battery voltage falls below this
Low Battery Voltage
V-DC 5.0 35.0 12.0 limit, this will generate a LOW
Warning Limit
BATTERY warning.
If the battery voltage falls below this
Low Battery Voltage limit, this will generate a LOW
V-DC 5.0 35.0 9.0
Shutdown Limit BATTERY shutdown alarm and the
engine will stop.
f the battery voltage goes over this limit,
High Battery Voltage
V-DC 5.0 35.0 29.0 this will generate a HIGH BATTERY
Warning Limit
warning.
If the battery voltage goes over this
High Battery Voltage limit, this will generate a HIGH
V-DC 5.0 35.0 30.0
Shutdown Limit BATTERY shutdown alarm and the
engine will stop.
If the battery voltage goes outside of the
Battery Voltage Fail
sec 0 10 3 limits during this timer, a battery voltage
Timer
fault will occur.
If any genset phase voltage differs from
the average more than this limit, it will
generate a Voltage Unbalance fault
Genset Voltage
% 0 100 0.0 condition. The action taken upon fault
Unbalance Limit
condition is programmable.
If this parameter is set to 0.0 then
voltage unbalance is not monitored
0: no action
Genset Voltage 1: shutdown alarm
- 0 3 0
Unbalance Action 2: loaddump alarm
3: warning

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If any genset phase current differs from
the average more than this limit, it will
generate a Current Unbalance fault
Genset Current
% 0 100 0.0 condition. The action taken upon fault
Unbalance Limit
condition is programmable.
If this parameter is set to 0.0 then
voltage unbalance is not monitored
0: no action
Genset Current 1: shutdown alarm
- 0 3 0
Unbalance Action 2: loaddump alarm
3: warning
If the genset power is negative and
goes above this limit then a REVERSE
Genset Reverse Power
kW 0 50000 0 POWER warning will be generated. If
Warning Limit
this parameter is set to 0 then reverse
power fault is not monitored.
If the genset power is negative and
Genset Reverse Power
kW 0 50000 0 goes above this limit then a REVERSE
Loaddump Limit
POWER loaddump will be generated.
If the genset power is negative and over
Genset Reverse Power
sec 0 120 5 limits during this timer, a reverse power
Fail Timer
fault will occur.
If one of the genset phase currents goes
over this limit when feeding the load, this
will generate a genset overcurrent fault
Genset Overcurrent Limit Amp 0 50000 0 condition. The action taken upon fault
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
When secondary voltage is selected, if
one of the genset phase currents goes
over this limit when feeding the load, this
Genset Overcurrent will generate a genset overcurrent fault
Amp 0 50000 0
Limit-2 condition. The action taken upon fault
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
When tertiary voltage is selected, if one
of the genset phase currents goes over
this limit when feeding the load, this will
Genset Overcurrent generate a genset overcurrent fault
Amp 0 50000 0
Limit-3 condition. The action taken upon fault
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
Genset Overcurrent 0: shutdown alarm
- 0 3 0
Action 1: loaddump alarm
This parameter defines the reaction
speed of the overcurrent detector. A
Overcurrent Time
0 1 64 16 higher number means higher sensitivity.
Multiplier
Detailed explanation is given at chapter:
“Overcurrent Protection”

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If the total genset active power goes over
this limit when feeding the load, this will
Genset Overload Limit kW 0 50000 0 generate a genset overload loaddump
alarm. If this parameter is set to 0 then
overload fault is not monitored.
If the genset active power is over the
Genset Overload Fail
sec 0 120 3 limit during this timer, an overload fault
Timer
will occur.
If the genset power goes below this limit
then the load shedding relay will be
Load Shedding Low Limit kW 0 50000 0
deactivated. Review chapter “Load
Shedding” for more details.
If the genset power goes above this
Load Shedding High limit then the load shedding relay will be
kW 0 50000 0
Limit activated. Review chapter “Load
Shedding” for more details.
This is the minimum delay between 2
Load Add Delay sec 0 240 0 load_add pulses. Review chapter “Load
Shedding” for more details.
This is the minimum delay required for a
load_add pulse after a load_substract
Load Subtract-Add Delay min 0 120 0
pulse. Review chapter “Load Shedding”
for more details.
This is the time between the mains
voltages and frequency entered within
Mains Waiting Timer sec 0 50000 30
the limits and the generator contactor is
deactivated.
This is the connection topology of mains
voltages and CTs. Detailed
explanations are given in the chapter:
“TOPOLOGIES”.
0: 2 phase, 3 wire L1-L2
Mains Connection 1: 2 phase, 3 wire L1-L3
- 0 7 5
Topology 2: 3 phase, 3 wire
3: 3 phase, 3 wire, 2CTs L1-L2
4: 3 phase, 3 wire, 2CTs L1-L3
5: 3 phase, 4 wire star
6: 3 phase, 4 wire delta
7: single phase, 2 wire
This is the connection topology of
genset voltages and CTs. Detailed
explanations are given in the chapter:
TOPOLOGIES.

0: 2 phase, 3 wire L1-L2

Genset Connection
- 0 7 5 1: 2 phase, 3 wire L1-L3
Topology
2: 3 phase, 3 wire
3: 3 phase, 3 wire, 2CTs L1-L2
4: 3 phase, 3 wire, 2CTs L1-L3
5: 3 phase, 4 wire star
6: 3 phase, 4 wire delta
7: single phase, 2 wire

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
This is the period after the generator
contactor has been deactivated and
Mains Contactor Timer sec 0 600 0.5
before the mains contactor has been
activated.
After the mains MCB_undervoltage coil
is energized and mains
MCB_undervoltage coil timer is
Mains MCB Close Pulse sec 0 10 0.5 elapsed, the mains MCB_close relay
will be activated during this period.
Review chapter “Motorized Circuit
Breaker Control” for more details.
The mains MCB_open relay will be
activated during this period.
Mains MCB Open Pulse sec 0 10 0.5
Review chapter “Motorized Circuit
Breaker Control” for more details.
The mains MCB_undervoltage coil is
energized during this period before the
Mains MCB
sec 0 10 0.5 mains MCB_close relay is activated.
Undervoltage Coil Timer
Review chapter “Motorized Circuit
Breaker Control” for more details.
0: shutdown alarm
MCB Alarm Level - 0 1 0
1: loaddump alarm
If a mains MCB feedback input is
defined and if the mains MCB fails to
Mains MCB Fail Timer sec 0 600 2.0
change position before the expiration of
this timer, then a fault condition occurs.
0: mains phase order checking disabled
Mains Phase Order 1: if mains phase order is faulty, then a
- 0 1 0
Check Enable warning is given and mains contactor
deenergized.
This is the period after the mains
contactor has been deactivated and
Genset Contactor Timer sec 0 600 0.5
before the genset contactor has been
activated.
After the genset MCB_undervoltage coil
is energized and genset
MCB_undervoltage coil timer is
Genset MCB Close Pulse sec 0 10 0.5 elapsed, the genset MCB_close relay
will be activated during this period.
Review chapter “Motorized Circuit
Breaker Control” for more details.
The genset MCB_open relay will be
activated during this period.
Genset MCB Open Pulse sec 0 10 0.5
Review chapter “Motorized Circuit
Breaker Control” for more details.
The genset MCB_undervoltage coil is
energized during this period before the
Genset MCB
sec 0 10 0.5 genset MCB_close relay is activated.
Undervoltage Coil Timer
Review chapter “Motorized Circuit
Breaker Control” for more details.

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16.2. ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
0: shutdown alarm
GCB Alarm Level - 0 1 0
1: loaddump alarm
If a genset MCB feedback input is
defined and if the genset MCB fails to
Genset MCB Fail Timer sec 0 600 2.0
change position before the expiration of
this timer, then a fault condition occurs.
0: genset phase order checking
disabled
Genset Phase Order
- 0 1 0 1: if genset phase order is faulty, then a
Check Enable
genset phase order fail loaddump alarm
is given.
When a genset closes to the Busbar, if
the mater genset controller does detect
Busbar Fail Timer sec 0 30 2.0 the Busbar voltage at the expiration of
this period, a “BUSBAR FAIL” fault
condition will occur.
This is the delay after all generators
close to the busbar and before the
Busbar Ready Timer sec 0 30 2.0
master genset controller acknowledges
“Busbar ready” signal.
When the genset active power goes
Multi Load Subtract over this limit, the controller will start
kW 0 65000 0
Power Level substracting load as described in
chapter Five Step Load Management.
When the genset active power goes
Multi Load Add Power below this limit, the controller will start
kW 0 65000 0
Level adding load as described in chapter
Five Step Load Management.
If the load stays over the Multi Load
Multi Load Substract Substract Power Level parameter
sec 0 36000 0
Start Delay during this timer, then 1 step of load is
substracted.
Multi Load Substract This is the minimum period between
sec 0 36000 0
Wait Delay two load subtract operations.
If the load stays below the Multi Load
Multi Load Add Start
sec 0 36000 0 Add Power Level parameter during this
Delay
timer, then 1 step of load is added.
Multi Load Add Wait This is the minimum period between
sec 0 36000 0
Delay two load add operations.
If the genset active power goes above
Excess power Warning
kW 0 50000 0 this limit then the controller will give an
Limit
Excess Power Warning.

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16.3. ENGINE PARAMETERS GROUP

Parameter Definition Unit Min Max Factory Description

Set
The nominal value of engine rpm. Low-
Nominal RPM rpm 0 50000 1500 high rpm limits are defined by reference
to this value.
When secondary frequency is selected,
this is the nominal value of engine rpm.
Nominal RPM-2 rpm 0 50000 1800
Low-high rpm limits are defined by
reference to this value.
When tertiary frequency is selected, this
is the nominal value of engine rpm.
Nominal RPM-3 rpm 0 50000 1800
Low-high rpm limits are defined by
reference to this value.
If the engine rpm goes under this limit
Low RPM Warning Limit % R-100 R+100 R-10% when feeding the load, this will generate
a GENSET LOW RPM warning.
If the engine rpm goes under this limit
Low RPM Shutdown when feeding the load, this will generate
% R-100 R+100 R-15%
Limit a GENSET LOW RPM shutdown alarm
and the engine will stop.
If the engine rpm goes over this limit
High RPM Warning Limit % R-100 R+100 R+10% when feeding the load, this will generate
a GENSET HIGH RPM warning.
If the engine rpm goes over this limit
High RPM Shutdown when feeding the load, this will generate
% R-100 R+100 R+15%
Limit a GENSET HIGH RPM shutdown alarm
and the engine will stop.
If the engine rpm goes outside of the
RPM Fail Timer sec 0 10 3 limits during this timer, an engine speed
fault will occur.
If the engine rpm goes over the “High
RPM Shutdown Limit” by this quantity,
Overspeed Overshoot HRSL- HRSL HRSL
% this will generate immediately a GENSET
Limit 100 +100 +10%
HIGH RPM shutdown alarm and the
engine will stop.
0: speed signal existency not checked
1: If the speed signal is lost, it will
Loss of Signal Check - 0 1 0 generate a Speed Signal Lost fault
condition. The action taken upon fault
condition is programmable.
0: shutdown alarm
Loss of Speed Signal
- 0 2 0 1: loaddump alarm
Action
2: warning
If the speed signal is lost during this
Loss of Speed Signal
sec 0 240 0 timer, a Speed Signal Lost fault will
Timer
occur.
If the charge alternator voltage goes
Low Charge Voltage
V-DC 0 40 6.0 under this limit, a charge alternator
Warning Limit
voltage warning will occur.
If the charge alternator voltage goes
Low Charge Voltage under this limit, a charge alternator
V-DC 0 40 4.0
Shutdown Limit voltage shutdown will occur and the
engine will stop.

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If the charge alternator voltage goes
Charge Voltage Fail
sec 0 120 1 under limits during this timer, a charge
Timer
alternator voltage fault will occur.
If it is requested that the engine runs
Engine Heating without load until reaching a certain
°C 0 80 0
Temperature temperature, this parameter defines the
temperature.
This is the time between the mains fails
and the fuel solenoid turns on before
Engine Start Delay min 0 720 1 starting the genset. It prevents
unwanted genset operation in battery
backed-up loads.
This is the time after the fuel solenoid is
energized and before the genset is
Preheat Timer sec 0 30 0 started. During this period the
PREHEAT relay output is energized (if
assigned by Relay Definitions)
This is the maximum start period.
Crank Timer sec 1 15 6 Starting will be automatically cancelled
if the genset fires before the timer.
This is the waiting period between two
Wait Between Starts sec 1 240 10
start attempts.
This is the period used for engine
Engine Heating Timer sec 0 240 4
heating before load transfer.
The genset will not take the load before
engine heating is completed.
0: engine is heated during Engine
Heating Timer.
Engine Heating Method - 0 1 0
1: engine is heated until the coolant
temperature reaches the Engine
Heating Temperature and at least
during the Engine Heating Timer.
This is the period that the generator runs
Cooldown Timer sec 0 600 120 for cooling purpose after the load is
transferred to mains.
This is the maximum time duration for
the engine to stop. During this period
the STOP relay output is energized (if
Stop Solenoid Timer sec 0 90 10 assigned by Relay Definitions). If the
genset has not stopped after this
period, a FAIL TO STOP warning
occurs.
Number of Starts - 1 6 3 Number of Starts
This is the control delay of CHOKE
output.
The choke output is activated together
Choke Timer sec 0 240 5
with the crank output. It is released
after this delay or when engine runs
(whichever occurs first).

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
When the engine runs, the Idle output
relay function will be active during this
Idle Speed (Run) Timer sec 0 240 0 timer. While the IDLE output is active,
low voltage, low frequency and low rpm
checks are disabled.
Before the engine stops, the Idle output
relay function will be active during this
Idle Speed (Stop) Timer sec 0 240 0 timer. While the IDLE output is active,
low voltage, low frequency and low rpm
checks are disabled.
While the IDLE period is over, low
voltage, low frequency and low speed
Idle Holdoff Timer sec 0 30 10
checks are enabled after the expiration
of this timer.
The gas solenoid of the gas engine (if
Gas Solenoid Delay sec 0 240 5 assigned by Relay Definitions) will be
opened after this delay during cranking.
The crank relay output is deenergized
Crank Cut Voltage V-AC 0 65000 100 when the genset phase L1 voltage
reaches this limit.
The crank relay output is deenergized
Crank Cut Frequency Hz 0 100 10 when the genset frequency reaches this
limit.
The crank relay output is deenergized
Crank Cut RPM rpm 0 65000 500
when the engine rpm reaches this limit.
The crank relay output is deenergized
Crank Cut Charge
V-DC 0 40 6 when the charge alternator voltage
Voltage
reaches this limit.
0: no crank cut with oil pressure
Crank Cut with Oil 1: cranking is cut when oil pressure
- 0 1 0
Pressure switch is open or the oil pressure
measured is above shutdown limit.
If crank cutting with oil pressure is
enabled, cranking is cut after this delay
Crank Cut with Oil
sec 0 30 2 when oil pressure switch is open or the
Pressure Delay
oil pressure measured is above
shutdown limit.
0: Crank cutting with charge input
disabled
Charge Input Connected - 0 1 0
1: Crank cutting with charge input
enabled
The full capacity of the fuel tank. If this
Fuel Tank Capacity Lt 0 65000 0 parameter is zero, the fuel quantity in
the tank is not displayed.
This parameter is the threshold for
sending FUEL THEFT and FUELLING
sms messages.
If this parameter is set to 0, then no
Fuel Consumption per
% 0 100 0.0 Fuel Theft and Fuelling sms messages
Hour
will be sent.
If SMS is required, set this parameter to
a value above the hourly fuel
consumption of the genset.

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
If the coolant temp is above this limit then
Coolant Cooler On °C 0 250 90 the cooler relay function will become
active.
If the coolant temp is below this limit then
Coolant Cooler Off °C 0 250 80 the cooler relay function will become
inactive.
If the coolant temp is below this limit then
Coolant Heater On °C 0 250 50 the heater relay function will become
active.
If the coolant temp is above this limit then
Coolant Heater Off °C 0 250 60 the heater relay function will become
inactive.
The cooler relay will stay active during
Fan Overrun Timer sec 0 240 0 this timer after the coolant temp is below
“Coolant Cooler Off” limit.
If the canopy temp is above this limit then
Canopy Fan Turn-On °C 0 250 90 the canopy fan relay function will become
active.
If the canopy temp is below this limit then
Canopy Fan Turn-Off °C 0 250 80 the canopy fan relay function will become
inactive.
If the ambient temp is above this limit
Ambient Fan Turn-On °C 0 250 90 then the ambient fan relay function will
become active.
If the ambient temp is below this limit
Ambient Fan Turn-Off °C 0 250 80 then the ambient fan relay function will
become inactive.
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
hours from the last service. If the period
Service-1 Engine Hours hours 0 5000 250
is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-1
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
Service-1 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-1
Period.
0: no action
1: shutdown alarm
Service-1 Alarm Level - 0 3 3
2: loaddump alarm
3: warning

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
hours from the last service. If the period
Service-2 Engine Hours hours 0 5000 250
is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-2
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
Service-2 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-2
Period.
0: no action
1: shutdown alarm
Service-2 Alarm Level - 0 3 0
2: loaddump alarm
3: warning
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
hours from the last service. If the period
Service-3 Engine Hours hours 0 5000 250
is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-3
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
Service-3 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-3
Period.
0: no action
1: shutdown alarm
Service-3 Alarm Level - 0 3 0
2: loaddump alarm
3: warning
0: The J1939 port is inoperative.
1: The analog measurements (oil, temp,
J1939 Enable - 0 1 0 and rpm) are picked up from the ECU. If
the ECU communication is lost, then the
engine will be stopped.

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description

Set
0: GENERIC
1: CUMMINS
2: DETROIT DIESEL
3: DEUTZ
4: JOHN DEERE
5: PERKINS
J1939 Engine Brand - 0 15 0 6: VOLVO
7: CATERPILLAR
8: SCANIA
9: IVECO
10: MTU-MDEC
11: BOSCH
Other values: Reserved. Do not use.
GENERIC ENGINE BRAND
0: Generic
CUMMINS ENGINE
0: CM850
1: CM570
DETROIT DIESEL ENGINE
0: Generic
DEUTZ ENGINE
0: Generic
1: EMR2
2: EMR3
JOHN DEERE ENGINE
0: Generic
PERKINS ENGINE
0: Generic
1: ADEM3
2: ADEM 1.3
VOLVO ENGINE
0: Generic
1: without CIU unit
J1939 ECU Type - 0 7 0 2: EDC4
CATERPILLAR ENGINE
0: Generic
SCANIA ENGINE
0: Generic
1: S6 (Single Speed)
2: S8 (All Speed)
IVECO ENGINE
0: Generic
1: Vector
2: NEF/CURSOR
MTU-MDEC ENGINE
0: MDEC 302
1: MDEC 201
2: MDEC 303
3: MDEC 304
4: MDEC 506
BOSCH INJECTION SYSTEM
0: Generic
1: EDC 731
2: EDC 9.3

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16.3. ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory Description
Set
This parameter adjusts the speed of an
J1939 Speed Adjust % -100 +100 0.0
ECU controlled engine by +/- 8%.
If the air inlet temperature measured
High Air Inlet
through ECU is over this limit, then a
Temperature Warning °C 0 200 0
high air inlet temperature warning will
Limit
occur.
If the air inlet temperature measured
High Air Inlet through ECU is over this limit, then a
°C 0 200 0
Temperature Alarm Limit high air inlet temperature
shutdown/loaddump alarm will occur.
High Air Inlet 0: shutdown alarm
Temperature Alarm - 0 1 1: loaddump alarm
Action
If the coolant level measured through
Low Coolant Level
% 0 100 0 ECU is below this limit, then a low
Warning Limit
coolant level warning will occur.
If the coolant level measured through
Low Coolant Level Alarm ECU is below this limit, then a low
% 0 100 0
Limit coolant level shutdown/loaddump alarm
will occur.
Low Coolant Level Alarm 0: shutdown alarm
- 0 1 0
Action 1: loaddump alarm
If the battery voltage goes below this
Battery Charge Run limit the engine will be automatically
V-DC 0 35.0 0
Voltage started in order to charge the battery
using the charge alternator.
If the battery voltage goes below the
Battery Charge Run Voltage limit, the
Battery Charge Run
min 0 1200 0 engine will be automatically run during
Timer
this period in order to charge the
battery using the charge alternator.
The oil pump is activated prior to the
crank cycle and stopped when this
Oil Pump Stop Pressure bars 0 20 0 pressure level is reached.
If this value is set to zero, then the oil
pump is not activated.
0: no action
Service Reset-1 - 0 1 0
1: reset service-1 counters
0: no action
Service Reset-2 - 0 1 0
1: reset service-3 counters
0: no action
Service Reset-3 - 0 1 0
1: reset service-3 counters
0: Engine speeed checking is
performed with the RPM information
Disable ECU speed coming from the engine ECU unit.
- 0 1 0
control 1: the RPM information coming from
the engine ECU unit is not used for
engine speed checking.
The SPN number written to this
J1939 SPN Mask - 0 65535 0 parameter is excuded from engine ECU
alarm list.
The FMI number written to this
J1939 FMI Mask - 0 65535 0 parameter is excuded from engine ECU
alarm list

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16.4. ADJUST DATE AND TIME

These parameters allow adjusting the battery backup real time clock of the module. Once set, the clock
will continue to run even if DC power is removed from the unit.
Parameter Definition Unit Min Max Description
Date - 01 31 Current day of the month.
Month - 01 12 Current month.
Year - 00 99 Last two digits of the current year.
Hours - 00 23 Current hour of the day.
Minutes - 00 59 Current minute of the hour.
Seconds - 00 59 Current second of the minute.

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16.5. WEEKLY OPERATION SCHEDULE

In AUTO mode, it is possible to define the periods where automatic operation is desired. It may be
required that the genset does not start at night or weekends.
Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week.
There are 7days x 24hours =144 parameters. Each hour of the week can be independently defined as
AUTO or OFF period.

If automatic operation is disabled by the weekly

exerciser, the AUTO led will flash.

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16.6. EXERCISER SCHEDULE

The unit provides 7 independent automatic exerciser programs. Automatic exercise may be done in
weekly or monthly basis.
If monthly exercise is selected, the week, day and hour is adjustable for each exercise item.
If weekly exercise is selected, the day and hour is adjustable for each exercise item.
Exercise can be done with or without load.
Thus the genset can be instructed to run automatically in given days and times of a week and take the
load.

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16.7. SENDER CONFIGURATION

The unit has 5 analog sender inputs. Only parameters of one sender are explained below. Other senders
have identical parameter set.
Each sender has 16 step programmable curves. The sender name and reading unit is freely
programmable, thus the sender can be adapted to any type through programming.
Each sender has below programmable parameters:
Parameter Definition Unit Min Max Factory Description
Set
Selects between predefined sender
functions. If this parameter is set to 13-
Sender Type - 0 15
14-15 then the sender name string can
be freely entered.
0: shutdown alarm
Alarm Level - 0 1
1: loaddump alarm
0: always
1: on engine running
Alarm Handling - 0 3
2: after hold-off timer
3: reserved
If sender resistor is above 5000 ohms,
a fault case is generated. This
parameter defines the action taken
upon fault case.
Sender Open Alarm - 0 3
0: no alarm
1: shutdown alarm
2: loaddump alarm
3: warning
The low alarm may be selected as
shutdown or loaddump with “alarm
Low Alarm Check Enable 0 0 1 level” parameter.
0: low value alarm disabled
1: low value alarm enabled
Low Warning Check 0: low value warning disabled
0 0 1
Enable 1: low value warning enabled
The high alarm may be selected as
shutdown or loaddump with “alarm
High Alarm Check
0 0 1 level” parameter.
Enable
0: high value alarm disabled
1: high value alarm enabled
High Warning Check 0: high value warning disabled
0 0 1
Enable 1: high value warning enabled
If enabled, defines the low alarm limit.
The low alarm may be selected as
Low Alarm Level x 0 10000
shutdown or loaddump with “alarm
level” parameter.
Low Warning Level x 0 10000 If defined, defines the low warning.
If enabled, defines the high alarm limit.
The high alarm may be selected as
High Alarm Level x 0 10000
shutdown or loaddump with “alarm
level” parameter.
High Warning Level x 0 10000 If defined, defines the high warning.

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Factory Description
Parameter Definition Unit Min Max
Set
Sender Curve-1 ohm ohms 0 5000 Point-1 ohm value
Sender Curve-1 value x 0 10000 Point-1 reading
Sender Curve-2 ohm ohms 0 5000 Point-2 ohm value
Sender Curve-2 value x 0 10000 Point-2 reading
Sender Curve-3 ohm ohms 0 5000 Point-3 ohm value
Sender Curve-3 value x 0 10000 Point-3 reading
Sender Curve-4 ohm ohms 0 5000 Point-4 ohm value
Sender Curve-4 value x 0 10000 Point-4 reading
Sender Curve-5 ohm ohms 0 5000 Point-5 ohm value
Sender Curve-5 value x 0 10000 Point-5 reading
Sender Curve-6 ohm ohms 0 5000 Point-6 ohm value
Sender Curve-6 value x 0 10000 Point-6 reading
Sender Curve-7 ohm ohms 0 5000 Point-7 ohm value
Sender Curve-7 value x 0 10000 Point-7 reading
Sender Curve-8 ohm ohms 0 5000 Point-8 ohm value
Sender Curve-8 value x 0 10000 Point-8 reading
Sender Curve-9 ohm ohms 0 5000 Point-9 ohm value
Sender Curve-9 value x 0 10000 Point-9 reading
Sender Curve-10 ohm ohms 0 5000 Point-10 ohm value
Sender Curve-10 value x 0 10000 Point-10 reading
Sender Curve-11 ohm ohms 0 5000 Point-11 ohm value
Sender Curve-11 value x 0 10000 Point-11 reading
Sender Curve-12 ohm ohms 0 5000 Point-12 ohm value
Sender Curve-12 value x 0 10000 Point-12 reading
Sender Curve-13 ohm ohms 0 5000 Point-13 ohm value
Sender Curve-13 value x 0 10000 Point-13 reading
Sender Curve-14 ohm ohms 0 5000 Point-14 ohm value
Sender Curve-14 value x 0 10000 Point-14 reading
Sender Curve-15 ohm ohms 0 5000 Point-15 ohm value
Sender Curve-15 value x 0 10000 Point-15 reading
Sender Curve-16 ohm ohms 0 5000 Point-16 ohm value
Sender Curve-16 value x 0 10000 Point-16 reading
If the sender type parameter is set to
zero (not used), this string is used as
Sender Name - - -
sender name while displaying the
sender reading.
If the sender type parameter is set to
zero (not used), this string is used as
Sender Low Fault String - - -
sender low value fault in the alarm
display.
If the sender type parameter is set to
zero (not used), this string is used as
Sender High Fault String - - -
sender high value fault in the alarm
display.

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16.8. DIGITAL INPUT CONFIGURATION

The unit has 6 digital inputs. By using external input extension modules, up to 38 inputs in total are
available.
Only parameters of one input are explained below. Other inputs have identical parameter set.
The input name is freely programmable, thus the input can be adapted to any functionality through
programming.

The input name entry is made through RainbowPlus

program only.

Each sender has below programmable parameters:

Parameter Definition Unit Min Max Factory Description
Set
Selects between predefined input
functions. Selected input name is
Input Function - 0 99 displayed in the line below.
If this parameter is set to 0 then the
input name string can be freely entered.
0: shutdown alarm
1: loaddump alarm
Action - 0 3
2: warning
3: no fault condition from this input.
0: always
1: on engine running
Sampling - 0 3
2: after hold-off timer
3: reserved
0: non-latching. The fault disappears
when cause is removed.
Latching - 0 1 1: latching. The fault persists even if the
cause is removed. Requires manual
reset.
0: Normally open
Contact type - 0 1
1: Normally closed
0: Battery negative
Switching - 0 1
1: Battery positive
0: No delay
1: Delayed (1sec)
Response delay - 0 3
2: Delayed (10sec)
3: Delayed (1800sec)

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INPUT FUNCTION LIST

No Description No Description No Description
1 User Defined Function 41 Over Resonance 81 -
2 Low Oil Press. Switch 42 Short-Circuit Alarm 82 -
3 High Temp. Switch 43 Reset Service 1 Alm 83 -
4 Coolant Level Switch 44 Reset Service 2 Alm 84 -
5 Rectifier Fail Switch 45 Reset Service 3 Alm 85 -
6 Emergency Stop 46 Heavy Duty 86 -
7 Alternator High Temp 47 Synchro Genset Run 87 -
8 Excitation Loss Sw. 48 Synch Genset on Load 88 -
9 Low Fuel Switch 49 Program Lock 89 -
10 Earthquake Detector 50 Fire Circuit [Link]. 90 -
11 Gen Cont Auxiliary 51 Lamp Test 91 -
12 Mains Cont Auxiliary 52 Combat Mode 92 -
13 Force AUTO Mode 53 Tertiary Volt Freq. 93 -
14 Force OFF Mode 54 Remote priority+1 94 -
15 Force TEST Mode 55 Remote priority+2 95 -
16 Over Load Switch 56 Remote priority+4 96 -
17 Manual Fuel Fill! 57 Remote priority+8 97 -
18 Priority 58 Mains restore inhibit 98 -
19 Remote Start 59 Speed UP 99 -
20 Disable Auto Start 60 Speed DOWN 100 Input not in Use
21 Force to Start 61 Force parallel op.
22 Fault Reset 62 -
23 Alarm Mute 63 -
24 Panel Lock 64 -
25 Fuel Pump Switch 65 -
26 Secondary Volt&Freq 66 -
27 Disable Protections 67 -
28 Auto Restore Inhibit 68 -
29 GensetLoadingInhibit 69 -
30 Air Flap Fault 70 -
31 Canopy Door Open 71 -
32 Station Door Open 72 -
33 Station Over-Heat Sw. 73 -
34 Weather Cloudy 74 -
35 Weather Rainy 75 -
36 Lightning 76 -
37 Cooler Fan Fault 77 -
38 Heater Fan Fault 78 -
39 Canopy Fan Fault 79 -
40 Station Fan Fault 80 -

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16.9. OUTPUT CONFIGURATION

The parameters below define the functions of relay outputs. The unit has 6 relay outputs. All relays have
programmable functions, selected from a list.

Relays may be extended up to 40 using Relay Extension Modules.. Other relays are in the optional
Extension Modules.

Parameter Definition Factory Terminal Description

set number
Relay-01 3 4 Factory set as Crank Relay output
Relay-02 1 5 Factory set as Fuel Relay output
Relay-03 2 6 Factory set as Horn Relay output
Relay-04 8 7 Factory set as Preheat Relay output
Relay-05 4 8 Factory set as Stop Relay output
Relay-06 7 9 Factory set as Idle Speed Relay output

Relay-09 1 - Relay extension module – 1

Relay-10 1 - Relay extension module – 1
Relay-11 1 - Relay extension module – 1
Relay-12 1 - Relay extension module – 1
Relay-13 1 - Relay extension module – 1
Relay-14 1 - Relay extension module – 1
Relay-15 1 - Relay extension module – 1
Relay-16 1 - Relay extension module – 1
Relay-17 1 - Relay extension module – 2
Relay-18 1 - Relay extension module – 2
Relay-19 1 - Relay extension module – 2
Relay-20 1 - Relay extension module - 2
Relay-21 1 - Relay extension module - 2
Relay-22 1 - Relay extension module - 2
Relay-23 1 - Relay extension module - 2
Relay-24 1 - Relay extension module - 2
Relay-25 1 - Relay extension module - 3
Relay-26 1 - Relay extension module - 3
Relay-27 1 - Relay extension module - 3
Relay-28 1 - Relay extension module - 3
Relay-29 1 - Relay extension module - 3
Relay-30 1 - Relay extension module - 3
Relay-31 1 - Relay extension module - 3
Relay-32 1 - Relay extension module - 3
Relay-33 1 - Relay extension module - 4
Relay-34 1 - Relay extension module - 4
Relay-35 1 - Relay extension module - 4
Relay-36 1 - Relay extension module - 4
Relay-37 1 - Relay extension module - 4
Relay-38 1 - Relay extension module - 4
Relay-39 1 - Relay extension module - 4
Relay-40 1 - Relay extension module - 4

Below is a short list for reference purposes. Please use

the RainbowPlus program for complete selection list.

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OUTPUT FUNCTION LIST

No Description No Description No Description
1 Fuel 46 Pgm Mode Active 91 Remote Control Out 11
2 Horn 47 Engine Running 92 Remote Control Out 12
3 Crank 48 Genset Voltage Ok 93 Remote Control Out 13
4 Stop Solenoid 49 Alarm Check Enable 94 Remote Control Out 14
5 Genset Contactor 50 Oil Pressure Ok! 95 Remote Control Out 15
6 Mains Contactor 51 Shutdown Alarm 96 Remote Control Out 16
7 Idle Speed 52 Loaddump Alarm 97 Multi Load Add Out 1
8 Preheat 53 Warning Alarm 98 Multi Load Subst. Out 1
9 Alternate Crank 54 Shutdown or Loaddump 99 Multi Load Add Out 2
10 Fuel Main Winding 55 Shut. or LDD or Warn 100 Multi Load Subst. Out 2
11 Genset Close Pulse 56 Test Mode 101 Multi Load Add Out 3
12 Genset Open Pulse 57 Auto Mode 102 Multi Load Subst. Out 3
13 Genset UV Coil 58 Manual Mode 103 Multi Load Add Out 4
14 Mains Close Pulse 59 Off Mode 104 Multi Load Subst. Out 4
15 Mains Open Pulse 60 Not In Auto 105 Multi Load Add Out 5
16 Mains UV Coil 61 Genset At Rest 106 Multi Load Subst. Out 5
17 Flashing Relay 62 Waiting Before Fuel 107 Heavy Duty Active
18 Gas Solenoid 63 Preheating 108 ECU Power On
19 Fuel Pump Control 64 Waiting Oil Flash Off 109 Battery Charge Run
20 Choke 65 Engine Heating 110 Fire Circuit PS Active
21 Block Heater 66 Synchronizing 111 Pre-transfer Delay
22 Coolant Cooler 67 Cooling Down 112 Secondary Volt Freq.
23 Coolant Heater 68 Stopping 113 Lamp Test Active
24 Fan Control 69 Protections Disabled 114 Alarm Mute Active
25 Air Flap Control 70 Remote Start Input 115 Combat mode
26 Canopy Fan Control 71 Disable Auto Start 116 Busbar Ready
27 Ambient Fan Control 72 Force to Start 117 Droop Mode Active
28 Remote Start Output 73 Auto Restore Inhibited 118 Tertiary Volt Freq
29 Genset Ready 74 [Link] Inhibited 119 Smart Load Management
30 Bus Bar Contactor 75 Inp.Expansion1Mounted 120 Follower mode active
31 Bus Bar Close Pulse 76 Inp.Expansion2Mounted 121 Oil pump output
32 Bus Bar Open Pulse 77 Out.Expansion1Mounted 122 Speed Up pulse output
33 Bus Bar UV Coil 78 Out.Expansion2Mounted 123 Speed down pulse output
34 Load Shedding 79 Master Unit 124 Volt up pulse output
35 Load Add 80 Multi Gen. Remote Start 125 Volt down pulse output
36 Load Substract 81 Remote Control Out 1 126 Synch OK output
37 Service 1 Request 82 Remote Control Out 2 127 Zero Power Relay output
38 Service 2 Request 83 Remote Control Out 3 128 Fuel Pull-in Coil
39 Service 3 Request 84 Remote Control Out 4 129 Crank-1/2
40 Mains [Link] Fail 85 Remote Control Out 5 130 Crank-2/2
41 Genset [Link] Fail 86 Remote Control Out 6 131
42 Auto Ready 87 Remote Control Out 7 132
43 Weekly Schedule On 88 Remote Control Out 8 133
44 Exerciser On 89 Remote Control Out 9 134
45 Mains Fail 90 Remote Control Out 10 135

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16.10. SITE ID STRING

The site identity string is designed to identify the current controller.

This is the site Id string sent at the beginning of SMS messages, e-mails and web page headers for the
identification of the genset sending the message. Any 20 character long string may be entered.

16.11. ENGINE SERIAL NUMBER

The engine serial number string is designed to identify the current controller.
Th s string is added to GSM-SMS messages, e-mails, web page headers etc.

16.12. MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS

These telephone number buffers accept up to 16 digits, including the wait character (“,”) in order to
enable dialing through a pabx.
If Modem Selection= External PSTN Modem: First 2 numbers are used for modem calls.
Other selections: all numbers are used for SMS sending.

Enter numbers starting from first character. Do not

leave blank characters at the beginning.

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16.13. GSM MODEM PARAMETERS

Parameter Definition Description

The APN (access point name) username may be required by the GSM
operator. However some GSM operators may allow access without
APN User Name username.
The exact information should be obtained from the GSM operator.
Please search the GSM operator’s website with “APN” string.
If the APN (access point name) username is required by the GSM
operator, most probably the APN password will also be required. However
APN Password some GSM operators may allow access without password.
The exact information should be obtained from the GSM operator.
Please search the GSM operator’s website with “APN” string.
The APN (access point name) is always required by the GSM operator.
APN Name The exact information should be obtained from the GSM operator.
Please search the GSM operator’s website with “APN” string.
The SMS service center number may be required by the GSM operator.
However some GSM operators may allow SMS sending without SMS
SMS Service Center
service center number.
Number
The exact information should be obtained from the GSM operator.
Please search the GSM operator’s website with “sms service center” string.

Below GSM modem related parameters are found in the

Controller Configuration group.

Factory Description
Parameter Definition Unit Min Max
Set
If the GSM SIM card uses pin number,
enter the pin number here. If incorrect
GSM Sim Card Pin - 0000 9999 0
pin number is entered, then the SIM
card will not operate.
0: SMS messages disabled
SMS Enable - 0 1 0
1: SMS messages enabled
GPRS Connection 0: GPRS disabled
- 0 1 0
Enable 1: GPRS enabled
This parameter controls SMS sending
when mains voltages status is changed.
SMS on Mains Change - 0 1 0 No warnings generated.
0: no SMS on mains failed or restored
1: SMS sent on mains failed or restored
This parameter controls SMS sending
when IP address of GPRS connection is
SMS on IP Change - 0 1 0 changed. No warnings generated.
0: no SMS on IP change
1: SMS sent on IP change

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16.14. ETHERNET PARAMETERS

Parameter Definition Factory Set Description

This is the IPv4 (internet protocol version 4) address
that the unit will require from the DHCP (dynamic host
control protocol) server.
Network IP Address [Link] If this parameter is set to [Link] then the unit will
require any IPv4 address from the DHCP server.
If you are not an IP professional please leave this
address as “[Link]”.
This is the router IPv4 address, If the Network IP
address and Gateway IP Address are set to “[Link]”
then the unit will get the gateway address
Gateway IP Address [Link]
automatically.
If you are not an IP professional please leave this
address as “[Link]”.
Reserved for IP professionals.
Subnet Mask [Link] If you are not an IP professional please leave this
address as “[Link]”.
These 3 registers control the IPv4 access to the unit.
The remote IPv4 address is logical AND’ed with these
[Link] IP addresses. If the result gives the remote IP address,
User IP Mask 1 (2) (3) [Link] then access is enabled.
[Link] Thus access may be limited to the same LAN
members (x.x.x.255) or strictly to predefined IPv4
addresses.
This string is used in “Dynamic DNS” feature. The unit
will register itself to the dynamic DNS server under this
name.
Domain Name [Link]
For more detailed information please review chapter
on “Dynamic DNS Feature” and the document
“Dynamic DNS Account Setting”.
Domain Name
- Rest of domain name if it is longer than 20 characters.
Extension
This string is used in “Dynamic DNS” feature. This is
the address used in registering to the dynamic DNS
server.
Membership Address [Link]
For more detailed information please review chapter
on “Dynamic DNS Feature” and the document
“Dynamic DNS Account Setting”.
These strings are used in “Dynamic DNS” feature
while registering to the dynamic DNS server.
Username/Password For more detailed information please review chapter
on “Dynamic DNS Feature” and the document
“Dynamic DNS Account Setting”.
This internet address is regularly accessed in order to
check the availability of internet access.
Ping Address [Link]
The access period is defined in parameter Controller
Configuration>Ping Period.
IP Confirmation This internet address is regularly accessed in order to
[Link]
Address read the IPv4 address of the unit.
These parameters accept both internet addresses and
IPv4 addresses. Information for remote monitoring is
Rainbow Address-1
[Link] sent to these addresses.
Rainbow Address-2
The port information of these addresses are found in
Controller Configuration group.

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16.14. ETHERNET PARAMETERS (continued)

Parameter Definition Factory Set Description

This is the account name appearing in the “from” tab
Mail Account Name d500_a
of the e-mail recipient. (ex: g545@[Link])
Mail Account
d500_1234 This is the e-mail password of above e-mail account.
Password
This is the Outgoing Mail Server Address of the above
Mail Server Address [Link]
e-mail account (ex: [Link])
E-mail Address-1 - These are e-mail recipient addresses where the unit is
E-mail Address-2 - intended to send e-mail messages. Up to 3 e-mails can
E-mail Address-3 - be sent at once.

Below ETHERNET related parameters are found in the

Controller Configuration group.

Factory Description
Parameter Definition Unit Min Max
Set
Web Programming 0: Web programming disabled
- 0 1 0
Enable 1: Web programming enabled
0: Web control disabled
Web Control Enable - 0 1 0
1: Web control enabled
The unit will refresh the web page with
Web Refresh Rate sec 0 240 5
this interval.
The unit will check the availability of the
Ping Period min 0 240 0
internet connection with this interval.
The unit will update the distant
Rainbow Refresh Rate sec 0 65535 5
monitoring terminal with this rate.
This is the port number of the first
Rainbow Address-1 Port - 0 65535 0
monitoring terminal address.
This is the port number of the second
Rainbow Address-2 Port - 0 65535 0
monitoring terminal address.
This is the port number of the internal
Web Server Port - 0 65535 80 web server. The unit will answer queries
to this port only.
This is the port number of the internal
Modbus TCP/IP terminal. The unit will
Modbus TCP/ Port - 0 65535 502
answer Modbus requests to this port
only.
This is the port number used for e-mail
SMTP Port - 0 65535 587
sending.
0: ethernet port disabled
Ethernet Enable - 0 1 1
1: ethernet port enabled
This parameter controls e-mail sending
when IP address of GPRS or ethernet
connection is changed. No warnings
E-mail on IP Change - 0 1 0
generated.
0: no e-mail on IP change
1: e-mail sent on IP change

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16.15. SNTP PARAMETERS

SNTP (simple network time protocol) communication allows the controller to querry high precision, atomic
clock based date/time servers through the internet and to adjust its internal real time clock to these
servers.
Thanks to the SNTP communication, the internal RTC will reach an atomic clock precision.
Parameter Definition Factory Set Description
This is the wait period between two SNTP requests of
SNTP Refresh Period 30 sec the unit in order to update its internal real time time
clock from the servers.
SNTP Address 1 Port 123 This is the port number of the first SNTP server.
SNTP Address 2 Port 123 This is the port number of the second SNTP server.
SNTP Address 1 [Link] This is the IP address of the first SNTP server.
SNTP Address 2 [Link] This is the IP address of the second SNTP server.

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16.16. SYNCHRONIZATION PARAMETERS

Factory Description
Parameter Definition Unit Min Max
Set
Genset Active Power It defines genset active power rating.
kW 1 65000 100
Rate
Genset Reactive Power It defines genset reactive power rating.
kVAr 1 65000 75
Rate
Mains Active Power Rate It defines mains transformer active
kW 0 65000 100
power rating.
Mains Reactive Power It defines mains transformer reactive
kVAr 0 65000 75
Rate power rating.
This parameter is used in order to force
data link addresses for fault free
Unit Datalink Address - 1 64 1
operation with broken communication
wires.
This parameter defines the priority level
Device Run/Stop Priority - 1 64 1
of G-545 on the same data link.
0: 50 Kbps
1: 100 Kbps
Datalink Baud Rate Kbps 0 4 3 2: 125 Kbps
3: 250 Kbps
4: 500 Kbps
Genset Number in Multi This is the number of synchronizing
- 1 48 1
Genset Systems gensets to the busbar.
This is action to be taken if the number
of available gensets is less than Genset
Number in Multi Genset Systems
Minimum Genset Fault
- 0 4 0 0: not used
Action
1: engine shutdown
2: load-dump alarm
3: warning
Mains Synch Unit This is the number of Mains
- 0 16 0
Number Synchronizing units in the system.
This parameter defines the minimum
time period difference between two
Master Change Delay hour 0 255 0
master change operations in equal
aging.
This parameter determines the number
of gensets to start, when there is a
REMOTE START signal.
0: Run With Start Power when Remote
Multi Genset Start-Up
- 0 2 0 Start signal arrives
Options
1: Run With Mains Power when Remote
Start signal arrives
2: Run all available gensets when
remote start signal arrives
This parameter decides the number of
gensets to start. If the total power of
Multi Genset Start-Up
kW 0 65000 100 starting gensets is less than this limit,
Power
then a TOO FEW GENSETS warning
will occur.
0: not used
Insufficient Multi Genset
1: engine shutdown
Start-Up Power Alarm - 0 3 3
2: load-dump alarm
Level
3: warning

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Factory Description
Parameter Definition Unit Min Max
Set
The master keeps this amount of extra
power available during whole operation
System Reserve Power kW 0 65000 20
under load as a safety against a sudden
load surge.
Load Management 0: Equal Aging
- 0 1 0
Method 1: Smart
Dead Busbar Limit for This parameter defines the minimum
VAC 0 300 50
Multi Genset System voltage for the detection of a live busbar.
0: Governor control disabled.
Governor Control Enable - 0 1 1
1: Governor control enabled.
0: Governor control normal polarity
Governor Output (speed increases with voltage increase).
- 0 1 0
Reverse Polarity 1: Governor control reverse polarity
(speed decreases with voltage increase).
This parameter defines governor control
Governor Output Low
% 0 100.0 0.0 output low limit. Limits from 0V to 10V
Lim
can be set by this parameter
Governor Output Gain This parameter defines governor control
% 0 100.0 100.0
Lim output gain.
Governor Output Rest This is the rest value of the governor
% 0 100.0 50.0
Point control output at no load.
0: Governor droop mode disabled.
Governor Droop Enable - 0 1 0
1: Governor droop mode enabled.
The controller will inject this quantity of
Governor Output Droop % 0 100.0 0 droop at the genset rpm at 100% active
power load.
0: AVR control disabled.
AVR Control Enable - 0 1 1
1. AVR control enabled.
0: AVR control normal polarity (voltage
increases with value increase).
AVR Reverse Polarity - 0 1 1
1: AVR control reverse polarity (voltage
decreases with value increase).
This parameter defines AVR output low
AVR Output Low Limit % 0 100.0 0.0 limit. Limits from -3.0V to +3.0V can be
set by this parameter
This parameter defines AVR output high
AVR Output High Limit % 0 100.0 100.0 limit. Limits from -3.0V to +3.0V can be
set by this parameter
This is the rest value of the AVR control
AVR Output Rest Point % 0 100.0 50.0
output at no load.
0: AVR droop mode disabled.
AVR Droop Enable - 0 1 0
1: AVR droop mode enabled.
The controller will inject this quantity of
AVR Output Droop % 0 100.0 0.0 droop at the genset voltage at 100%
reactive power load.
0: not used
Excitation Loss Alarm 1: engine shutdown
- 0 3 2
Level 2: load-dump alarm
3: warning
No Break Transfer 0: only interrupted transfer enabled
- 0 1 0
Enable 1: no break transfer enabled
If the phase and voltage synchronization
is not successful before the expiration of
Synchronization Fail
sec 0 600 30 this timer, then a Synchronization Fail
Timeout
warning is given and the transfer will be
performed with interruption.

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Factory Description
Parameter Definition Unit Min Max
Set
When synchronization is detected, both
Synchronization
sec 0 25.5 0.5 contactors will stay closed during this
Contactor Timeout
timer.
This is the maximum difference between
Max Frequency
Hz 0.1 2.0 0.5 mains and genset frequencies to close
Difference
both contactors.
Phase to Phase Voltage 0: Phase to neutral voltage check
- 0 1 0
Check 1: Phase to phase voltage check
This is the maximum difference between
the mains phase-L1 and the genset
phase-L1 voltages to close both
Max Volt Difference VAC 0 20 5
contactors. If voltage transformer is used,
this quantity is multiplied with voltage
transformer ratio.
This is the maximum phase angle
between the mains phase-L1 and the
Max Phase Difference deg. 0 20 10
genset phase-L1 voltages to close both
contactors.
This parameter is used to compensate
the phase angle introduced by voltage
transformers in case of MV
Phase Angle Offset deg. -60 +60 0
synchronization. This angle value is
added to the phase differential during
phase matching process.
The synchronization conditions must
Dwell Timeout Sec 0.01 0.50 0.10 remain satisfied during this timeout for the
controller to decide to close its contactor.
This parameter governs the phase
synchronization speed.
If this parameter is increased, the
Phase Synchronization G synchronization will be faster but
% 0 200 20
Gain unstable. If it is increased, the
synchronization will be slower but more
stable. The best setting is the fastest
stable synchronization.
This parameter governs the frequency
synchronization speed.
If this parameter is increased, the
Frequency synchronization will be faster but
% 0 200 20
Synchronization G Gain unstable. If it is increased, the
synchronization will be slower but more
stable. The best setting is the fastest
stable synchronization.
This parameter governs the voltage
synchronization speed.
If this parameter is increased, the
synchronization will be faster but
unstable. If it is increased, the
synchronization will be slower but more
stable. The best setting is the fastest
Voltage Synchronization
% 0 200 30 stable synchronization.
G Gain

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Factory Description
Parameter Definition Unit Min Max
Set
0: Soft Transfer disabled
Soft Transfer Enable - 0 1 0
1: Soft Transfer enabled.
This is the time duration of the Soft
Transfer. At the end of this timer one of
Soft Transfer Timer sec 0 240 30
the contactors will release to terminate
the parallel operation
In case of a soft transfer, the load’s active
Active Power Ramp
% 0 100.0 1.0 power (KW) will be transferred to the
(kW/sec)
mains with this rate vice versa.
In case of a soft transfer, the load’s
Reactive Power Ramp
% 0 100.0 1.0 reactive power (kVAr) will be transferred
(kVAr/sec)
to the mains with this rate vice versa.
If multi genset system total active power
goes over this limit while soft transferring
Ramp On High Limit % 0 100.0 80.0
to mains load contactor will be de-
energized.
If multi genset system total active power
goes under this limit while soft
Ramp Off Low Limit % 0 100.0 10.0
transferring to mains load contactor will
be de-energized.
This parameter defines the reaction
speed of the kW control during soft
loading. The standard value for this
Active Power Share G parameter is %20. But it must be
% 0 200 20
Gain readjusted for the genset during
manufacturing. If this parameter is too
high, a kW oscillation may occur. If it is
too low, the kW transfer will be slower.
This parameter defines the reaction
speed of the kVAr control during soft
loading. The standard value for this
Reactive Power Share G parameter is %20. But it must be
% 0 200 20
Gain readjusted for the genset during
manufacturing. If this parameter is too
high, a KVAr oscillation may occur. If it is
too low, the kVAr transfer will be slower.
This parameter governs the nominal
frequency catching of the master unit.
If this parameter is increased, the
Nominal Frequency G
% 0 200 8 operation will be faster but unstable. If it
Gain
is increased, the operation will be slower
but more stable. The best setting is the
fastest stable operation.
This parameter governs the nominal
voltage catching of the master unit.
If this parameter is increased, the
Nominal Voltage G Gain % 0 200 8 operation will be faster but unstable. If it
is increased, the operation will be slower
but more stable. The best setting is the
fastest stable operation.
If the total active load is above this level
for the period defined in Multi Genset
Run/Stop Delay, the slave genset will
Multi Genset Delayed start, synchronize and share the load.
% 0 120 80
Start This parameter is defined as a
percentage of the Genset Power Rating
parameter.

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Factory Description
Parameter Definition Unit Min Max
Set
If the total active load is above this level,
the slave genset will start, synchronize
Multi Genset Quick Start % 0 120 90 and share the load without delay. This
parameter is defined as a percentage of
the Genset Power Rating parameter.
If the total active load is below this level
Multi Genset Delayed during the period defined in Genset Start
% 0 120 30
Stop Power parameter, the slave genset will
stop.
This is the time delay used for starting
and stopping of the slave genset.
Multi Genset Run/Stop Related starting and stopping power
sec 0 240 10
Delay levels are defined in parameters Multi
Genset Delayed Start and Multi Genset
Delayed Stop.
This is the period after all gensets closed
Load Management Inhibit
sec 0 43200 30 to busbar and before the load
Delay
management function is put in service.
This is the delay after the mains contactor
is energized (for parallel to mains) and
Parallel Check Delay sec 0 25.0 0.2
before the protections for mains failure
are enabled.
This parameter defines the sensitivity of
the reverse power protection while
operating in parallel with the mains. When
the parallel protections are enabled, if the
Mains Reverse Power multi genset system supplies a power
kW 0 65000 20
Limit over this limit to the mains, the mains
contactor will be de-energized and a
warning will be generated. It is advised to
set this parameter to 15% of the genset
power rating.
This parameter defines the sensitivity of
the ROCOF (rate of change of frequency)
protection while operating in parallel with
mains. When the parallel protections are
ROCOF df/dt (Hz/Sec) HZ 0.5 15.0 5.0 enabled, if the mains frequency change
exceeds this limit for 4 consecutive
periods, the mains contactor will be de-
energized and a warning will be
generated.
This parameter defines the sensitivity of
the vector shift protection while operating
in parallel with mains. When the parallel
protections are enabled, if the phase of
the mains measured on last 2 cycles
Vector Shift Limit Deg. 1 30 10
jumps over this limit on the phase
measured on last 4th and 5th period, the
mains contactor will be de-energized and
a warning will be generated. It is advised
to set this parameter to 10 degrees.
0: Peak lopping disabled. In AUTO
mode the unit will start multi genset
system only if a mains failure occurs.
Peak Lopping Enable - 0 1 0 1: Peak lopping enabled. In AUTO
mode, the multi genset system will start
and share the load if the mains power
exceeds Peak Lopping Start Power

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Factory Description
Parameter Definition Unit Min Max
Set
In peak lopping mode, the unit will not
Peak Lopping Maximum allow the mains to deliver to the load a
kW 0 65000 100
Mains Power power higher than this limit in order to
protect the mains.
In peak lopping mode the multi genset
system will start and enter in parallel with
the mains only if the mains power
exceeds this limit. However it will supply
Peak Lopping Start
kW 0 65000 80 power to the load only if the load power
Power
exceeds Peak Lopping Maximum Mains
Power parameter. This parameter should
be set lower than Peak Lopping
Maximum Mains Power parameter.
In peak lopping mode the multi genset
system will stop only when the total load
Peak Lopping Stop
kW 0 65000 60 power falls below this limit. This
Power
parameter should be set lower than
Peak Lopping Start Power parameter.
In peak lopping mode the multi genset
Peak Lopping Start /Stop
sec 0 240 10 system will start/stop when load power
Delay
exceeds the limits during this period.
0: Normal operation.
Power Export Enable - 0 1 0
1: Power Export to Mains operation.
This is the active power to be exported to
Exported Power kW 0 65000 100 the mains in Power Export to Mains
operation mode
This is the power factor of the power
Exported Power Factor - 0.600 -0.600 1.000 exported to the mains in Power Export to
Mains operation mode.
This parameter governs the active power
catching speed of the synchronization
unit.
If this parameter is increased, the
Command Active Power
% 0 200 10 operation will be faster but unstable. If it
G Gain
is increased, the operation will be slower
but more stable. The best setting is the
fastest stable operation.

This parameter governs the reactive

power catching speed of the
synchronization unit.
Command Reactive If this parameter is increased, the
% 0 200 20
Power G Gain operation will be faster but unstable. If it
is increased, the operation will be slower
but more stable. The best setting is the
fastest stable operation.
In the Distributed Power Export to
Minimum Exported
kW 0 65000 100 Mains mode, the exported power will not
Power
fall below this limit.
In the Distributed Power Export to Mains
Export Power Ramp mode, the genset active export power
% 0 100.0 1.0
(kW/sec) (KW) will be increased/decreased with
this rate.
In the Distributed Power Export to Mains
mode, this is the minimum variation from
Frequency Barrier Hz 0.1 2.0 0.5 the nominal frequency causing an active
power rump-up or ramp-down.

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Factory Description
Parameter Definition Unit Min Max
Set
This parameter defines the minimum
Speed Up/Down
msec 10 200 10 pulse width in speed pulse control mode.
Pulse Minimum
This parameter defines the maximum
Speed Up/Down pulse width in speed pulse control mode.
msec 0 2000 0
Pulse Maximum Duration If this parameter is set to zero then no
maximum pulse width is used.
This parameter defines the minimum
Speed Up/Down
msec 20 1000 20 pulse delay between two speed up/down
Pulse Delay
control pulses.
Voltage Up/Down This parameter defines the minimum
msec 10 200 10
Pulse Minimum pulse width in voltage pulse control mode.
This parameter defines the maximum
Voltage Up/Down pulse width in voltage pulse control mode.
msec 0 2000 0
Pulse Maximum Duration If this parameter is set to zero then no
maximum pulse width is used.
This parameter defines the minimum
Voltage Up/Down
msec 20 1000 20 pulse delay between two of voltage
Pulse Delay
up/down control pulses.
This parameter controls the “Return to
Mid-point” output relay function.
Return to Mid-Point - 0 1 0 0: no return to mid-point output
1: return to mid-point output active during
stop timer.
Reactive Load Sharing In reactive load sharing, this is the period
msec 0 5000 10
Pulse Period between two voltage up/down pulses.
This is the minimum reactive power
Reactive Load Sharing
% 0 100 0.0 percentage in order to activate voltage
Start Limit
up/down pulses.
0: Mains has priority over genset. Genset
supplies only if mains power is
unsufficient.
Peak Lopping Priority - 0 1 0
1: Genset has priority over mains. Mains
supplies the load only if the genset power
is unsufficient.

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17. CRANK CUTTING

In order to insure fast and reliable crank cutting, the unit uses various resources for engine running
condition detection.
Cranking is stopped when at least one of below conditions is met:
- Crank timer expired:
The crank timer is adjusted through Engine Parameters > Crank Timer. The maximum allowed
timer is 15 seconds.
- Genset AC voltage over threshold:
If the genset phase L1 AC voltage reaches Engine Parameters > Crank Cut Voltage, then
cranking is immediately stopped.
- Genset frequency over threshold:
If the genset phase L1 frequency reaches Engine Parameters > Crank Cut Frequency, then
cranking is immediately stopped.
- Genset rpm over threshold:
If the genset rpm reaches Engine Parameters > Crank Cut RPM, then cranking is immediately
stopped.
- Charge alternator voltage over threshold
Following setting is necessary: Engine Parameters > Charge Input Connected = 1
If the charge alternator voltage reaches Engine Parameters > Crank Cut Charge Voltage, then
cranking is immediately stopped.
- Oil pressure above threshold
Following setting is necessary: Engine Parameters > Crank Cut with Oil Pressure = 1
The crank cutting with oil pressure offers a programmable delay through Engine Parameters >
Crank Cut with Oil Pressure Delay. The parameter is factory set to 2 seconds.
Both low oil pressure switch and oil pressure sender readings may be used for crank cutting. The
oil pressure switch is always used. The sender may be disabled through Controller
Configuration > Oil Pressure Switch Priority parameter.
If enabled, when oil pressure is detected, cranking is stopped after adjustable timer delay.

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18. OVERCURRENT PROTECTION (IDMT)

The unit offers a programmable IDMT protection function in order to protect the alternator against
excessive currents.
The IDMT (Inverse Definite Minimum Time) protection function has such tripping characteristics that the
tripping time varies inversely with the value of current. Beyond a certain current limit the tripping time
becomes constant (definite) and causes tripping in minimum time.
The tripping formula is defined as below:

Where:
TMS is the IDMT time multiplier setting. This is also the tripping time at 100% overload.
I is the current of the most loaded phase
Iset is the programmed overcurrent limit
t is the tripping time in seconds

Currents below the overcurrent limit are allowed to flow for unlimited time. Currents above the limit will
cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent. Higher the
current, faster the protection will trip.
When a non-tripping overcurrent condition occurs, the unit will keep trace of it. In case of a consecutive
overcurrent, the controller will take into account the residual heat caused by the previous overcurrent and
will trip faster than usual.
The IDMT multiplier adjusts the sensitivity of the IDMT detector. When the multiplier is low, then tripping
will be faster for the same current.
The unit provides separate Overcurrent limits for primary, secondary and tertiary volt/speed/amp settings.
Switching from primary volt/freq/amps to secondary or tertiary values will also switch the IDMT detector to
the secondary/tertiary setting.
The action of the tripping may be selected as a Loaddump (stop after cooldown) or shutdown alarm
(immediate stop).

Screenshot from RainbowPlus configuration program, Generator>Current section

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Below is a table showing the tripping delay in function of the percent load level (with TMS=36):
100% unlimited 170% 73s 240% 18s
110% 3600s 180% 56s 250% 16s
120% 900s 190% 44s 260% 14s
130% 400s 200% 36s 270% 12s
140% 225s 210% 30s 280% 11s
150% 144s 220% 25s 290% 10s
160% 100s 230% 21s 300% 9s

Below is the tripping delay curve in function of the load level (with TMS=36):

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19. MOTORIZED CIRCUIT BREAKER CONTROL

The unit offers full control for any brand and model of motorized circuit breakers (MCB).
The MCB control is performed through 3 digital output functions, namely Open, Close and Undervoltage
coil controls. Only 2 of these outputs are used in a single application.
Any digital output can be assigned to MCB control signals through programming menu.

The MCB CLOSE sequence is below:

Activate UV output, wait for undervoltage coil timer (tuv)
Activate CLOSE output, wait for close pulse timer (tcl)
Deactivate CLOSE output

The MCB OPEN sequence is below:

Deactivate UV output
Activate OPEN output, wait for open pulse timer (top)
Deactivate OPEN output

Open Pulse, Close Pulse and Undervoltage Coil timers

are adjusted through programming menu.

If MCB feedback input is defined and the MCB fails to

change position after the expiration of MCB Fail timer,
then a fault condition will occur.

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MCB modules can be operated by 2 different ways. The unit supports both configurations.
Below is the terminology used:
M: gear motor
PF: ready to close contact
XF: close coil
MX: open coil
MN: undervoltage trip (release)
AUX: auxiliary contacts

MCB WITH OPEN-CLOSE COILS MCB WITH CLOSE-UV COILS

In the diagram at left, relay function assignments should be as below:

OUTx: Mains (or Genset) Close Pulse
OUTy: Mains (or Genset) Open Pulse

In the diagram at right, relay function assignments should be as below:

OUTx: Mains (or Genset) Close Pulse
OUTy: Mains (or Genset) Undervoltage Coil

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20. AUTO LEARNING

The controller offers the automatic learning feature for adjusting synchronization & load sharing set-points
and PID coefficients.
The AUTO LEARNING makes the synchronization commissioning and fine adjusting a simple
straightforward operation.
In order to activate the AUTO LEARNING:
Please enter programming > synchronization parameters.
▪ Disable GOV control enable parameter.
▪ Gov Low Limit will be 0, Gov Gain will be 100 and Gov rest point will be 50.
▪ Disable AVR control enable parameter.
▪ AVR Low Limit will be 0, AVR Gain will be 100 and AVR rest point will be 50.

Start the generator manually.

▪ Adjust the required nominal frequency on the speed control unit using the speed pot.
▪ Adjust the required nominal voltage on the AVR unit using the voltage pot.

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Stop the generator and enter programming > synchronization parameters.

▪ Enable Gov control enable parameter.
▪ Enable AVR control enable parameter.

Next step will be auto learning.

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To activate Auto Learning, push MAN button and then hold pressed Up Arrow button .

The unit will ask for confirmation

Push OK button to start Auto Learning operation.

Genset will run automatically to and start to learn AVR & GOV limits.

Then below screen will come:

Auto learning is completed successfully. The G-545 will force the genset to its nominal speed and
voltage.

There will be no need to adjust any governor or AVR limits, neither PID coefficients. All is adjusted to
gurantee smooth synchronization and load share.

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21. SPEED & VOLTAGE UP/DOWN RELAY OUTPUTS

These outputs will be available in firmware version 5.7

The unit is able to control motorized potentiometers through up/down output functions.
In order to use up/down functions, corresponding digital output function parameter should be set properly.
External potentiometers should be set to mid-point position at initial conditions.

21.1. SPEED UP/DOWN CONTROL

If speed up/down outputs are enabled, the master unit will operate in order to adjust itself to the nominal
speed defined in program parameter Nominal Frequency.
If speed-up or speed-down functions are assigned to digital outputs, then the unit will start to generate speed
up/down pulses in order to control the external speed potentiometer. The analog GOV control output will be
still valid and functional.
The minimum speed pulse width is set through program parameter Speed Up/Down Pulse Minimum.
The minimum delay between two successive pulses is set through program parameter Speed Up/Down
Pulse Delay and the maximum speed pulse width is set through program parameter Speed Up/Down
Pulse Maximum Duration.

Parameter Definition Description

Speed Up/Down Minimum pulse width in speed pulse control mode.
Pulse Minimum
Speed Up/Down Maximum pulse width in speed pulse control mode. If this parameter is
Pulse Maximum Duration set to zero then no maximum pulse width is used.
Speed Up/Down Minimum pulse delay between two speed up/down control pulses.
Pulse Delay

21.2. VOLTAGE UP/DOWN CONTROL

If voltage up/down outputs are enabled, the master unit will operate in order to adjust itself to the nominal
voltage defined in program parameter Nominal Voltage.
If voltage-up or voltage-down functions are assigned to digital outputs, then the unit will start to generate
voltage up/down pulses to control the external voltage potentiometer. The analog AVR control output will be
still valid and functional.
The minimum voltage pulse width is set through program parameter Voltage Up/Down Pulse Minimum.
The minimum delay between two successive pulses is set through program parameter Voltage Up/Down
Pulse Delay and the maximum voltage pulse width is set through program parameter Voltage Up/Down
Pulse Maximum Duration.

Parameter Definition Description

Voltage Up/Down Minimum pulse width in voltage pulse control mode.
Pulse Minimum
Voltage Up/Down Maximum pulse width in voltage pulse control mode. If this parameter is
Pulse Maximum Duration set to zero then no maximum pulse width is used.
Voltage Up/Down Minimum pulse delay between two of voltage up/down control pulses.
Pulse Delay

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22. J1939 CANBUS ENGINE SUPPORT

The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU
(electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J1939-.
The connection between the unit and the engine should be made with an appropriate balanced 120 ohms
low capacitance coaxial cable. The external conductor should be grounded at one end only.
A 120 ohms termination resistor is installed inside the unit. Please do not connect external resistor.
The J1939 port is activated by setting the program parameter J1939 Enable to 1. The J1939 Engine
Type parameter should be set accordingly. The list of available engines is given at the programming
section. Please contact GRUPEL for the most current list of engines.
If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information
are picked up from the ECU unit. If connected, the MPU unit and related analog senders are discarded.
The controller is able to read and display all below parameters, under condition that the engine sends
these information. Most engines send only some of them. If the engine does not send a parameter, the
unit will simply skip it. Thus only available information are displayed.
The complete list of J1939 display parameters is below:
PGN 65253 / SPN 247 Engine Total Hours of Operation
PGN 65257 / SPN 250 Engine Total Fuel Used
PGN 65262 / SPN 110 Engine Coolant Temperature
/ SPN 174 Engine Fuel Temperature 1
/ SPN 175 Engine Oil Temperature 1
PGN 65263 / SPN 100 Engine Oil Pressure
/ SPN 94 Engine Fuel Delivery Pressure
/ SPN 98 Engine Oil Level
/ SPN 101 Engine Crankcase Pressure
/ SPN 109 Engine Coolant Pressure
/ SPN 111 Engine Coolant Level
PGN 65266 / SPN 183 Engine Fuel Rate
/ SPN 184 Engine Instantaneous Fuel Economy
/ SPN 185 Engine Average Fuel Economy
PGN 65269 / SPN 108 Barometric Pressure
/ SPN 171 Ambient Air Temperature
/ SPN 172 Engine Air Inlet Temperature
PGN 65270 / SPN 102 Engine Turbocharger Boost Pressure
/ SPN 105 Engine Intake Manifold 1 Temperature
/ SPN 106 Engine Air Inlet Pressure
/ SPN 107 Engine Air Filter 1 Differential Pressure
/ SPN 173 Engine Exhaust Gas Temperature
PGN 65271 / SPN 158
PGN 61443 / SPN 92 Engine Percent Load At Current Speed
/ SPN 91 Accelerator Pedal Position 1
PGN 61444 / SPN 190 Engine Speed
/ SPN 513 Actual Engine - Percent Torque
/ SPN 512 Driver's Demand Engine - Percent Torque
The J1939 measurements are also available for Modbus operation. Please check chapter Modbus
Communications for more details.
When the fuel output is active, if no information is received from the ECU during last 3 seconds, then the
unit will give a ECU FAIL alarm and stop the engine. This feature prevents uncontrolled engine operation.
The fault conditions of an electronic engine are considered by the unit as warnings and do not cause
engine stop. The engine is supposed protected by the ECU which will stop it when necessary.

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The electronic engine fault codes are displayed in text within the alarm list table, together with their
SPN-FMI codes. The complete list of fault codes is given in the engine manufacturer’s user manual.
Below is a basic list of fault conditions (x denotes any FMI)

SPN FMI DESCRIPTION

56 x Overspeed shutdown
57 x Low oil pressure shutdown
58 x High engine temp. shutdown
71 x Gain adjust potentiometer fault
75 x Generator speed circuit fault
79 x Frequency adjust potentiometer fault
80 x Droop adjust potentiometer fault
81 x Low oil pressure warning
82 x High engine temp. warning
91 x Accelerator pedal circuit fault
94 x Fuel filter restriction
Fuel pressure sensor fail
97 x Water in Fuel
99 x Oil filter differential pressure fault
98 x Low oil level, High oil level, Oil level sensor fail
100 x Low oil pressure, Oil pressure sensor fail
101 x Crankcase pressure fault
102 x Intake manifold 1 pressure fault
103 x Turbocharger 1 speed fault
105 x Intake manifold temp high, Intake manifold temp
sensor fail
106 x High boost pressure, Turbo outlet pressure sensor
fail
107 x Air filter restriction, Air filter sensor fail
108 x Atmospheric pressure sensor fail
109 x Coolant pressure fault
110 x High coolant temperature, Coolant temperature
sensor fail
111 x Low coolant level, Coolant level sensor fail
153 x Crankcase ventilation fault
158 x Battery voltage failure
164 x High injector activation pressure, Injector activation
pressure sensor fail
168 x Battery 1 voltage fault
172 x High inlet air temperature, High inlet manifold air
temperature, Inlet manifold air temperature sensor
fail
173 x Exhaust gas temp. fault
174 x High fuel temperature, Fuel temperature sensor fail
175 x High oil temperature, Oil temperature sensor fail
190 x Overspeed, Speed sensor loss of signal, Speed
sensor mechanical failure

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SPN FMI DESCRIPTION

234 x Incorrect ECM software
612 x Engine magnetic speed sensor fault
620 x ECU internal +5V fail
626 x Preheating relay fault
627 x Injector power supply fault
629 x ECU hardware fail
630 x ECU memory fail
633 x Fuel injector valve fault
636 x Camshaft sensor
637 x Flywheel sensor
639 x ECU memory fail
644 x External speed comm. Input fault
647 x Fan control circuit fault
651 x Injector cylinder #1 fault
652 x Injector cylinder #2 fault
653 x Injector cylinder #3 fault
654 x Injector cylinder #4 fault
655 x Injector cylinder #5 fault
656 x Injector cylinder #6 fault
657 x Injector cylinder #7 fault
657 x Injector cylinder #8 fault
677 x Start motor relay fail
723 x Secondary engine speed sensor fail
1075 x Electric lift pump circulation fault
1079 x ECU internal +5V fail
1111 x Check configuration parameters
1265 x Engine oil burn valve fault
1377 x Multiple unit synch. Switch fault
1378 x Engine oil change interval
1384 x Engine commanded shutdown
2000 x ECU failure
2433 x Exhaust gas temp. right manifold
2434 x Exhaust gas temp. left manifold
2791 x Internel EGR fail

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Below is a basic list of FMI codes.

Please be aware that these codes may differ slightly depending on the engine brand and model.

FMI DESCRIPTION
0 Value too high” Valid data, but above the normal working range
1 “Value too low” Valid data, but below the normal working range
2 “Faulty data” Intermittent or faulty data or
Short circuit to battery voltage, injector high voltage side
3 “Electrical fault” Abnormally high voltage or short circuit to battery
voltage, injector low voltage side
4 “Electrical fault” Abnormally low voltage or short circuit to battery
negative, injector low voltage or high voltage side
5 “Electrical fault” Abnormally low current or open circuit
6 “Electrical fault” Abnormally high current or short circuit to battery
negative
7 “Mechanical fault” Faulty response from mechanical system
8 “Mechanical or electrical fault” Abnormal frequency
9 “Communication fault” Abnormal updating rate or
Open circuit in injector circuit
10 “Mechanical or electrical fault” Abnormally large variations
11 “Unknown fault” Unidentified fault
12 “Component fault” Faulty unit or component
13 “Faulty calibration” Calibration values outside the limits
14 “Unknown fault” Special instructions
15 Data valid but above normal operating range - least severe level
16 Data valid but above normal operating range - moderately severe level
17 Data valid but below normal operating range - least severe level
18 Data valid but below normal operating range - moderately severe level
19 Received network data in error
20 not used (reserved)
21 not used (reserved)
22 not used (reserved)
23 not used (reserved)
24 not used (reserved)
25 not used (reserved)
26 not used (reserved)
27 not used (reserved)
28 not used (reserved)
29 not used (reserved)
30 not used (reserved)
31 Condition exist

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23. GPS SUPPORT

The unit supports external GPS module from USB-Host port.
USB GPS modules can be procured from GRUPEL or from the free market.

USB GPS MODULE

Related parameters are:

Factory
Parameter Definition Unit Min Max Description
Set
0: no modem
1: Internal GSM modem
2: external modem
Modem / GPS Selection - 0 5 0
3: external generic modem
4: no modem, GPS on RS-232
5: Internal modem, GPS on RS-232
External Modem / GPS This is the data rate of the RS-232 port
bps 2400 115200 115200
Baud Rate for the external modem / GPS.

The GPS screen is found under GSM Modem screen group.

Number
of
detected
satellites

GPS SCREEN

The GPS location determination is based on signals transmitted by GPS satellites circulating in earth’s
orbit. 24 satellites are available in total, but the number of satellites in sight will depend on the physical
location and time.

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A minimum of 3 satellites are necessary to determine the location. A fourth satellite is used for
verification. More satellites will mean more precision. The unit displays the number of effective satellites
on its GPS screen.
GPS satellites transmit a precision date and time information as well. This information is displayed on the
GPS Screen, but not used elsewhere.
The location determination quality of the GPS module will depend on the physical location. The GPS
should be installed in a location where it is capable of seeing a large portion of open sky. It can also work
on reflections from ground or other buildings without seeing the sky, but location precision will affected by
this.

GPS based location has priority over GSM based

location. If both type of locations are available, then
GPS location will be used.

Detection of a USB-GPS is automatic. The unit will

detect and use it without any programming.

Geographical location is stored in a non-volatile memory once an hour. Thus if the GPS signal is lost, the
unit continues to appear at the same location of the remote monitoring system. However a GPS warning
will be generated on loss of signal or communication with the module.
It is possible to program the geographical location inside the controller, forcing it to appear at the desired
location of the remote monitoring system. The location setting is done through Rainbow Plus only.
Location parameters are found under: Communication>Basic tab

Latitude Longitude

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24. ETHERNET CONFIGURATION

Please see related document: Ethernet Configuration Guide.

25. GSM CONFIGURATION

Please see related document: GSM Configuration Guide.

26. DYNAMIC DNS FEATURE

Please see related document: Dynamic DNS Account Setting.

27. ACCESSING THE EMBEDDED WEB SERVER

Please see related document: Ethernet Configuration Guide.

28. WEB MONITORING AND CONTROL OF GENSETS

Please see related document: Ethernet Configuration Guide.

29. CENTRAL MONITORING OF GENSETS

Please see related document: Rainbow Scada Usage Guide.

30. E-MAIL SENDING

Please see related document: Ethernet Configuration Guide.

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31. SMS COMMANDS

SMS messages are accepted only from phone numbers recorded in the
Communication>GSM>Message Numbers tab.
Answers to SMS messages will be sent to all phone numbers in the list.

SMS messages must be written exactly as below, without any preceding blanks.
Only UPPERCASE characters are permitted.

COMMAND DESCRIPTION ANSWER

GET IP If GPRS connection is
active, the controller will IP: [Link]
reply by an SMS message
indicating the IP address of
the GSM modem.
GPRS 1 Activates the GPRS
connection GPRS enabled!

GPRS 0 Stops the GPRS connection

GPRS disabled!

RESET Clears alarms of the controller.

The operating mode is not
Alarms cleared!
ALARMS
modified.
REBOOT Performs a hard reset on the no answer
controller

MODEM RESET Performs a hard reset on the no answer

modem

GET INFO Returns the alarm list and

actual measured values ALARMS (if exists)
GEN: Vavg/ıAVG/kWtot/pf/Freq
MAINS: Vavg/ıAVG/kWtot
OIL_PR/TEMP/FUEL%

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COMMAND DESCRIPTION ANSWER

MODE STOP Puts the controller into STOP mode. Alarms
are also cleared. Unit forced to STOP!

MODE AUTO Puts the controller into AUTO mode. Alarms

are also cleared. Unit forced to AUTO!

MODE MANUAL Puts the controller into MANUAL (RUN)

mode. Alarms are also cleared.
Unit forced to RUN!

MODE TEST Puts the controller into TEST mode. Alarms

are also cleared. Unit forced to TEST!

OUT1 ON Sets remote controlled output #1 to active

state OUT 1 = ON

OUT1 OFF Sets remote controlled output #1 to passive

state OUT 1 = OFF

OUTxx ON Sets remote controlled output #xx to active

state (xx denotes any number between 1 and OUT xx = ON
16).
OUTxx OFF Sets remote controlled output #xx to passive
state (xx denotes any number between 1 and OUT xx = OFF
16).

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32. LOAD TRANSFER MODES

The unit offers 3 ways of transferring the load from genset to mains and vice versa:
-transfer with interruption,
-no break transfer, (from genset to mains)
-soft transfer

32.1. TRANSFER WITH INTERRUPTION

This is the most conventional way of transferring the load between the genset and mains. There will be a
power interruption period during the transfer. Note that the program parameters Mains Contactor Timer
and Genset Contactor Timer define the power interruption period.

If this transfer method is used, it is advised to make an electrical

interlock between the two contactors to prevent an accidental
phase to phase short circuit.

Transfer from genset (or busbar) to mains:

-The generator (or busbar) contactor releases,
-The unit waits for Mains Contactor Timer
-The mains contactor is energized.
Transfer from mains to genset (or busbar):
-The mains contactor releases,
-The unit waits for Generator Contactor Timer
-The generator (or busbar) contactor is energized.

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32.2. UNINTERRUPTED TRANSFER

In this mode, the transfer will be made without power interruption from genset to mains. This implies
that both of the mains and generator contactors will be active during transfer.
The maximum duration that both contactors will be active is programmable. However this process may be
quicker with the use of one auxiliary feedback contact from each contactor. Thus the changeover will be
quite instantaneous, preventing any excess or reverse power condition.
To prevent a phase to phase short circuit below criteria must be met:
-The mains and generator voltages must be equal,
-The mains and generator voltages must have the same phase,
-The mains and generator voltages must have the same phase sequence.
The unit will allow an Uninterrupted Transfer only if all of the below conditions are fulfilled:
-Mains phase voltages within the programmed limits,
-Mains frequency within the programmed limits,
-Genset phase voltages within the programmed limits,
-Genset frequency within the programmed limits,
-Mains phase order correct (or phase order check must be disabled),
-Genset phase order correct (or phase order check must be disabled),
-The difference between mains and genset frequencies not more than programmed limit,
-The voltage difference mains-L1 and genset-L1 not more than programmed limit,
-The phase angle between mains-L1 and genset-L1 not more than programmed limit,
When an uninterrupted transfer cycle is started, the unit will wait until the expiration of the
Synchronization Fail Timer, to find a matching frequency, phase and voltage.
Usually, with frequencies matching at +/- 2Hz and voltages matching at +/-10 volts an Uninterrupted
Transfer is expected to successful.
If matching is found before the expiration of the Synchronization Fail Timer, then both contactors will be
activated. If contactor auxiliary contacts are used, the other contactor will release immediately. If
contactor auxiliary contacts are not used, the other contactor will release after contactor timeout .
The unit offers below parameters for the setup of the Uninterrupted transfer feature.

Parameter Definition Description

No Break Transfer 0: only interrupted transfer enabled

Enable 1: no break transfer enabled
If the phase and voltage synchronization is not successful before the
Synchronization Fail
expiration of this timer, then a Synchronization Fail warning is given and the
Timeout
transfer will be performed with interruption.
Synchronization When synchronization is detected, both contactors will stay closed during this
Contactor Timeout timer.
This is the maximum difference between mains and genset frequencies to
Max Freq Difference
close both contactors.
This is the maximum difference between the mains phase-L1 and the genset
Max Volt Difference phase-L1 voltages to close both contactors. If voltage transformer is used, this
quantity is multiplied with voltage transformer ratio.
This is the maximum phase angle between the mains phase-L1 and the
Max Phase Difference
genset phase-L1 voltages to close both contactors.
This parameter is used to compensate the phase angle introduced by voltage
Phase Offset transformers in case of MV synchronization. This angle value is added to the
phase differential during phase matching process.

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32.3. SOFT TRANSFER

In this mode, the transfer will be made without interruption like the Uninterrupted Transfer mode. But the
load will be gradually transferred under active and reactive power control.

The Soft Transfer sequence starts like an Uninterrupted transfer. But when both contactors are activated,
the unit starts transferring the kW and kVAr load to the mains with a predefined ramp (Active Power
Ramp, Reactive Power Ramp). The duration of the load transfer sequence is controlled by the Soft
Transfer Timer.

The unit offers a comprehensive set of protection functions to detect quickly a mains failure during parallel
operation with mains. The protections are enabled after the timeout defined by the parameter Parallel
Check Delay. These protections will be explained with more detail in the following chapter.

If a mains failure occurs during parallel with mains operation, the mains contactor will immediately de-
energize, a general Parallel Mains Fail warning and a specific protection function warning will be
generated.

At the end of the Soft Transfer Timer, the load contactor will be released. If any alarm is encountered
during the Soft Transfer sequence, the G-545 will revert to the Interrupted transfer.

The G-545 has a set of programmable parameters to define the Soft Transfer operation. All parameters
used in Uninterrupted Transfer are also used in Soft Transfer. Additional parameters are:

Parameter Definition Description

Soft Transfer Enable This parameter enables/disables the Soft Transfer feature.
This is the time duration of the Soft Transfer. At the end of this timer one of
Soft Transfer Timer
the contactors will release to terminate the parallel operation
Active Power Ramp The load’s active power (kW) will be transferred to the mains with this rate.
Reactive Power
The load’s reactive power (kVAr) will be transferred to the mains with this rate.
Ramp
Ramp On High Limit This parameter defines high limit of soft transferring from busbar to mains.
Ramp Off Low Limit This parameter defines low limit of soft transferring from busbar to mains.
This is the delay after the mains contactor is energized (for parallel to mains)
Parallel Check Delay
and before the protections for mains failure are enabled.

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33. LOAD SHARING

This chapter is only applicable to units operated in multi-genset

SYNCHRONIZATION & LOAD SHARE mode.

The load sharing functionality brings flexibility and economy to the genset system, where only the
necessary number of gensets to supply the load run.
The reliability is also improved, where the user may have redundancy for failure cases or reserve power
for accidental increase in power demand. The redundancy allows also stopping one genset for
maintenance without interrupting the load power supply.
A maximum of 48 gensets can be paralleled on the same busbar using G-545 units. Always one of the
gensets will become the MASTER one.
The master genset will determine the voltage and frequency of the busbar. It should be noted that, when
the number of gensets in parallel increases, the stability of the system will be deteriorated, thus smaller
kW and kVAr gains should be used.
When more than one genset start together, the master genset will always feed the busbar first. Other
gensets will synchronize to the busbar, get in parallel and share the load.

TO LOAD

Genset
Busbar

Analog
Load Share Datalink
Line Bus
Max 48 To mains Genset
gensets controller Contactor
s

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Load sharing may be performed in 3 different ways:

• Digital load share, based on Datalink communication
• Active power sharing based on the Analog Load Share Line
• Uncontrolled load share, based on droop operation

33.1. DIGITAL LOAD SHARING (DATALINK)

The Datalink is an isolated Canbus line where all controllers communicate between them. The default
Datalink bit speed is factory set to 250kbps. However speeds from 50kbps to 500kbps may be manually
selected.

All units on the same Datalink bus must operate with the same bit
speed.

The Datalink is the best performing way of load sharing. All controllers will broadcast all their power
parameters and both active and reactive powers will be shared.
The load sharing display of each unit will show precisely the total system power loading and the individual
genset power loading.
Based on the total power demand and own parameter setting, each genset will decide when to run.
When a genset decides to run, it will synchronize to the busbar, close its genset contactor and ramp-up
until reaching the necessary power rate.
When a genset decides to stop, it will ramp-down, then open its genset contactor, then cooldown and
stop.
The load sharing takes into account the genset nominal power settings. Gensets of various power ratings
may be used in parallel. Each genset will be loaded with the same percentage of its nominal power.

Parameters used in the load sharing: (detailed descriptions are in the programming section)

Genset Active Power Rate Dwell Timeout

Genset Reactive Power Rate Active Power Ramp (kW/sec)
Genset Number in Multi Genset Systems Reactive Power Ramp (kVAr/sec)
Minimum Genset Fault Action Ramp On High Limit
Multi Genset Start-Up Options Ramp Off Low Limit
Multi Genset Start-Up Power Active Power Share G Gain
Insufficient Multi Genset Start-Up Power Alarm Reactive Power Share G Gain
Level Nominal Frequency G Gain
System Reserve Power Nominal Voltage G Gain
Load Management Method Multi Genset Delayed Start
Governor Droop Enable Multi Genset Quick Start
Governor Output Droop Multi Genset Delayed Stop
AVR Droop Enable Multi Genset Run/Stop Delay
AVR Output Droop Load Management Inhibit Delay

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33.2. ANALOG LOAD SHARING

Load sharing can be performed as well using the Analog Load Share line.

The Analog Load Share facility is designed as an emergency backup to the digital load share for
increased reliability.

When the Datalink line is active, the Analog Load Share Line is not used.

The analog load share is a wire where all load sharing controllers are in parallel.

Mains controllers do not use the analog load share line.

Only the active power is shared using the analog line. Thus it provides no control over the reactive
power sharing. However reactive power sharing may be still performed using the droop function. Please
see next chapter for the droop function.
As there is no communication between controllers in the absence of the Datalink, no smart load
management is performed. When the REMOTE START signal comes, the genset runs, synchronizes to
the busbar and supplies the active power requested by the load share line. It will stop only when the
REMOTE START signal is removed.

Analog load sharing is less stable than digital load sharing.

Parameters used in the analog load sharing: (details are in the programming section)

Governor Droop Enable Reactive Power Ramp (kVAr/sec)

Governor Output Droop Ramp On High Limit
AVR Droop Enable Ramp Off Low Limit
AVR Output Droop Active Power Share G Gain
Dwell Timeout Reactive Power Share G Gain
Active Power Ramp (kW/sec)

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33.3. DROOP MODE OPERATION

Droop mode allows an uncontrolled load share for emergency cases where the Datalink and Analog Load
Share are not available.
This is the most primitive load sharing method, often used in old times.
The speed droop consists of a slight decrease in the genset speed with increasing active power demand.
The voltage droop is a slight decrease in the alternator voltage with increasing reactive power demand.

In order to achieve an acceptable load sharing, each genset must have

the same nominal voltage and frequency settings.

As there is no communication between controllers in the absence of the Datalink, no smart load
management is performed. When the REMOTE START signal comes, the genset runs, synchronizes to
the busbar and closes its genset contactor.
The amount of active and reactive powers supplied to the load is controlled by the droop function. The
genset will stop only when the REMOTE START signal is removed.

Droop mode load sharing is less accurate than digital load sharing.
Differences between genset loads should be considered as normal.

Parameters used in the droop mode load sharing: (details are in the programming section)

Governor Droop Enable

Governor Output Droop
AVR Droop Enable
AVR Output Droop

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34. PARALLEL OPERATION WITH MAINS

34.1. PEAK LOPPING

It is not currently available for this version.

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34.2. POWER EXPORT TO MAINS

GENSET MAINS

LOAD

The Export to Mains mode allows the multi genset system to supply the mains power grid under
constant power factor. Thus the multi genset system will be part of the mains power supply system.
The Export to Mains mode is activated by setting the program parameter Power Export Enable.
When Export to Mains is enabled, the mains voltages and frequency are within limits and the G-545 in
AUTO mode, the unit will run the genset system, synchronize with mains and close the Load Contactor.
Then the output active power of the genset system will ramp-up at the rate defined in program parameter
Active Power Ramp. The reactive power is continuously adjusted in order to hold the power factor
constant (defined in Exported Power Factor).
When the requested output power is reached, the ramping will be terminated. The requested power is
defined by Exported Power program parameter.
The G59 protections for mains failure in parallel are active during the Export to Mains operation, with the
exception of Mains Reverse Power protection. If a mains failure is detected during paralleling, then the
mains contactor will open, and the G-545 will continue to feed the local load. When the mains is restored,
then the genset system will resume Export to Mains operation.
The Export to Mains operation is compatible with the Weekly Operating Schedule. Thus the genset can
be programmed for supplying the mains only during given time intervals.
The power export mode may be disabled momentarily with an external signal. In order to achieve this, a
digital input should be programmed as Disable Power Export function input. More information about
input programming is found in the PROGRAMMING chapter.

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34.3. DISTRIBUTED POWER EXPORT TO MAINS

GENSET

MAINS

GENSET

GENSET
The Distributed Power Export to Mains mode allows an unlimited number of gensets to export power
to the mains and share active and reactive loads without any communication between controllers.
The application of this feature is large independent areas, relying only on generators for power
generation. Gensets are distributed to the area, making any communication between controllers
impossible. Thus each controller has to determine the required power to export independently from other
controllers.
OPERATING PRINCIPLE:
When required to run, each generator is synchronized and closed to the mains independently. Usually
generators are run and stopped manually by staff charged of power generation. The energy request will
depend of the time of the day, thus the required number of gensets will vary.
The operating principle is based on the precise measurement of the mains frequency by the controllers.
When the frequency is below the nominal value, this means a need for extra power, and each controller
will slowly ramp-up the exported power. When the frequency is above the nominal value, this shows an
excess of power export, thus each controller will ramp-down its export power. For stability reasons a
frequency band of no-action is also defined.
The reactive power export is controlled by the grid voltage. The controller tends to maintain the mains
voltage at its nominal value, resulting in the production of the exact amount of reactive power requested
by the load.

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PARAMETERS TO ADJUST:
The Distributed Power Export functionality is enabled by a digital input set to the “Distributed Power
Export” function (function_56). When signal arrives to this input, then the Distributed Power Export
operating mode is enabled.

Parameter Definition Description

Minimum Exported Power The exported power will not fall below this limit.
Export Power Ramp The genset active export power (KW) will be increased/decreased with
(kW/sec) this rate.
This is the minimum variation from the nominal frequency causing a
Frequency Barrier
power rump-up or ramp-down operation.

Other than above parameters, all parameters related to Power Export to Mains should be adequately
programmed and the Power Export mode should be enabled.

34.4. PEAK LOPPING WITH GENSET PRIORITY

The purpose of this operating mode is to supply the with genset power wherever this is possible. This
occurs generally in gas producing [Link] mains is used in order to back gensets up when the genset
power or the gas production is insufficient

All gensets in the system synchronize and share the load. When genset power reaches the set limit, then
gensets synchronize with tha mains and start parallel operation. The extra load demand is supplied by the
mains.
In order to activate Peak Lopping with Genset Priority, the Peak Lopping Enable parameter must be
activated and the Peak Lopping Priority parameter must be set as Genset Priority.
If the total genset power available reaches Multi Genset Quick Start value, then the genset system will
synchronize to the busbar and the excess load will be supplied by the mains. Gensets continue their
operation at the power rating defined in Multi Genset Quick Start parameter. If the load falls below the
Multi Genset Quick Start parameter then the mains contactor opens and the load will be supplied by the
genset system only.
If one of the digital inputs of the Mains Synchronizing unit is adjusted as Force Parallel Operation and a
signal is applied to this input, the genset system will immediately synchronize to the mains regardsless of
the load value. However the load will be supplied by the genset system only. This operation mode allows
synchronizing to the mains to be ready before heavy loads enter into service.

PARAMETERS TO BE ADJUSTED:

Parameter Definition Description

Peak Lopping Enable This parameter allows the genset system to share the load with mains.
Peak Lopping Priority If this parameter is adjusted as Genset has priority over mains, then the
mains supplies the load only if the genset power is unsufficient.
If the genset total active load is above this level, the genset system will
Multi Genset Quick Start synchronize to the mains and the excess load will be supplied by the
mains.

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35. PROTECTION FUNCTIONS PARALLELING WITH MAINS

The G-545 includes a comprehensive set of protection functions to detect quickly a mains failure during
parallel with mains operation.

The protections are enabled after the timeout defined by the parameter Parallel Check Delay in order not
to detect a mains failure during transients caused by the closing of the contactors.

Do not forget that the protections are disabled during Parallel

Check Delay. Set this timeout as short as possible.

If any of the protection functions detects a mains failure during parallel with mains:
-the mains contactor is immediately de-energized,
-a Parallel Mains Fail warning is generated,
-a specific warning to the related protection function is generated.

Immediate disconnection of the generator from the mains in

case of a mains failure, is required in most countries for
paralleling of synchronous generators to the mains.

35.1. ROCOF FUNCTION (rate of change of frequency)

The ROCOF measures the frequency of the mains for each period. If the frequency change exceeds the
predefined limit for 4 successive periods, then the ROCOF function detects a mains failure. Thus the
response time of the ROCOF is approximately 4 cycles.

However the ROCOF will not detect relatively slow changes in mains frequency.

Related parameter: ROCOF df/dt

If the parameter is set to zero, then the protection function will be disabled.

35.2. VECTOR SHIFT FUNCTION

The Vector Shift measures and stores the period of last 5 cycles. At the end of each cycle it compares the
average period of last 2 cycles with the average period of 4th and 5th cycles. If the difference exceeds the
predefined limit, then the vector shift detects a mains failure. Thus the response time of the vector shift is
5 cycles.

However the vector shift will not detect relatively slow changes in mains frequency.

Related parameter: Vector Shift Limit

If the parameter is set to zero, then the protection function will be disabled.

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35.3. OVER/UNDER FREQUENCY FUNCTION

This protection function measures the frequency of the mains for each period. If the frequency is outside
limits for 4 successive periods, it detects a mains failure. The response time of the mains frequency is
approximately 4 cycles.

Related parameters:
Mains Frequency Low Limit
Mains Frequency High Limit

35.4. OVER/UNDER VOLTAGE FUNCTION

The mains phase voltages are measured twice a second and compared with predefined high and low
limits. If at least one of the phase voltages is outside limits, this will mean a mains failure. The response
time is approximately 500ms.

Related parameters:
Mains Voltage Low Limit
Mains Voltage High Limit

35.5. NO FREQUENCY FUNCTION

The unit counts the time after the last detection of the mains frequency pulses. If no mains pulses is
detected for a period corresponding to 2,5 times the Mains Frequency Low Limit, a mains failure alarm
is generated.

Related parameter: Mains Frequency Low Limit

If the parameter is set to zero, then the protection function will be disabled.

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36. DATA RECORDING

36.1. DATA RECORDING MEDIA

Data can be recorded in USB flash memory. As soon as a USB flash memory is inserted, the unit will
start data recording and continue until the memory is removed.

USB HOST
Port

USB FLASH MEMORY

If USB-Device is plugged then USB-Host port will not function.

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36.2. DIRECTORY STRUCTURE

The unit will record data in either an USB-Flash memory or a micro-SD flash memory card. The record
structure is the same in both cases.

SITE-ID Year 2012 Last day of

the year

Year 2011

Previous years First day of

the year

The unit will record data in a directory named with the first 11 characters of its site-id parameter. In order
to avoid confusion between records, it is highly recommended to configure the site-id parameter
accordingly to the genset installation place. Thus the same memory module may be used for recording in
different controllers,
Inside the <SITE-ID> directory, the unit will open a separate directory for each year of recording. The
directory will be simply named by the year, like 2012, 2013 etc...
Inside the year directory, the controller will record data in a different file for each day of recording. The
record file will be named YYYYMMDD like “20120331” representing March ’31, 2012. Thus alphabetical
listing will produce a sorted list by date of recording.
The recorded file is of CSV (comma separated values) type. This is a text file which can be directly
opened with Microsoft Excel program without any loss of information. It can be also opened with any text
editor (like Notepad program).
Inside the file, each record consists of a line including a large set of measured parameters. The recorded
parameters list is not adjustable. The controller records all practically necessary parameters.

36.3. UNDERSTANDING THE CSV FORMAT

The “.csv” file is basically a text file format. Thanks to this, it can be opened by any text editor in any
operating system.
When opened with the Microsoft Excel program, the values will appear in tabulated form, enabling
application of formulas, graphs and other features of Excel program.

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36.4. RECORDED DATA LIST, RECORD PERIOD

The recording period is adjustable between 2 seconds and 18 hours by program parameter.
A short period will give better resolution, but it will generate more data in the memory card.
One data record is typically 250 bytes long, thus with a minimum period of 2 seconds, the unit will store
10.8 MB of data per day (250x30x60x24). A typical memory of 4GB will store data during 370 days, more
than 1 year.
With a recording period of 1 minute, 4GB memory card will store data during 30 years.
Below parameters are recorded:
Date and time of recording Gen voltage phase L1 to neutral
Operating mode Gen voltage phase L2 to neutral
Mains voltage phase L1 to neutral Gen voltage phase L3 to neutral
Mains voltage phase L2 to neutral Gen average voltage phase to neutral
Mains voltage phase L3 to neutral Gen voltage phase L1-L2
Mains voltage phase L1-L2 Gen voltage phase L2-L3
Mains voltage phase L2-L3 Gen voltage phase L3-L1
Mains voltage phase L3-L1 Gen current phase L1
Mains frequency Gen current phase L2
Mains current phase L1 Gen current phase L3
Mains current phase L2 Gen average current
Mains current phase L3 Gen frequency
Mains average current Gen kW phase L1
Mains frequency Gen kW phase L2
Mains kW phase L1 Gen kW phase L3
Mains kW phase L2 Gen total kW
Mains kW phase L3 Gen kVA phase L1
Mains total kW Gen kVA phase L2
Mains kVA phase L1 Gen kVA phase L3
Mains kVA phase L2 Gen kVAr phase L1
Mains kVA phase L3 Gen kVAr phase L2
Mains kVAr phase L1 Gen kVAr phase L3
Mains kVAr phase L2 Gen pf phase L1
Mains kVAr phase L3 Gen pf phase L2
Mains pf phase L1 Gen pf phase L3
Mains pf phase L2 Gen total pf
Mains pf phase L3 Neutral current
Mains total pf Oil pressure (bar & psi)
Mains neutral current Coolant temperature (°C & °F)
Fuel level (%)
Oil temperature (°C & °F)
Canopy temperature (°C & °F)
Engine speed (rpm)
Battery voltage
Charge input voltage
Engine hours

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37. SOFTWARE FEATURES

37.1. LOAD SHEDDING / DUMMY LOAD

The load shedding feature consists on the disconnection of the least crucial loads when the genset power
approaches to its limits. These loads will be supplied again when the genset power falls below the
programmed limit. The internal Load Shedding function is always active. Any digital output may be used
as the load shedding output.
The dummy load function consists on the connection of a dummy load if the total genset load is below a
limit and to disconnection of the dummy load when the total power exceeds another limit. The dummy
load function is the inverse of the load shedding function, thus the same output may be used for both
purposes.
It is also possible to control more complex external systems with multiple steps, using LOAD_ADD and
LOAD_SUBSTRACT output functions. Any digital output may be assigned to these signals.
When the load is above the Load Shedding High Limit, the controller will activate the Load Shedding
output.
When the load is below the Load Shedding Low Limit, the controller will release the Load Shedding
output.
The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Load Shedding Low Limit: If the genset power goes below this limit then the load shedding relay will be
deactivated.
Load Shedding High Limit: If the genset power goes above this limit then the load shedding relay will be
activated.

t1: the load goes below the Load Shedding Low Limit, thus the Load Shedding output becomes inactive.
t2: the load goes above the Load Shedding High Limit, thus the Load Shedding output becomes active.
t3: the load goes below the Load Shedding Low Limit, thus the Load Shedding output becomes inactive.

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37.2. LOAD ADD / SUBSTRACT

The load add/subtract output functions are designed to provide control signals for an external, multi-step
load adding/substracting system.
This external system will add either linearly or by small steps a dummy load that will prevent the genset
from running below the minimum required load level.
The same function may be used in order to supply loads of different priority levels following the available
genset capacity.
When the load is below the Load Shedding Low Limit, the controller will activate the Load Add output.
The external system will increase the load until it goes over the low limit, where the Load Add output will
become inactive.
When the load is above the Load Shedding High Limit, the controller will activate the Load Substract
output. The external system will decrease the load until it goes below the high limit, where the Load
Substract output will become inactive.
There are protection delays between two pulses. These timers help to stabilizing the decision algorithm
and preventing unwanted multiple operations.

The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Load Shedding Low Limit: If the genset power goes below this limit then the load_add relay will be
active.
Load Shedding High Limit: If the genset power goes above this limit then the load_substract relay will
be active.
Load Add Delay: This is the minimum delay between 2 load_add pulses. This is also the minimum delay
between 2 load_substract pulses.
Load Subtract-Add Delay: This is the minimum delay between load_add and load_substract pulses.

t1: the load goes below the Load Shedding Low Limit, thus the Load Add output becomes active.
t2: the load goes above the Load Shedding Low Limit, thus the Load Add output becomes inactive.
t3: the load goes above the Load Shedding High Limit, thus the Load Substract output becomes active.
t4: the load goes below the Load Shedding High Limit, thus the Load Substract output becomes inactive.
t5: the load goes below the Load Shedding Low Limit, but the Load Substract-Add delay is not expired. The
controller waits until expiration of the timer.
t6: the timer is expired and the load is still below the Load Shedding Low Limit, the Load Add output
becomes active.
t7: the load goes above the Load Shedding Low Limit, thus the Load Add output becomes inactive.

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37.3. FIVE STEP LOAD MANAGEMENT

The controller is able to manage the supply of up to 5 prioritized loads. The loads are supplied starting
from the number #1 (highest priority) and unloaded from the highest number (lowest priority) available.
Protection timers help to stabilizing the decision algorithm and preventing unwanted multiple operations.
When the load is below the Multi Load Add Power Level during Multi Load Add Start Delay, then 1
step of load is added. The minimum wait period between two load_adds is Multi Load Add Wait Delay.
When the load is above the Multi Load Substract Power Level during Multi Load Substract Start
Delay, then 1 step of load is unloaded. The minimum wait period between two load_substracts is Multi
Load Subtract Wait Delay.
Add and subtract outputs send pulses of 0.25s duration.
The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Multi Load Substract Power Level: When the genset active power goes over this limit, the controller will
start subtracting load.
Multi Load Add Power Level: When the genset active power goes below this limit, the controller will
start adding load.
Multi Load Substract Start Delay ( tLSD): If the load stays over the Multi Load Substract Power Level
parameter during this timer, then 1 step of load is substracted.
Multi Load Substract Wait Delay (tLSW): This is the minimum period between two load subtract pulses.
Multi Load Add Start Delay (tLAD): If the load stays below the Multi Load Add Power Level parameter
during this timer, then 1 step of load is added.
Multi Load Add Wait Delay (tLAW): This is the minimum period between two load add pulses.

t1: the load goes below the Multi Load Add Power Level.
t2: after Multi Load Add Start Delay the load is still below Multi Load Add Power Level, the Load_Add_1
sends a pulse.
t3: after Multi Load Add Start Delay and Multi Load Add Wait Delay, the load is still below Multi Load Add
Power Level, thus Load_Add_2 output sends a pulse.
t4: the load goes above the Multi Load Substract Power Level.
t5: after Multi Load Substract Start Delay, the load is still above Multi Load Substract Power Level, thus the
Load_Substract_2 sends a pulse.
t6: the load goes above the Multi Load Substract Power Level.
t7: Multi Load Subtract Wait Delay is already expired. After Multi Load Subtract Start Delay, the load is still
above Multi Load Substract Power Level, thus the Load_Subtract_1 output sends a pulse.

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37.4. REMOTE START OPERATION

The unit offers the possibility of Remote Start mode of operation. Any digital input may be assigned as
Remote Start Input using Input Function Select program parameters.
The Remote Start signal may be a NO or NC contact, switching to either battery positive or battery negative.
These selections are made using programming menu.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarm from this input.
When a Remote Start input is defined, the mains phases are not monitored. When the Remote Start
signal is present then the mains will be supposed to fail, inversely when the Remote Start signal is
absent then mains voltages will be supposed to be present.
The front panels mimic diagram’s mains LEDs will always reflect the status of the Remote Start input.

37.5. DISABLE AUTO START, SIMULATE MAINS

The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as Disable
Auto Start using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery
negative. These selections are made using the programming menu.
If the Disable Auto Start input is defined and the input signal is active, the mains phases are not
monitored and supposed to be inside limits. This will prevent the genset from starting even in case of a
mains failure. If the genset is running when the signal is applied, then usual Mains Waiting and Cooldown
cycles will be performed before engine stop. When the Disable Auto Start signal is present, the front
panels mimic diagram’s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides DISABLE AUTO

START and FORCE TO START operations.

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37.6. BATTERY CHARGING OPERATION, DELAYED

SIMULATE MAINS
The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are
able to supply the load during a certain period. The genset is requested to run only when battery voltage
drops below the critical level. Once the engine runs, the rectifier system starts charging the batteries and
the battery voltage goes up immediately. Thus the engine should continue to run a programmed period
for effective charging. The critical battery voltage level will be detected by an external unit which provides
the digital Disable Auto Start signal for the genset control unit.
The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as
Simulate Mains using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery
negative. These selections are made using the programming menu.
If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the
genset is not feeding the load, the mains phases are not monitored and supposed to be inside limits. This
will prevent the genset from starting when the simulate mains signal is present (batteries charged). The
genset will start when mains voltages are out of limits and the simulate mains signal not present.
If the genset is running when the signal is applied, then MAINS SIMULATION will be prevented during
Flashing Relay On Timer program parameter. After this, usual Mains Waiting and Cooldown cycles will
be performed before engine stop. When the SIMULATE MAINS signal is present, the front panels mimic
diagram’s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides Disable

Auto Start operation. When both “Remote Start
Operation” and “Delayed Simulate Mains” are
enabled then REMOTE START operation mode is
performed.

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37.7. DUAL GENSET MUTUAL STANDBY OPERATION

Dual genset intermittent operation consists of regular switching of the load between 2 gensets. The use of
2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous
operation requesting service stops.
The running period for each genset is adjustable using Flashing Relay On Timer and Flashing Relay
Off Timer program parameters. If the time is adjusted as 0 hours, it will be actually set to 2 minutes for
faster testing purposes.
A flashing relay output function is provided, based on the parameter Flashing Relay On/Off Timers.
Each time the period programmed using Flashing Relay Timer elapses, the relay output will change
position.
The flashing relay function may be assigned to any digital output using Output Configuration program
parameters.
The dual genset intermittent operation uses also the Disable Auto Start feature. Please review related
chapter for a detailed explanation of this feature.

Priority In Dual Genset Mutual Standby Operation:

It may be required that the dual genset system starts the same genset at every mains failure. This is
achieved using the PRIORITY input.
Any digital input may be assigned as Priority using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Priority signal may be a NO or NC contact, switching to either battery positive or battery negative. These
selections are made using the programming menu.
If a Priority input is defined, then the system will work in priority mode. If the priority signal is applied, the
unit will become master after each mains failure. If the priority signal is not applied, then the unit will
become the slave one and the other genset will start.

Please contact GRUPEL for a complete application

manual.

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37.8. MULTIPLE VOLTAGE AND FREQUENCY

The unit offers 3 sets of voltage and frequency protection limit values. The user is allowed to switch
between these 3 sets anytime.
This feature is especially useful in multiple voltage or frequency gensets for easy switching between
different operating conditions.
The switching to the second or third set of limit values can be done via digital input signal.

If switching is done with digital input signal, one of digital inputs has to be defined as “2nd Volt-Freq
Select” using “INPUT FUNCTION SELECT“program group.
If third set is used, the one of digital inputs has to be defined as “3 rd Volt-Freq Select” using “INPUT
FUNCTION SELECT“program group.
Below parameters are available for second voltage-frequency selection:
Nominal Voltage
Nominal Frequency
Nominal RPM
Genset Overcurrent Limit

37.9. SINGLE PHASE OPERATION

If the unit is used in a single phase electrical network, it is advised to select the topology as Single
Phase 2 Wires.
When the topology is set to Single Phase 2 Wires, then the unit will measure electrical parameters only
on phases L1 of genset and mains.
Voltage and overcurrent checks will be performed on phases L1 only.
Phases L2 and L3 parameters, as well as phase-to-phase voltages are removed from display screens.

37.10. EXTERNAL CONTROL OF THE UNIT

The unit offers total external control through programmable digital inputs. Any digital input may be
programmed for below functions:
- Force STOP mode
- Force AUTO mode
- Force TEST mode
- Disable Auto Start
- Force to Start
- Fault Reset
- Alarm Mute
- Panel Lock
External mode select signals have priority on mode buttons of the unit. If the mode is selected by external
signal, it is impossible to change this mode with front panel pushbuttons. However if the external mode select
signal is removed, the unit will revert to the last selected mode via pushbuttons.
It is also possible to lock the front panel completely for remote command.

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37.11. AUTOMATIC EXERCISER

The unit offers 7 independent automatic exercisers. The exercise operation may be done on a weekly or
monthly basis.
The start day and time of the exercise is programmable as well as its duration. The exercise may be done
with or without load following programming.
Program parameters related to the exerciser are:
Exercise start day and hour
Exercise duration
Exercise off_load/on_load
Please refer to the programming section for a more detailed description of the above parameters.
When the start day and hour of exercise has come, the unit will automatically switch to either RUN or
TEST mode. The engine will run. If the on_load exercise is selected then the load will be transferred to
the genset.
If a mains failure occurs during the off-load exercise, the load will not be transferred to the genset unless
the Emergency Backup Operation is allowed by setting the related program parameter to 1. Thus it is
highly recommended that the Emergency Backup mode enabled with off-load exerciser.
At the end of the exercise duration, the unit will switch back to the initial mode of operation.
If any of the mode selection keys are pressed during exercise, then the exercise will be immediately
terminated.
Using the weekly exercise mode and with suitable parameter setting, the unit may feed the load from the
genset during predefined hours of each day. This operation may be used in high tariff periods of the day.

37.12. WEEKLY OPERATION SCHEDULER

In most applications, the genset is requested to operate only in working hours. Thanks to the weekly
program feature, unwanted operation of the genset may be prohibited.
The scheduler is active only in AUTO mode. When the scheduler prevents genset operation in AUTO
mode, the AUTO led will flash.

When the scheduler prevents genset operation in

AUTO mode, the AUTO led will flash.

The scheduler consists of 144 programmable parameters, one for each hour in a week. Thus every hour
of the week may be independently selected as ON or OFF times.
These programmable parameters allow the genset to operate automatically only in allowed time limits.
The unit has a battery backed-up precision real time clock circuit. The real time clock circuit will continue
its operation even in power failures. The real time clock is precisely trimmed using the Real Time Clock
Adjust program parameter. For more details check the programming section.

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37.13. ENGINE HEATING OPERATION

Especially on engines without a body heater, or with a failing one, it may be desired that the genset
should not take the load before reaching a suitable temperature. The unit offers 2 different ways of engine
heating.
1. Timer controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 0. In this mode,
the engine will run during parameter Engine Heating Timer, and then the genset will take the load.
2. Timer and temperature controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 1. In this mode, at
first the engine will run during parameter Engine Heating Timer, then it will continue to run until the
measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature.
When the requested temperature is reached, the load will be transferred to the genset. This operation
mode may be used as a backup to the engine body heater. If the engine body is warm the heating will be
skipped.

37.14. ENGINE IDLE SPEED OPERATİON

It may be required that the engine runs at the idle speed for a programmed duration for engine heating.
The idle operation duration is adjusted with the parameter Idle Speed Timer. The idle speed will be set
by the governor control unit of the engine.
Any digital output may be assigned as IDLE output using Relay Definition program parameters.
The Idle speed operation is performed both in engine start-up and cool-down sequences. Low speed and
low voltage protections are disabled during idle speed operation.

37.15. ENGINE BLOCK HEATER

The unit is able to provide a digital output in order to drive the block heater resistor. The temperature
reference is the coolant temperature measured from the analog sender input.
The block heater output function may be assigned to any digital output using Relay Definition program
parameters.
The engine body temperature limit is adjusted using the parameter Engine Heating Temperature. The
same parameter is used for engine heating operation.
The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine
Heating Temperature. It turns off when the body temperature exceeds Engine Heating Temperature.

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37.16. FUEL PUMP CONTROL

The unit is able to provide a digital output function in order to drive the fuel pump motor.
The fuel pump is used to transfer fuel from the large capacity main tank (if exists), to the genset daily tank
which is generally integrated in the chassis and has a limited capacity.
The fuel level reference is measured through the analog fuel level sender. When the measured fuel level
falls below Fuel Pump Low Limit parameter, the fuel pump output function will become active. When the
fuel level reaches Fuel Pump High Limit parameter, the output function will become passive. Thus the
chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit
parameters.
If the Fuel Pump High Limit is not reached within Fuel Filling Timer duration, then the fuel pump will
stop for safety.
The fuel pump relay function may be assigned to any digital output using Relay Definition program
parameters.

37.17. GAS ENGINE FUEL SOLENOID CONTROL

The unit provides a special function for the fuel solenoid control of a gas engine.
The fuel solenoid of a gas engine is different from a diesel engine. It should be opened after the cranking
has been started and should be closed between crank cycles. The delay between the crank start and
solenoid opening is adjusted using the Gas Solenoid Delay program parameter.
The gas engine fuel solenoid relay function may be assigned to any digital output using Relay Definition
program parameters.

37.18. PRE-TRANSFER SIGNAL

The controller is able to provide a pre-transfer digital output function.
This function is designed for elevator systems, in order to bring the cabin to a floor and open cabin doors
before transfer.
The duration where this output is active is adjusted with the Pre-Transfer Delay parameter.

If the Pre-transfer Delay parameter is not zero, this will delay

transfers by the same amount.

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37.19. CHARGING THE ENGINE BATTERY

The controller offers an automatic charge cycle for the engine battery.
When the engine battery weakens, the genset will run automatically during programmed period in an
unloaded state in order to charge the engine battery, protecting it from total discharge when the genset
has not run for a long time.
Related parameters:
Battery Charge Run Voltage: If this parameter is different from zero and the engine battery voltage falls
below this limit then the controller will run the engine unloaded, in order to charge engine battery. The
running duration is determined by the Battery Charge Run Timer parameter.
Battery Charge Run Timer: This parameter determines the engine battery charge running duration. The
minimum run time is 2 minutes.
Emergency Backup: If this parameter if activated and the mains fails during engine battery charging run,
then the genset will take the load.

37.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS

The controller offers 16 externally controllable digital output functions.

These output functions have no effect in the operation of the unit; however they can be redirected to any
digital output, allowing remote control of functions or external devices.
The remote control of these outputs are enabled through Modbus, Modbus TCP/IP and Rainbow Scada
remote control functions.
The outputs are in 16 bits of the same Modbus register, placed at address 11559d.

Output statuses are kept in a non-volatile memory and are not

affected by power failures.

Please review the Modbus manual for more details.

37.21. COMBAT MODE

The controller offers a combat mode input function.

When a digital input is defined as Combat Mode and signal applied to this input, the controller will turn off
all led lamps and the backlight illumination 10 seconds after any key is pressed.
When a button is pressed, the illumination will be enabled for 10 seconds.

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37.22. RESETTING THE CONTROLLER

When necessary, the controller may be manually reset by holding the STOP button pressed for 30
seconds.
The manual reset will cause the hardware to be configured following new settings.
It is advised to proceed to a manual reset or power off/on cycle after every hardware configuration
modification.

37.23. AUTOMATIC CONNECTION TOPOLOGY DETERMINATION

The controller offers the capability of automatically determining the connection topology and setting the
voltage checks in accordance.
Related parameters are:
If this parameter is enabled, when the
engine runs, the controller will detect
Automatic Topology the connection topology automatically
- 0 1 0
Detection and will select alarm levels accordingly.
0: auto detect not enabled
1: auto detect enabled

If the automatic topology determination is activated by program parameter, when the engine runs, the
connection topology is tested to be one of below ones during “holdoff timer” period.
If below voltage conditions are met continuously during 3 seconds, then the topology is considered to be
determined.
If the topology cannot be determined during holdoff timer duration, then an “Unknown Topology”
loaddump is generated, and the engine stops after cooldown.

During topology determination phase, if the RUN button is held

pressed, the holdoff timer will not expire and the controller will
try to determine the topology as long as the RUN button is held
pressed.

This feature is especially useful for manual voltage adjustment after a new topology selection.

Available topologies to be determined are:

TOPOLOGY Voltage Overcurrent Limit Overload Limit

High Wye 314V > L1&L2&L3 > 182V Overcurrent limit x1 Overload limit x1
Low Wye 157 V > L1&L2&L3 > 92 V Overcurrent limit x2 Overload limit x1
High Zigzag 276 V > L1&L2 > 204 V Overcurrent limit x1 Overload limit x 2/3
Low Zigzag 136 V > L1&L2 > 84 V Overcurrent limit x2 Overload limit x 2/3

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37.24. ZERO POWER AT REST

In a manual genset, it is possible to reduce the current consumption of the unit down to true zero
Amperes, in order to prevent the battery from discharging.
For “zero power at rest operation”, an external relay and “wake-up” pushbutton is necessary.
A digital output should be set to ZERO POWER RELAY function. An external relay should be driven with
this digital output. The relay contact will feed the controller power supply.
Any digital output may be assigned as zero-power-relay output. Please refer to the relay function list for
the setup.

CONTROLLER
SUPPLY OUTx

Wake-Up Zero Power

pushbutton Relay

BAT+
The controller wakes-up on applying the power through the “wake-up” pushbutton. Then it will
immediately activate the zero power output which will cause the zero power relay to feed the controller.
If the engine is not run, or if the engine stops, a timer of 5 minutes will be counted. At the expiration of the
counter, the controller will deenergize the zero power relay which will cut the power supply. The controller
will wait in a zero-power state until the wake-up pushbutton is depressed again.

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38. MODBUS COMMUNICATIONS

This chapter is a brief description of the Modbus properties of

the controller. For a complete documentation please use “G-
545 Modbus Application Manual”

The unit offers the possibility of MODBUS communication through below carriers:
-RS485 serial port, with adjustable baud rate between 2400 and 115200 bauds
-MODBUS-TCP/IP through Ethernet port (10/100Mb)
-MODBUS-TCP/IP through GPRS (85/42kb), client mode through Rainbow Scada only

The MODBUS properties of the unit are:

-Data transfer mode: RTU
-Serial data: selectable baud rate, 8 bit data, no parity, 1 bit stop
-Modbus-TCP/IP: Ethernet 10/100Mb or GPRS Class 10.
-Supported functions:
-Function 3 (Read multiple registers)
-Function 6 (Write single register)
-Function 16 (Write multiple registers)

Each register consists of 2 bytes (16 bits). A larger data structure will contain multiple registers.

The Modbus communications requires a slave address to be assigned to each device in the Modbus
network. This address ranges between 1 and 240 and allows the addressing of different slave devices in
the same network.

Each device in the same RS-485 serial network must be

assigned a different slave address. Otherwise the Modbus
communications will not be performed.

Devices using Modbus-TCP/IP with different IP or port

addresses may use any slave address. It is advised to set
these slave addresses to the default setting which is 1.

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38.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION

Modbus Slave Address: may be set between 1 and 240

RS-485 Enable: must be set to 1 (or checkbox enabled)
RS-485 Baud Rate: selectable between 2400 and 115200 bauds. All devices in the same network must
use the same Baud Rate.

Selecting a higher baud rate will allow faster communication, but will reduce the communication distance.
Selecting a lower baud rate will increase the communication distance, but will cause slower response
times.
Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable.

38.2. PARAMETERS REQUIRED FOR MODBUS-TCP/IP VIA ETHERNET

Modbus Slave Address: may be set between 1 and 240. If only one unit is available in the same IP
address, it is advised to keep the default address (1).
Ethernet Enable: This parameter should be set to 1 (or checked) in order to enable the ethernet port.
Modbus TCP/IP Port: The usual setting is 502. However the unit is able to work on any port address.
User IP Mask: There are 3 mask registers available. The use of the registers are emphasized in the G-
545 User Manual. Please set the first mask as [Link] for the proper operation.
Ethernet Network IP: May be left as [Link] for automatic address claim or set to a value in order to
claim a defined address.
Ethernet Gateway IP: Should be set in accordance with your local switch configuration.
Ethernet Subnet Mask: Should be set in accordance with your local switch configuration.

38.3. DATA FORMATS

16bit variables: These variables are stored in a single register. Bit_0 denotes the LSB and bit 15
denotes the MSB.
32 bit variables: These variables are stored in 2 consecutive registers. The high order 16 bits are in the
first register and the low order 16 bits are in the second register
Bit arrays: Arrays larger than 16 bits are stored in multiple registers. The LSB of the first register is bit_0.
The MSB of the first register is bit_15. The LSB of the second register is bit_16. The MSB of the second
register is bit_31, and so on.

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Below is a shortlist of available Modbus registers. For complete register map please refer to G-545
Modbus Application Manual.

ADDRESS R/W DATA COEFF. DESCRIPTION

(decimal) SIZE
8193 W 16bit x10 Pushbutton simulation
BIT [Link] Stop button
BIT [Link] Manual button
BIT [Link] Auto button
BIT [Link] Test button
BIT [Link] Run button
BIT [Link] GCB button
BIT [Link] Menu+ button
BIT [Link] Menu- button
BIT [Link] Up button
[Link] Down button
[Link] Long pressed
[Link] Very Long Pressed
10240 R 32bit x10 Mains phase L1 voltage
10242 R 32bit x10 Mains phase L2 voltage
10244 R 32bit x10 Mains phase L3voltage
10246 R 32bit x10 Genset phase L1 voltage
10248 R 32bit x10 Genset phase L2 voltage
10250 R 32bit x10 Genset phase L3 voltage
10252 R 32bit x10 Mains phase L1-L2 voltage
10254 R 32bit x10 Mains phase L2-L3 voltage
10256 R 32bit x10 Mains phase L3-L1voltage
10258 R 32bit x10 Genset phase L1-L2 voltage
10260 R 32bit x10 Genset phase L2-L3 voltage
10262 R 32bit x10 Genset phase L3-L1 voltage
10264 R 32bit x10 Mains phase L1 current
10266 R 32bit x10 Mains phase L2 current
10268 R 32bit x10 Mains phase L3 current
10270 R 32bit x10 Genset phase L1 current
10272 R 32bit x10 Genset phase L2 current
10274 R 32bit x10 Genset phase L3 current
10276 R 32bit x10 Mains neutral current
10278 R 32bit x10 Genset neutral current
10292 R 32bit x10 Mains total active power
10294 R 32bit x10 Genset total active power
10308 R 32bit x10 Mains total reactive power
10310 R 32bit x10 Genset total reactive power
10324 R 32bit x10 Mains total apparent power
10326 R 32bit x10 Genset total apparent power
10334 R 16bit x10 Mains total power factor
10335 R 16bit x10 Genset total power factor
10338 R 16bit x100 Mains frequency
10339 R 16bit x100 Genset frequency
10341 R 16bit x100 Battery voltage
10361 R 16bit x10 Oil pressure in bars (multiply by 14.50 to for psi)
10362 R 16bit x10 Engine temp in °C (multiply by 1.8 then add 32 for °F)
10363 R 16bit x10 Fuel level in %
10364 R 16bit x10 Oil temp in °C (multiply by 1.8 then add 32 for °F)
10365 R 16bit x10 Canopy temp in °C (multiply by 1.8 then add 32 for °F)
10366 R 16bit x10 Ambient temp in °C (multiply by 1.8 then add 32 for °F)
10376 R 16bit x1 Engine rpm

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ADDRESS R/W DATA COEFF. DESCRIPTION

(decimal) SIZE
10504- R 256bit - Shutdown alarm bits. Bit definitions are given at the end of the
10519 document.
10520- R 256bit - Loaddump alarm bits. Bit definitions are given at the end of the
10535 document.
10536- R 256bit - Warning alarm bits. Bit definitions are given at the end of the
10551 document.
10604 R 16bit - Unit operation status
0= genset at rest
1= wait before fuel
2= engine preheat
3= wait oil flash off
4=crank rest
5=cranking
6= engine run idle speed
7= engine heating
8= running off load
9= synchronizing to mains
10= load transfer to genset
11= gen cb activation
12= genset cb timer
13= master genset on load,
14= peak lopping
15= power exporting
16= slave genset on load
17= synchronizing back to mains
18= load transfer to mains
19= mains cb activation
20= mains cb timer
21= stop with cooldown
22= cooling down
23= engine stop idle speed
24= immediate stop
25= engine stopping
10605 R 16bit - Unit mode
0= STOP mode
1= AUTO mode
2= MANUAL mode
3= TEST mode
10606 R 16bit x1 Genset operation timer. In various wait statuses, the genset
operation status will change at the expiration of this timer.
10610 R 16bit - Device hardware version information
10611 R 16bit - Device software version information
10616 R 32bit x1 Counter: number of genset runs
10618 R 32bit x1 Counter: number of genset cranks
10620 R 32bit x1 Counter: number of genset on load
10622 R 32bit x100 Counter: engine hours run
10624 R 32bit x100 Counter: engine hours since last service
10626 R 32bit x100 Counter: engine days since last service
10628 R 32bit x10 Counter: genset total active energy (kWh)
10630 R 32bit x10 Counter: genset total inductive reactive energy (kVArh-ind)
10632 R 32bit x10 Counter: genset total capacitive reactive energy (kVArh-cap)
10634 R 32bit x100 Counter: remaining engine hours to service-1
10636 R 32bit x100 Counter: remaining engine days to service-1
10638 R 32bit x100 Counter: remaining engine hours to service-2
10640 R 32bit x100 Counter: remaining engine days to service-2
10642 R 32bit x100 Counter: remaining engine hours to service-3
10644 R 32bit x100 Counter: remaining engine days to service-3

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39. SNMP COMMUNICATIONS

The unit offers the possibility of SNMP communication through its Ethernet port (10/100Mb)

The supported version of the SNMP is V1.0 and V1.1

Below parameters may be set to the Genset Operation Status

controller: Charge Input Voltage
Battery Voltage
Control Buttons
Oil Pressure
Remote Controlled Digital Outputs
Coolant Temperature
Fuel Level
Oil Temperature
Below parameters may be read from the
Canopy Temperature
controller:
Ambient Temperature
Mains voltages (L1, L2, L3, L12, L23, L31) Engine RPM
Mains Currents (I1, I2, I3, IN) Total Genset Cranks Counter
Mains Active Power (L1, L2, L3, Total) Total Genset Runs Counter
Mains Reactive Power (L1, L2, L3, Total) Engine Run Hours Counter
Mains Apparent Power (L1, L2, L3, Total) Total kW-h counter
Mains Power Factor (L1, L2, L3, Total) Total kVAR-h (inductive) Counter
Mains Phase Angle Total kVAR-h (capacitive) Counter
Mains Frequency Engine Hours to Service-1 Counter
Genset voltages (L1, L2, L3, L12, L23, L31) Days to Service-1 Counter
Genset Currents (I1, I2, I3, IN) Engine Hours to Service-2 Counter
Genset Active Power (L1, L2, L3, Total) Days to Service-2 Counter
Genset Reactive Power (L1, L2, L3, Total) Engine Hours to Service-3 Counter
Genset Apparent Power (L1, L2, L3, Total) Days to Service-3 Counter
Genset Power Factor (L1, L2, L3, Total) Shutdown Alarm List
Genset Phase Angle Loaddump Alarm List
Genset Frequency Warning Alarm List
Genset Operation Mode Remote Controlled Digital Outputs

The SNMP MIB file is available at Grupel.

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39.1. PARAMETERS REQUIRED FOR SNMP VIA ETHERNET

Modbus Slave Address: may be set between 1 and 240. If only one unit is available in the same IP
address, it is advised to keep the default address (1).
Ethernet Enable: This parameter should be set to 1 (or checked) in order to enable the ethernet port.
Modbus TCP/IP Port: The usual setting is 502. However the unit is able to work on any port address.
User IP Mask: There are 3 mask registers available. The use of the registers are emphasized in the G-
545 User Manual. Please set the first mask as [Link] for the proper operation.
Ethernet Network IP: May be left as [Link] for automatic address claim or set to a value in order to
claim a defined address.
Ethernet Gateway IP: Should be set in accordance with your local switch configuration.
Ethernet Subnet Mask: Should be set in accordance with your local switch configuration.

39.2. SNMP TRAP MESSAGES

When a fault case occurs or the genset runs or the genset takes the load or the genset unloads or the
genset stops, an automatic SNMP TRAP message is send to the SNMP Client.
In order to enable SNMP TRAP messages, the Client has to send at least one SNMP request message to
the controller in order to inform it about its IP address. The controller records the address of the last
SNMP Client and sends trap messages to this address.

The SNMP TRAP message message contains the controller operating mode, engine status and the alarm
list.

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40. DECLARATION OF CONFORMITY

The unit conforms to the EU directives

-2014/35/EC (low voltage)
-2014/30/EC (electro-magnetic compatibility)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)

The CE mark indicates that this product complies with the European requirements for safety,
health environmental and customer protection.

UL / CSA Conformity:
-UL 6200, Controls for Stationary Engine Driven Assemblies (Certificate # - 20140725-E314374)
-CAN/CSA C22.2 No. 14-13 – Industrial Control Equipment

41. MAINTENANCE

DO NOT OPEN THE UNIT !

There are NO serviceable parts inside the unit.

Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

42. DISPOSAL OF THE UNIT

Following DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL

of 27 January 2003 on waste electrical and electronic equipment (WEEE) , this unit should be stored and disposed
separately from the usual waste.

43. ROHS COMPLIANCE

The european ROHS directive restricts and prohibits the use of some chemical materials in electronic
devices.

Following the “DIRECTIVE 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of
8 June 2011 on the restriction of the use of certain hazardous substances in electrical and
electronic equipment”, this product is listed in annex-I under category: “Monitoring and control
instruments including industrial monitoring and control instruments” and exempted from ROHS
directive.

However we are not using any ROHS uncompliant electronic components in the production. Only the
solder contains lead. The switching to unleaded solderin is in progress.

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44. TROUBLESHOOTING GUIDE

Below is a basic list of most often encountered

troubles. More detailed investigation may be
required in some cases.

The genset operates while AC mains are OK or continues to operate after AC mains are OK:

-Check engine body grounding.

-AC mains voltages may be outside programmed limits, measure the phase voltages.
-Check the AC voltage readings on the screen.
-Upper and lower limits of the mains voltages may be too tight. Check the parameters Mains Voltage
Low Limit and Mains Voltage High Limit. Standard values are 170/270 volts.
-The hysteresis voltage may be given to excessive. The standard value is 8 volts.

AC voltages or frequency displayed on the unit are not correct:

-Check engine body grounding, it is necessary.

-The error margin of the unit is +/- 2 volts.
-If there are faulty measurements only when the engine is running, there may be a faulty charging
alternator or voltage regulator on the engine. Disconnect the charging alternator connection of the
engine and check if the error is removed.
-If there are faulty measurements only when mains are present, then the battery charger may be failed.
Turn off the rectifier fuse and check again.

KW and cosΦ readings are faulty although the Amp readings are correct:

-Current transformers are not connected to the correct inputs or some of the CTs are connected with
reverse polarity. Determine the correct connections of each individual CT in order to obtain correct KW
and cosΦ for the related phase, and then connect all CTs. Please review chapter “AC CURRENT
INPUTS”

Short circuit outputs of unused Current Transformers.

When the AC mains fails the unit energizes the fuel solenoid, but does not start and OIL
PRESSURE EXISTS ! message is displayed:

The unit is not supplied with battery (-) voltage at the oil pressure input.
-Oil pressure switch not connected.
-Oil pressure switch connection wire cut.
-Oil pressure switch faulty.
-Oil pressure switch closes too lately. If oil pressure switch closes, the unit will start. Optionally oil
pressure switch may be replaced.

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The engine does not run after the first start attempt, then the unit does not start again and OIL
PRESSURE EXISTS ! message is displayed:

-The oil pressure switch closes very lately. As the unit senses an oil pressure, it does not start. When oil
pressure switch closes the unit will start. Optionally the oil pressure switch may be replaced.

When the AC mains fails, the engine starts to run but the unit gives START FAIL alarm and then
the engine stops:

-The generator phase voltages are not connected to the unit. Measure the AC voltage between
terminals GEN L1-L2-L3 and Generator Neutral at the rear of the unit while the engine is running. A
fuse protecting the generator phases may be failed. A misconnection may be occurred. If everything is
OK, turn all the fuses off, and then turn all the fuses on, starting from the DC supply fuse. Then test the
unit again.

The unit is late to remove engine cranking:

-The generator voltage rises lately. Also the generator remnant voltage is below 15 volts. The unit
removes starting with the generator frequency, and needs at least 15 volts to measure the frequency.
-The unit is also able to cut cranking from charge alternator voltage and oil pressure input. Please read
chapter “CRANK CUTTING”

The unit is inoperative:

Measure the DC-supply voltage between terminals BAT+ and BAT- at the rear of the unit. If OK, turn all
fuses off, then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

Programming mode can not be entered:

The program lock input disables programming mode entry. Disconnect the program lock input from
battery negative before modification. Do not forget to make this connection again to prevent
unauthorized program modifications.

Some program parameters are skipped:

These parameters are reserved for factory setting and cannot be modified.

AUTO led flashes and the genset does not run when mains fail:

The unit is in Weekly Schedule OFF time. Please check date and time setting of the unit. Please check
also Weekly Schedule program parameters.

The genset runs but does not take the load:

Check that the genset Yellow led is on steadily. Adjust genset voltage and frequency limits if necessary.
Check that the digital output-8 is configured as “Genset Contactor”
Check “Genset Contactor Timer” program parameter.
Check that a Genset Loading Inhibit input signal is not active. Check input functions. If an input is
configured as “Genset Loading Inhibit” then check the signal is not present at this input.

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