Gencon - 2 PDF

Discontinued Product
DSL
- electronic —
GmbH
Schiricksweg 2 41751 Viersen Tel.: +49 2162-40025 Fax: +49 2162-40035
www.dsl-electronic.com info@dsl-electronic.de
®
Hardware: GENCON II is a computing platform that combines comprehensive,
accurate and true RMS set of electrical measurements with control and
monitoring functions.
®
Software: GENCON II with a special software is an extremely powerful generator-set
control system for prime and for stand-by (emergency) power generation. The
control system includes all the facilities necessary for paralleling a generator-
set with the mains (the electric utility) as well as with other generator-sets.
Tolerance: Ground or earth, analog or analogue, emergency generator-set or standby

generatorset, the utility or the mains... does it really matter?
Disclaimer: We believe that this document is a faithful description of the system. We

may have erroneous information and we reserve the right to change the
specification without notice. We do not assume any liability arising out of
the application or use of the product or any circuit described herein.
Table of Contents
Features .......................................................................................................................I
Abstract .......................................................................................................................II
Outlook........................................................................................................................II
Applications .................................................................................................................1
Single generator-set applications.......................................................................1
#1 American standby.............................................................................1
#2 Euro standby ....................................................................................2
#4 Paralleling with the mains .................................................................2
#5 Euro standby with soft load transfer .................................................3
#6 Euro standby with soft mains return & paralleling with the mains......3
Multiple generator-set applications ...................................................................3
#3 Random access paralleling ................................................................3
#3 Load dependent start/stop sequencing ..............................................4
Hybrids .................................................................................................5
Augmented American standby....................................................5
Augmented Euro standby...........................................................5
Augmented Euro standby with soft mains return ........................5
#0 The generic configuration ............................................................................6
Miscellaneous ...................................................................................................7
Mechanical mode switches ....................................................................7
Dynamic export quota control ...............................................................7
Basic load control .................................................................................7
Non essential load release and re-entry.......................................7
Parallel genset automatic start/stop ............................................7
Handling motor driven contactors (breakers).........................................8
CAVEATS............................................................................................8
GENCON II -- The main unit.......................................................................................8
Attention! .........................................................................................................8
Front panel .......................................................................................................8
LED's....................................................................................................8
STOP and RESET push buttons............................................................8
Liquid Crystal Display navigation primer ...............................................9
Common menu options .....................................................................................9
OVERVIEW.........................................................................................9
REPORT ..............................................................................................10
COMMAND.........................................................................................10
OFF mode .................................................................................10
MANual mode...........................................................................10
AUTOmatic mode .....................................................................11
EXPORT...................................................................................11
SEQUENCE .............................................................................11
SET-CLOCK.............................................................................11
SET-COUNT ............................................................................11
MEASURE...........................................................................................11
ENGINE ...................................................................................11
GENERATOR ..........................................................................12
OVERVIEW..................................................................12
POWER+PF ..................................................................12
GEN ΦA, GEN ΦB and GEN ΦC .................................12
GEN ΦΦ .......................................................................12
MAINS or BUS.........................................................................12
SYNCscope...............................................................................12
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IN 1..16 .................................................................................... 13
SYSTEM .................................................................................. 13
SET-UP................................................................................................ 13
HELP ................................................................................................... 13
The SET-UP menu........................................................................................... 13
Attention! ............................................................................................. 13
DELAYS.............................................................................................. 14
SET-POINTS ....................................................................................... 16
OPTIONS ............................................................................................ 18
IN 1..16................................................................................................ 21
BASICS ............................................................................................... 21
FACTORY........................................................................................... 21
Tuning up the paralleling switch gear................................................................ 22
Getting started...................................................................................... 22
Tuning up the feedback controls ........................................................... 22
Synchronizer tune up tips .......................................................... 23
Paralleling with the mains tune up tips ....................................... 23
Multiple set paralleling tune up tips ........................................... 23
Rear panel........................................................................................................ 24
V1,V2,V3,V4 - Voltage inputs ............................................................. 24
I1,I2,I3 - Current transformer inputs..................................................... 24
BATTERY & Ground Noise Hazards!.................................................. 24
Magnetic Pickup Input.......................................................................... 25
ANALOG OUT.................................................................................... 26
PWM OUT........................................................................................... 26
RS-485 serial port................................................................................. 26
AUXILIARY I/O ................................................................................. 27
Dip-switches......................................................................................... 27
RELAYS #1, #2 and #3........................................................................ 27
Error messages................................................................................................. 27
GENCON II dimensions................................................................................... 30
IOB1 -- Auxiliary I/O board......................................................................................... 31
Attention!......................................................................................................... 30
General ............................................................................................................ 31
Input channels .................................................................................................. 31
Output channels ............................................................................................... 32
IOB1 dimensions.............................................................................................. 33
AVRx -- A universal voltage regulator interface........................................................... 33
AVRx dimensions ............................................................................................ 33
Block diagram.................................................................................................. 33
Operation......................................................................................................... 34
Remote control and monitoring.................................................................................... 34
Software maintenance.................................................................................................. 35
Text editing...................................................................................................... 35
Software down loading..................................................................................... 35
Automatic text translation ................................................................................ 35
Reading the EEPROM ..................................................................................... 36
Writing the EEPROM -- The Fast Way! ........................................................... 36
EMC questions for the control panel builder ................................................................ 36
Installation Diagram..................................................................................................... 37
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Features
GENCON® II, running the STANDBY V2.3C software, is a complete control system for
measurement, monitoring and control of synchronous and asynchronous (induction) generators.
Its applications include: 1. Automatic mains failure standby (emergency),
2. Paralleling with the mains,
3. Paralleling multiple generator-sets.
The GENCON® II control system, whilst so light and small,…

♦ Performs high accuracy (0.5%) and true RMS set of measurements.
♦ Includes feedback control loops for automatic synchronization, for sharing a common load
active/kW & reactive/kVAr components proportionally among up-to eight paralleling generator-
sets, and for exporting power to the mains with programmable loading and unloading ramp.
♦ Displays 29 electrical parameters of 3Φ Φ , wye (star) connected, generators: Volts (L-N, L-L),
Amps, kVA's, kW's, kVAr's, kWH, Power-factors, Frequency (0.01 Hz resolution) and Harmonic
Distortions. In-built galvanic isolation allows direct connection to the generator phases with high
degree of transient protection (IEEE 587 class C). Currents are read by 5A current transformers.
♦ Displays 3 parameters of the bus/mains: Volts, Frequency and Harmonic distortion.
♦ Displays the Battery Volts, the Engine Speed and the Elapsed Run Time.
♦ Displays during synchronization the frequency slip, the phase shift and the voltage difference
between the generator and the bus/mains -- ie no need for a synchroscope.
♦ Continuously monitors the incoming stream of measurements to detect any irregularity:
Engine Over-Speed, Battery Over or Under Voltage, Generator Over or Under Voltage, Generator
Over or Under Frequency, Generator Overcurrent (with inverse time constant), Generator Reverse
Power, Generator Loss of Excitation, Excessive Harmonic Distortion, Mains Failure and more!
♦ Complies with the American stand-by generator-sets code NFPA 110 level 1.
♦ Provides for European stand-by generator-sets an integral Automatic Transfer Switch (ATS)
logic, ie that controls the mains ⇔ genset changeover contactors.
♦ Up-to 8 generator-sets can run in parallel with random access to the bus: The generator-set that
builds its voltage first is connected without delay to the (dead) bus. The others join, one by one,
after synchronization. The gensets can start and stop automatically according to the bus load --
the user can change their start/stop sequence from any controller panel!
♦ Provides on the LCD a clear genset activity report including display of timers countdown.
♦ Logs warning and shutdown messages, with a time tag, in memory.
♦ Facilitates adjustment of the numerous parameters (delays, set-points, options…) from the front
panel key-pad or from a remote PC. The adjustment process is self-explanatory -- there is no need
to carry the manual around! Passwords limit access to important user commands and to sensitive
installation parameters.
♦ Operates in a wide battery voltage range. Withstands even a high voltage LOAD DUMP#1 !!!
♦ Operates in a wide temperature range, from -20°C to +70°C.
♦ Has a sealed fascia panel (IP65) that protects it from dust and from splashing.
♦ Provides a "duplicate" control panel, up-to 1,200 meters away, on an IBM compatible PC console,
through the RS485 communication LAN. Eight control panels can be displayed simultaneously to
monitor all the paralleling sets in the system. Easy user interface through mouse (8) clicking.
♦ Provides multilingual support -- all the LCD commands and messages are user translatable!
#1 A phenomenon that occurs when the battery open circuits while the engine is running.
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Abstract
The controller is made of three parts:
GENCON II This is the main unit that performs all computations, measurements, paralleling and
communication. Standard models nominal line to neutral Vac: 120, 127, 220, 240 and 277.
IOB1 This is an auxiliary 16 input and 8 output relay board that is mounted on a DIN rail inside the
control cubicle. It takes care of engine management (eg fuel-solenoid), handles external alarms
(eg low oil pressure), etc. Standard models nominal battery Vdc: 12 and 24.
AVRx This is a small interface circuit between the main unit and the generator's (alternator) automatic
voltage regulator (AVR). It is required for voltage-matching during synchronization and for
reactive power (kVAr) control when in parallel.
Outlook
There are many situations that can be handled best by operating two or more generator sets in parallel on a
common bus. Typical reasons are --
Reliability: In a standby system, when there is a mains failure, all generators in the system are started. The
probability of having a generator start and achieve nominal voltage and frequency is increased
according to the number of sets available.
Flexibility: Maintenance operations can be performed without having to shut down the whole system.
Economy: When the loads are expected to expand substantially, the initial investment is minimized by
installing one smaller generator set, and then adding more sets in parallel as the loads increase.
The number of generator sets running can change according to the load. In contrast, having one
large genset run under light load conditions accelerates engine wear.
There are reasons to let a single generator set also have switch gear for paralleling with the mains --
Reliability: A standby generator set with a paralleling switch gear, when the mains supply is restored, can
transfer the load back to the mains smoothly without the consumers having to undergo a
(second) power cut.
Flexibility: Exercising standby generator sets under load does not interrupt the consumers supply.
Economy: Exporting to the mains lines can reduce the peak kilowatt demand of a facility at high tariff
hours. Also, when an engine heat recovery system is installed (Combined Heat & Power), the
generator set can export power through the mains lines to a local community and reach high
overall efficiency.
With all these good reasons to use paralleling, for a given project kW requirements, the decision whether to opt
for paralleling depends to a large extent on the following costs' ratio:
Control Equipment + Design/Installation/Commissioning Man-Hours

kW Generating Set
The GENCON II is designed to bring this ratio as low as possible with present day electronics.
Each numerator factor is carefully optimized:
Equipment: The generator set controller takes complete care of measurement, engine management,
protection and paralleling. Virtually nothing but an electric governor and an AVR is
additionally required.
Design: Numerous delays, set-points and options (parameters) adapt the controller's software to suit
any application. Software programming skills are not necessary.
Installation: Compact design and unprecedented integration of functions, which are "interconnected" by
software, makes wiring extremely simple (see the installation diagram).
Commissioning: With a built in measurement system, one can find wiring mistakes easily, eg incorrect phasing
of a CT. As fault messages are logged in memory in plain language, marked with the time of
their arrival, one does not confuse a "cause" with a "result". The large stock of parameters is
edited using the controller's own LCD and keypad. Each parameter value is displayed with a
short explanation -- no need to consult the manual each step.
The result: Paralleling is no longer the realm of heavy kW genset projects.
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Applications3
It is obvious that a switchboard design depends on the generator-set Normal Source Transfer
use: prime, standby, mains peak demand lopping (shaving), etc. Switch
However, the difference in the scope of the switchboard design between Loads
the continents is less known. Here is a block diagram of a classic
standby set:
G
• In the USA, the transfer switch function is normally implemented by
Emergency Source
an independent device, the Automatic Transfer Switch (ATS):
Detecting power failure, triggering the engine to start, transfer of load to the generator after build up of
voltage and frequency, re transfer to normal source when power is restored and engine shutdown, are all
handled by the ATS. The genset switchboard does not include these functions.
• However, particularly in Europe, all these functions are normally included in the genset switchboard.
Typically the switchboard with two contactors directly implements the load transfer (called the changeover
contactors).
The Americans claim that their approach is more reliable…
The Europeans claim that their approach is more economical…
GENCON II does not take sides -- It supports both traditions and its large number of parameters (delays, set
points,…), all adjustable from the front panel, make it easy to adapt to any application.
Genset applications are built around the following seven configurations:
YES NO
GENERIC?
NO YES
#0 PARALLEL?
NO YES NO YES
ATS? ATS?
NO YES NO YES
#1 #2 COGEN? COGEN?
#3 #4 #5 #6
Abbreviation SET-UP\OPTIONS Description

GENERIC Generic Configure? Is contactors' switching under external control?
PARALLEL Parallelin System? Are the synchronizer and the load-sharing functions active?
ATS Mains Standby ATS? Does the relay K#8 control the mains contactor?
COGEN Cogeneration Mode? Will the genset parallel with the mains continuously?
The generic configuration, #0, is designed for the "special projects" department. Access is given to all the
GENCON II functions, but the "glue logic", particularly control over the contactors (breakers), is handled by
an external logic device, a PLC usually.
The configurations #1..#6, however, constitute complete solutions, including control of the contactors.
The following description of the applications assumes that the controller is in AUTO mode and that no
shutdown fault is pending.
Single generator-set applications

#1 American standby
The controller starts the genset immediately when its In#1 input K#7
becomes active. When the genset is ready for load the relay K#7 is
energized, the contactor is closed and the genset takes the load. When
In#1 G ATS or LOAD
In#1 is deactivated, K#7 is de energized and the genset stops after a
cooling off period. Momentary activation of In#2 starts the genset for
a test without load session (ie K#7 is not energized).
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#2 Euro standby
The controller monitors the voltage and frequency of one phase of the mains K#8
by its V4 input (for 3 phase protection the external relay should disconnect Mains Contactor
V4 input on a mains failure). On a mains failure the controller energizes
relay K#8 which, through a normally closed#1 contact, opens the mains K#7
LOAD
contactor. After a predetermined time delay the genset is started. When the V4
genset is ready for load, the relay K#7 is energized and its normally open In#1 G
contact closes the generator contactor. When the mains power is restored, Gen Contactor
after a predetermined time, the load is transferred back to the mains. To protect the load (eg synchronous
motors), a time delay is introduced between the load power cut and load power re connection. In this
configuration the two contactors are electrically interlocked (and sometimes mechanically interlocked) to
prevent simultaneous engagement.
An active In#1 input starts the genset. When the genset is ready for load the relay K#8 is energized and the
mains contactor opens, there is a time delay and then the relay K#7 is energized and the genset takes the load.
Momentary activation of the In#2 input starts the genset for a test without load session.
#4 Paralleling with the mains
Note: This configuration also supports induction (asynchronous) generators. LOAD
See in SET-UP\OPTIONS the parameter Generator Syn|Asy. K#7
The genset starts immediately on an active In#1 input. The genset is
synchronized with the mains. When the voltage and phase of V1 (generator) In#1 G
are sufficiently close to the voltage and phase of V4 (the mains), the relay K#7
is energized and parallel connection begins. The genset raises the amount of active (kW) and reactive (kVAr)
power it exports to the mains at a predetermined rate, until the export quotas are met. When the In#1 input is
deactivated, power export is reduced at a predetermined rate. When reaching zero the relay K#7 is de energized,
the generator contactor opens and the genset stops after a cooling off period:
Engine Active Power Output Generator Reactive Power Output
+ kW/Sec Ramp - kW/Sec Ramp + kVAr/Sec Ramp - kVAr/Sec Ramp

kW Export Quota kVAr Export Quota
Time Time
Sync with Mains Parallel Connection Cooling-off Sync with Mains Parallel Connection Cooling-off
In#1 ON In#1 OFF In#1 ON In#1 OFF
Momentary activation of the In#2 input starts the genset for a test without load session -- the genset is
synchronized with the mains but the relay K#7 is not energized.
When detecting loss of mains during paralleling, the relay K#7 is de energized and the generator contactor
opens. Loss of mains is detected within 100 ms, as follows:
1. PARALLEL LOAD SURGE: Built-in protection mechanism: A sudden load change is measured, larger than
the Parll kW Surge set-point. Response to load decrease is optional, see kW Drop=LoadSurge?.
2. PARALLEL MAINS FAIL: External protection: Low voltage is measured by V4 -- an external relay
disconnects V4 input.
The user can select export quotas within the genset ratings, ie Export-kW ≤ Rating-kW and
(Export-kW)² + (Export-kVAr)² ≤ (Rating-kVA)². See SET-UP\BASICS Xre and Xap.
In this configuration the genset is used to parallel and export power to the mains in order to reduce the
electricity supply tariff for peak loads. The electricity companies also surcharge consumers with low power
factor (PF). The user should know that improper choice of the export quotas can worsen the mains supply PF:
Suppose a plant load is 444 kVA at 0.9 PF, ie 400 kW & 193.7 kVAr. If the genset exports 200 kW only, ie the
mains still carries the full 193.7 kVAr load, it turns that the mains is supplying power at an uneconomic 0.72
PF. However, if the genset export quotas are 200 kW and 150 kVAr (using a 250kVA genset at 0.8 PF) the
mains is supplying power at an excellent 0.98 PF.
#1 In this way the mains is connected to the load when GENCON® II is without DC supply.
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K#8
#5 Euro standby with soft load transfer Mains Contactor
Unlike the configuration "#2 Euro Standby" here the changeover contactors
must not be interlocked. On the mains return, the genset is synchronized and K#7
LOAD
V4
goes into paralleling with the mains. The genset power is reduced at a
predetermined rate, gradually transferring the load back to the mains. When In#1 G
reaching zero genset power output, the relay K#7 is de-energized, the Gen Contactor
generator contactor opens and the genset stops after a cooling off period. The diagram on the left describes the
mains failure and return cycle for the genset kW output (the kVAr case is similar).
Engine Active Power Output Engine Active Power Output
- kW/Sec Ramp + kW/Sec Ramp - kW/Sec Ramp

Unknown Plant Load Unknown Plant Load
kW Export Quota
Time Time
Isochronous Sync Parallel Cooling-off Sync with Mains Parallel Isochronous Parallel Cooling-off
Governor with Connection Connection Governor Connection
Operation Mains Operation
Mains Failure Mains Return In#1 ON In#1 OFF
When the mains is available, an active In#1 input starts the genset immediately. Before the genset takes the full
plant load it reaches through paralleling a user selected export power quotas.
Momentary activation of the In#2 input starts the genset for a test without load session -- The genset is
continuously synchronized with the mains but there is no load transfer.
In this configuration the genset stays in parallel with the mains only for the brief time it takes to perform a
smooth power transfer (called "occasional paralleling"). Most electricity boards are more lenient in approving
an installation of this sort than approving continuous paralleling with the mains.
#6 Euro standby with soft mains return & paralleling with the mains
This configuration provides an automatic mains failure standby operation K#8
with one power cut only as in configuration #5. Mains Contactor

Active In#1 input starts the genset for continuous paralleling with the mains
as in configuration #4. K#7
LOAD
When detecting loss of mains during paralleling, the relay K#8 is energized, V4
the mains contactor opens and the genset remains with the load. Loss of In#1 G
mains is detected within 100 ms, as follows: Gen Contactor
1. PARALLEL LOAD SURGE: Built-in protection mechanism: A sudden load change is measured, larger than
the Parll kW Surge set-point. Response to load decrease is optional, see kW Drop=LoadSurge?.
2. PARALLEL MAINS FAIL: External protection: Low voltage is measured by V4 -- an external relay
disconnects V4 input.
Multiple generator-set applications

Up to 8 generator-sets can operate in parallel on a common bus. Their ratings need not be equal.
The controllers coordinate their operation by communicating through their RS485 local area network (LAN).
The LAN maximal length, end to end, is 1,200 meters.
An IBM compatible PC can be connected to the LAN: The program, REMOTE.EXE, creates virtual duplicates
to all the controllers' front panels, display and keys, simultaneously on the PC screen.
#3 Random access paralleling
All the controllers use configuration #3. The controllers synchronize the genset phase, measured by V1 input,
with the bus phase, measured by V4 input.
The gensets start by activating their In#1 inputs. If the bus is dead, the first genset is connected without delay.
Other gensets are synchronized with the bus before connecting them, one by one, to the bus. The K#7 relays
control the generator to bus contactors. The K#8 relays follow K#7 with a time delay and can be used to ensure
some time of paralleling on the bus without load.
The gensets share the load active (kW) and reactive (kVAr) components proportionally, ie each genset
contributes an equal share of its kW and kVAr ratings. The genset connecting first to the (dead) bus is called
the "master" genset. Other gensets that are in parallel on the bus are called the "slave" gensets. If the "master"
genset is disconnected from the bus, immediately one of the "slave" gensets becomes a "master" genset. The
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voltage and frequency of the bus are determined by the A.K#7
"master" genset governor and AVR independent

characteristics. The "slave" gensets however by continuously A.In#1 G1
varying the governor and AVR external controls make the A.V4 F= (A.K#8 and B.K#8) or
"slave" gensets load share exactly match the load share of the
(B.K#8 and C.K#8) or
"master". B.K#7 (C.K#8 and A.K#8)
The figure describes a three genset system with controllers A,
B and C. The bus to load contactor is closed only if the bus is B.In#1 G2 LOAD
powered by at least two gensets. B.V4
#3 Load dependent start/stop sequencing GENERATORs
C.K#7
In power plants based on paralleling gensets it is often BUS
required to start and stop gensets automatically according to C.In#1 G3

the plant load. If all the gensets have equal kW rating, the
Parall Auto Start option in configuration #3 provides an all C.V4
software solution. If there are only two gensets this option can still be used even if the ratings are different, see
example 2. The power plant operator can define the gensets' starting/stopping sequence from any controller
panel via the SEQUENCE command.
The following rules determine when the system starts and when it stops a genset. The word "system" means the
collection of all the controllers that are connected to the RS485 network -- there is no dedicated "managing
computer."
Denote the gensets' Xre: Rated kW as one unit of power (100%). Denote also by:
λ The power that each paralleling genset contributes. Thus, (1−λ) is the spare genset power capacity.
Ν The number of gensets that run in parallel. Thus, (1−λ)∗Ν is the spare system power capacity.
α The set-point +%kW/Xre→ Start, usually the same value is defined in all the controllers.
β The set-point +%kW/Xre→ Stop, usually the same value is defined in all the controllers and α<β.
1. One genset starts when the condition (1−λ)∗Ν ≤ α exists for Parll Start time.
The genset starts immediately when (1−λ)∗Ν ≤ 0, eg when λ ≥ 1 the system is near collapse.
2. One genset stops when the condition (1−λ)∗Ν ≥ 1+β exists for Parll Stop time. Ie, giving up one unit of
spare system power capacity still leaves the system with at least β spare units.
3. Another genset can start or stop only after LS SettlingTime delay following a previous genset change of
state (time is required to re-distribute the load evenly).
Example 1:
A plant has 3 gensets, rated 80 kW each. Assume that all the gensets can in less than 20 seconds start and
synchronize. Assume also that it is unlikely for the load to increase by more than 20 kW in 30 seconds.
Let α ≡ +%kW/Xre→ Start = 25%, Parll Start = 0'10"0, β ≡ +%kW/Xre→ Stop = 50%, Parll Stop = 1'00"0.
Suppose that all the conditions to start gensets automatically exist…, that the bus is dead and that the gensets
operating sequence (the controllers ID numbers sequence) is →1→2→3:
Genset number 1 starts immediately because no genset is on load, ie Ν = 0. Suppose that the load is 64 kW, ie
the system's λ is 80%. After 10 seconds genset number 2 starts and connects to the bus after synchronization.
The system's λ becomes 40% (the load needs to fall below 40 kW for 1 minute to stop this genset). If one
changes now the sequence to →3→2→1 (by an exchange 1,3 command) genset number 3 immediately starts
and one minute after genset 3 connects to the bus genset 1 stops.
The load must be at least 140 kW for 10 seconds to start the third genset…
Example 2 (a special case):
A plant has 2 gensets: G1 rated X1 = 800 kW and G2 rated X2 = 500 kW. If only one genset is running, either
G1 or G2 according to the defined SEQUENCE, when its spare capacity falls below A = 100 kW we need to
start the second genset. When the two gensets run in parallel, we can stop one genset only if the remaining
capacity would be B = 300 kW minimum. Solution:
G1: α = A/X2 = 20%, β = (X1−X2+2∗B) / (X1+X2) = 69%.

G2: α = A/X1 = 13%, β = (X2−X1+2∗B) / (X1+X2) = 23%.
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Hybrids
A hybrid paralleling system is made of one (but only one) controller in configuration #1, #2, #4, #5 or #6 and a
number of controllers in configuration #3. The controllers in configuration #3 are said to be "permanent slaves"
-- the different controller is said to be a "permanent master". The use of the hybrid system is similar to the use
of the master controller. The slave gensets constitute an auxiliary power generation capacity that augments the
capacity of the master genset. The following operating rules are common to all hybrids:
1. When the master genset starts, all the slave gensets start#1,
2. When the master genset is taken off load, all the slave gensets are taken off load,
3. When the master genset stops, all the slave gensets stop,
4. The master genset is always first to be connected to the bus,
5. The slave gensets maintain the same load share of the master genset.
Hybrids will be demonstrated by a few practical examples:
A.K#7
CONFIG.#1
Augmented American standby
When A.In#1 starts genset G1, controller B automatically ESSENTIAL
A.In#1 G1
LOAD
starts up genset G2. G1 takes the essential load first.
Controller B, sensing the bus phase through V4,
synchronizes G2 with the bus and the two gensets share the B.K#7 B.K#8
essential load. After a certain time, through B.K#8 the non
essential load is also introduced and the two gensets share NON ESSENTIAL
CONFIG.#3 G2 LOAD
both loads proportionally. Since controller A does not use the
B.V4 GEN BUS
auto synchronizer function,
G1 does not require an electric governor, nor an AVR with external voltage control.
A.K#8
Augmented Euro standby MAINS CONTACTOR
In this example only the combined power of gensets G1 and G2 LOAD
can supply the load:
A.V4
Genset G1 is started either by a mains failure, detected by A.V4, A.K#7
or by an active A.In#1 input. Controller B automatically starts CONFIG.#2
B.K#8
up the genset G2 too. When G1 is ready for load it is connected A.In#1 G1
to the generators bus. Controller B then synchronizes the G2 B.K#7
phase it measures by V1 with the bus phase it measures by V4. GENs CONTACTOR
CONFIG.#3 G2
After a certain time of running in parallel without load, the relay
B.K#8 is energized and the plant load is taken and shared B.V4
GENs BUS
proportionally between the gensets. The Euro standby
changeover delay between A.K#7 and A.K#8 driven contactors exists also between B.K#8 and A.K#8 since as
soon as A.K#7 is de energized, according to the hybrids operating rules, B.K#7 and B.K#8 are also de
energized. Since controller A does not use the auto synchronizer function,
G1 does not require an electric governor, nor an AVR with external voltage control.
Augmented Euro standby with soft mains return
A.K#8
In this example only the combined power of gensets G1 and G2
MAINS CONTACTOR
can supply the load: Automatic mains failure standby is provided
LOAD
as in the previous example. When the mains returns, G1
synchronizes with the mains and in doing so "drags" G2 into
A.V4 A.K#7
synchronism with the mains. This works as follows: When G1
slightly increases its speed, it increases its load share. G2, being B.K#8
CONFIG.#5 G1
G1's slave, in trying to match his load share with his master,
B.K#7
raises its governor speed setting and so forth. When synchronism
GENs CONTACTOR
is reached, controller A de energizes the relay K#8 and the CONFIG.#3 G2
"hybrid" enters into paralleling with the mains. As G1 gradually B.V4
GENs BUS
reduces its active and reactive export, smoothly
transferring the load back to the mains, G2 does the same and at the same rate. When controller A de energizes
the relay K#7, controller B does the same, the two gensets cool down and stop.
#1 Unless it is not in AUTO mode or faulty.

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#0 The generic configuration
This configuration provides GEN ΦΑ BUS OR MAINS ΦΑ
maximal flexibility in the design of V1 V4

A B MODE
parallel systems. The controller RUN WITH LOAD In#1
operates under the command of a GENCON II
Œ OFF OFF SYNC W/O LOAD
PLC (Programmable Logic TEST W/O LOAD In#2 • OFF ON EXPORT
Controller) that also controls the Ž ON OFF LOAD-SHARE
system contactors. SLEEP (BYPASS) In#3
• ON ON SYNC WITH LOAD
The controller starts the genset when A In#15 K#7 READY FOR LOAD
activating its In#1 RUN or MODE
In#2 TEST command lines. An B In#16 K#8 IN SYNC
active In#3 SLEEP command RS485
overrides In#1 RUN and In#2 TEST

and stops the genset.
When the controller starts the genset following an In#1 RUN command, after build up of the genset oil-
pressure, frequency and voltage and waiting the Set Stabil Min time delay, it energizes the relay K#7 to indicate
that it is ready to accept load.
Note: The controller does not energize the relay K#7 following an In#2 TEST command! When removing the
In#2 TEST command the genset stops after a Test Delay.
The controller's operating mode is selected by In#15 and In#16 according to the above table. If the genset is not
ready for load, ie the relay K#7 is not energized, mode Œ must be selected by the PLC within a Contactor
Delay time or the GENERIC CONFIG ERROR shutdown is declared.
In modes Œ and • the synchronizer is active. By adjusting the genset speed and voltage it tries to match the
generator phase (V1) with the bus/mains phase (V4). The synchronizer energizes the relay K#8 any time it
succeeds in holding V1 within a Sync Window ° and Sync Window V distance from V4 continuously for
Sync Dwell Time.
In mode • the controller runs the genset in parallel with the mains. If the command In#1 RUN is active, the
genset power increases at Ramp +kW/Sec and Ramp+kVAr/Sec rates until reaching the Export Power Quotas
where they are maintained as long as the command is active. When removing the In#1 RUN command, the
genset power reduces at Ramp -kW/Sec and Ramp-kVAr/Sec rates until, when reaching zero, the relay K#7 is de
energized, indicating to the PLC that it needs to take the genset off load.
Note: Detecting PARALLEL LOAD SURGE in mode • de energizes the relay K#8 to warn the PLC against a
possible mains failure.
In mode Ž the controller runs the genset in parallel with other sets. If one of the other genset controllers is in
mode • or • that controller is "the master" and all the other controllers in mode Ž, "the slaves", try to match
their active (kW) and reactive (kVAr) load share with that of the master (ie in proportion to each genset
Xre: Rated kW and Xap: Rated kVA). If all the controllers are in mode Ž, one of them is nominated as the
master and its genset determines the speed and the voltage of the bus.
Example: Given a group of standby gensets sharing a common load, ie the controllers run in mode Ž under
In#1 RUN commands. The PLC needs to transfer the load softly from the generators to the mains:
1. The PLC selects one of the paralleling controllers and switches its V4 channel to measure the mains (before
V4 is connected to the bus). The PLC places the controller in mode •. This controller automatically
becomes the bus master and drags the other gensets into synchronism with the mains.
2. When the selected controller relay K#8 energizes, the PLC connects the bus with the mains and places the
controller in mode •.
3. The PLC places all the other controllers also in mode •.
4. The PLC removes all the In#1 RUN commands. The gensets power export gradually reduces. When each
genset power reaches zero the controller's relay K#7 is de energized. The PLC then opens the genset
contactor and places the controller in mode Œ.
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Miscellaneous
Mechanical mode switches
Traditional rotary mode switches can be constructed AUTO TEST
In#2 TEST W/O LOAD
using the IOB1 In#1/2/3 lines. See this figure: OFF
In#3 SLEEP
It is an alternative to the controller's OFF→AUTO, MAN
In#1 RUN WITH LOAD
AUTO→OFF, OFF→MAN and MAN→OFF
software commands. The rotary switch operates in AUTO mode only. It is also possible to reset the pending
faults by activating In#3 SLEEP, see the SleepClearsFaults? option.
Dynamic export quota control
When paralleling a generator-set with the mains, with the controller in configuration #4, it is often required to
prevent export of genset power to the grid. Indication of export to the grid can be obtained from a reverse power
relay that is installed on the mains. When the reverse power relay trips, it is required to decrease temporarily the
export quota.
kW Output
IOB1 input terminal In#16, receives this kW
CONFIG. #4 -- Paralleling With The Mains
QUOTA LIMIT indication: Full Export Quota IN THIS EXAMPLE In#16 IS ACTIVE WHEN THE
GENSET kW Output EXCEEDS THE DASHED LINE
An active In#16, after a kW QuotaDec time-delay,

decreases the kW export quota by a kW Quota Dec kW Quota Dec.
set-point
set-point value. An inactive In#16, after a

kW QuotaInc time-delay, increases the kW export In#16 is active
kW Quota Inc.
quota by a kW Quota Dec set-point value. In#16 is inactive set-point
The time-delays can be adjusted from 0 to 100

minutes. The set-points can be adjusted in 1 kW kW QuotaDec
time-delay
kW QuotaDec
time-delay
kW QuotaInc
time-delay
steps. Time
Basic load control

The controller monitors the system's load per rating ratio, ΣkW/ΣXre, in single and in parallel genset
applications. ΣkW is the total active load. ΣXre is the running sets total kW rating. If the option
R#1 Shunt|kW Load: is 1, RELAY#1 provides the following decisions based on the load ratio:
Non essential load release and re-entry
Case 1: The two set points satisfy: %kW/Xre→R#1 On < %kW/Xre→R#1 Off:
If the load ratio is ≤ %kW/Xre→R#1 On for R#1 Off→On time continuously, RELAY#1 is energized.
If the load ratio is ≥ %kW/Xre→R#1 Off for R#1 On→Off time continuously, RELAY#1 is de energized.
Dummy load control example:
It is required to introduce an artificial load to a lightly loaded genset and to remove this load once normal
loading returns. The dummy load is 20% of the rated kW.
Solution: Drive the artificial load contactor by RELAY#1 AND K#7 (ie both relays must be energized).
Set points: %kW/Xre→R#1 On = 15, %kW/Xre→R#1 Off = 40,
Delays: R#1 Off→On = 5'00"0, R#1 On→Off = 5'00"0.
When the engine load is for 5 minutes less than 15% of its rating the dummy load contactor is closed. When the
load is for 5 minutes more than 20% of the engine rating the dummy load contactor opens.
Parallel genset automatic start/stop
Case 2: The two set points satisfy: %kW/Xre→R#1 Off < %kW/Xre→R#1 On:
If the load ratio is ≥ %kW/Xre→R#1 On for R#1 Off→On time continuously RELAY#1 is energized.
If the load ratio is ≤ %kW/Xre→R#1 Off for R#1 On→Off time continuously RELAY#1 is de energized.
Example:
We are given two 100 kW gensets, G1 and G2, that can parallel on a common bus. Eg, the genset controllers
are in configuration #3 (random access paralleling). It is required that G1 operates alone if the load is 60 kW or
lower and that G2 is started automatically when the load is 80 kW or higher.
Solution: Activate In#1 RUN of the controller handling G2 by its RELAY#1 and set the set-points as follows:
%kW/Xre→R#1 On = 80%, kW Load→R#1Off Seite=12
30%.vonTime43 delays are set according to need.
Handling motor driven contactors (breakers)
In high current installations the use of spring charged motor operated contactors is common. ~
They are suited for auto-sync applications since they have a fast, ≈ 50 ms, closing action. M
This type of contactor has two notable characteristics:

~
1. Charging the spring by the motor takes a few seconds, no more than 5 seconds usually.
2. Unless an undervoltage release mechanism is installed, the contactor stays closed when AC is OPEN
removed from the motor.

This requires special handling because: CLOSE
1. Before a contactor can be closed, time must be given to charging the spring.
2. In European standby applications, time must be given to opening the mains contactor before
closing the generator contactor.
The solution is: Set the K#6 Engine|Gen On option to 1: The relay K#6 energizes when the generator builds
normal phase voltages. Delay the generator contactor closing command (through the relay K#7) by an
appropriate Set Stabil Min time delay. K#6 can then switch AC to the contactors' motors to charge the springs
or, where applicable, to open the mains contactor, long enough before the closing command is given.
If you want to verify the contactors' action set the Check Contactors and Motor Contactors options to 1.
CAVEATS
GENCON II reliability had already been proven in many installations. Nevertheless, in a good switchboard
design there should exist additional means, even duplicate, to prevent catastrophic consequences if there is a
single component failure -- GENCON II is a single component in this respect.
Since the probability of simultaneous failure of two, same function, protection devices whose failure mechanism
is statistically independent is the product of the failure probability of each, the effective overall system
reliability is greatly enhanced.
For a generator-set operating in parallel with the mains we recommend to add as a minimum a short-circuit and
a sync-check protection relays.
GENCON II -- The main unit

Attention!
The system supports three phase wye (star) connected generators (alternators). There are several controller
models to choose from according to the phase (line to neutral) voltage and current to measure#1. Be sure that
you are using the correct model!
The following models are standard#2:
Nominal AC phase voltage: 120, 127, 220, 240, 277.
Nominal AC phase current: 5 amps.
Note! The maximum voltage or current value that can be measured is approximately 120% times the nominal.
For example, a 220 nominal phase volts model can measure 260.4 volts maximum.
Front panel
LED's
The green LED should always blink. Fast blinking rate indicates existence of one or more of the following
conditions:
1. Normal engine oil pressure (ie In#5 OIL PRESS SHUT = OFF),
2. Engine speed greater than 60 RPM,
3. Gen frequency greater than 15 Hz.
Blinking red LED indicates detection of a shutdown fault.
Blinking yellow LED indicates detection of a warning fault.
Press RESET to clear fleeting faults.
STOP and RESET push buttons
• To stop the genset press the red STOP push-button. Shutdown fault is declared.
• To silence the audible alarm press the yellow RESET push-button once.
• To clear fleeting faults, if the audible alarm was silenced, press the RESET push-button again.
Pending faults cannot be cleared. If you press RESET, the faults will be re declared.
#1 Model variations affect one low cost PCB (A50-3). Re-calibration must follow its replacement.
#2 Contact factory for special requirements.
Seite 13 von 43
Liquid Crystal Display navigation primer
A user function can display on the LCD a set of measurements, it can execute a command or it can examine the
system status. To select a particular function, the LCD presents a multilevel menu of options: Each option
designates a function or it leads to a lower, more detailed, menu.
• A selected option is indicated by . The root menu
• Use the left← and right→ arrow push-buttons to select another option. OVERVIEW REPORT
• Press the ENTER push-button to call a selected option. COMMAND MEASURE
• Press ESC to return to a higher menu level. SET-UP HELP
• Press any push-button to return from a measurement display function Select Enter Esc
back to the menu mode.
Short-cuts:
1. Enter any menu. The option that is selected by default is the one that was selected before leaving the menu
by Esc . Example: You are using a function from the MEASURE menu and need to call a function from
COMMAND. Go up to the root (by Esc s) and down to COMMAND... To return to the MEASURE
function, go up to the root, select MEASURE and make a series of blind ENTER s.
2. When a fault is detected, if no push-button is pressed for 20 seconds or if ESC is pressed, REPORT is
automatically called. Quit REPORT and you are back at the previous location.
3. The push-button 0 directly calls the system OVERVIEW function. Quit OVERVIEW and you are back at
the previous location.
In this manual, references to functions are preceded with the path leading to them, beginning from the topmost
menu level, the root. For example, MEASURE\GENERATOR\POWER+PF shows how to call the function
that displays the genset power output and the power factors (cosφ). Ie starting from the root call MEASURE,
call GENERATOR and finally call POWER+PF.
Note!
The contrast of the LCD characters may change slightly with temperature (visibility is guaranteed from -20°C
to +70°C). For adjustment use the trimmer on the rear panel.
Common menu options

OVERVIEW
OVERVIEW is a useful display function. It explains what the controller is doing at any moment. Hence, in
addition to reaching OVERVIEW through the menu, you can call OVERVIEW by:
1. Pressing the 0 push-button at any menu level,
2. Pressing the ESC push-button at the highest (root) menu level.
The following are a few OVERVIEW "snapshots" taken during the operation of a Euro standby generator-set
installation with soft load transfer. See configuration #5 in Applications.
Snapshot 1 Snapshot 2
Line 1: Mode=Auto Tue 22:35 Mode=Auto Tue 22:37
Line 2: GenSet Stationary GenSet Stationary
Line 3: Mains OK Stand- Mains Fail Run:
Line 4: by! 0'05
Power Source: Mains Power Source: None!
Line 2: Set Runs with Load Set Runs with Load *
Line 3: Mains Failure Mains OK Stop:
Line 4: Run! 0'24
Power Source: GenSet Power Source: GenSet
Line 2: kW Down Ramp: 0'04 * Cooling-off: 2'45 *
Line 3: Mains OK Stand- Mains OK Stand-
Line 4: by! by!
Parallel Connection! Power Source: Mains
Seite 14 von 43
• Line 1 shows the controller operating mode and the clock. The clock appears only if the operator initialized
the clock by the COMMAND\SET-CLOCK.
• Line 2 shows the genset current activity and the remaining time to its end. Asterisk (*) indicates that the
genset is running in sync with the auxiliary phase V4, ie the mains phase A.
• Line 3 shows the genset command or countdown to the command start.
• Line 4 shows the automatic transfer switch status.
On the right is an OVERVIEW display of a generator-set test run triggered
by In#2. Line 3 indicates that the genset will stop in 2 minutes and 38 Mode=Auto Sat 22:15
seconds. Set Runs w/o Load
Test w/o Load: 2'38
Press any key...
On the right is an OVERVIEW display of a #3 configured controller serving Mode=Auto Sat 22:11
in multiple generator-set "random access paralleling" system. Set Runs with Load
Line 3 shows that the controller IOB1 input number 1 is active. In#01 Run with
Line 4 shows that other gensets are connected to the bus too. Load!
Parallel on Gen Bus
This OVERVIEW displays a controller in multiple generator-set parallel Mode=Auto Sat 22:26
system. Line 3 indicates that a system condition initiated the run command, Set Runs with Load
eg response to increase in the system load. System Run With
Load
REPORT Parallel on Gen Bus
HIGH WATER TEMP SHUT REPORT examines the log of messages.
Logged -- Sat 17:06 Each message includes the time it entered the log. If the clock was not
Clear message by running, "time ???" will appear. Most messages report some fault such as
Earlier Later Esc the example on the left.
• Press the ENTER button to remove the displayed message from the log.
• Press the left arrow button (←) to examine earlier logged messages.
• Press the right arrow button (→) to examine later logged messages.
• Press ESC to leave the REPORT function.
Note!
1. Every new message automatically calls REPORT.
2. Clearing a fault message does not "accept" or "clear" the fault. Use the RESET button to accept faults.
3. REPORT opens the log of messages showing the most recent message first. The log keeps the last 8
messages.
COMMAND
OFF mode
When in OFF mode, the monitoring system is active except for the relays R#3 AUDIBLE ALARM and K#4
AIR DAMPER. If Mains Standby ATS = 1, the mains contactor, irrespective of the mains (V4) status is closed
(ie K#8 MAINS CONTACTOR relay is off). It is possible to define the OFF mode as a warning fault.
OFFð ð AUTO
This function changes the operating mode to AUTO. User password may be required.
OFFð ð MAN
This function changes the operating mode to MAN. The genset immediately starts unless a shutdown fault
exists.
MANual mode
When in MAN mode, the genset runs unless a shutdown fault exists. It is possible to define the MAN mode as a
warning fault.
MANð ð OFF
This function changes the operating mode to OFF. The genset stops after cooling down if necessary.
LOAD-GEN
This function instructs the genset to take the load. User password may be required.
OFF-LOAD
This function instructs the genset running in MAN mode to remove the load.
Seite 15 von 43
AUTOmatic mode
When in AUTO mode, unless a shutdown fault exists, the genset…
1. Starts immediately on active In#1 RUN WITH LOAD signal.
2. Starts immediately on active In#2 TEST W/O LOAD signal. Stops after a time delay following In#2
deactivation.
3. Starts after delay following a mains failure (ie abnormal V4 voltage). Stops after delay following the mains
return. All this is provided that SET-UP\OPTIONS Mains Standby ATS = 1.
4. SLEEP is a special AUTO mode where genset start is disabled. It is selected by active In#3 SLEEP signal.
AUTOð ð OFF
This function changes the operating mode to OFF. User password may be required.
EXPORT
This function examines and changes the amount of active (kW)
and reactive (kVAr) power that is exported to the mains in genset p.f. = cos φ = kW / kVA
configurations #4, #5 and #6. The user may be required to enter
a password to change the export quotas. In configurations #4
kVA
and #6, export to the mains is continuous. In configuration #5, kVAr
export to the mains is maintained until ramp up brings the
φ
genset power output to the defined export quotas, the mains
contactor opens, and the load is completely transferred to the
kW
genset. See Applications for further details. The export quotas
must be within the genset kW and kVA ratings which are defined in SET-UP\BASICS. The user should be
familiar with the power right triangle relationship and with the generator derating characteristics at low power
factors (below 0.8 p.f.).
In configuration #4 it is possible to control dynamically the kW export quota through In#16.
See Applications for further details.
SEQUENCE
This function examines and changes the order in which controllers start and IDs 2 1 3
stop their gensets in response to an increase or decrease in their common This Gen-Set ID No=1
load. If any genset in the sequence cannot run, the next one is called. This Exchange Command 2,3
function is applicable to controllers in configuration #3 (random access Initial Sequence 0,0
paralleling) that have the option Parall Auto Start set.
In this example three controllers are connected to the RS-485 network. The genset whose Controller ID No is 2 runs all
the time. As the load increases genset 1 and later genset 3 join the bus. When the load decreases genset 3 is
disconnected from the bus first.
The exchange command propagates to all the network controllers. It is called up by the ENTER key (cancelled
by ESC ) followed by pressing 0. Entering the 2,3 exchange example results in the 3 1 2 sequence.
Entering 0,0 followed by the user password, selects the 1 2 3 4 5 6 7 8 sequence.
The sequence is stored in the EEPROM memory, ie it is not lost when disconnecting the battery.
SET-CLOCK
The clock has no memory.Set it up after switching on the battery to have messages logged with time.
SET-COUNT
This function is for changing the kW Hours and HoursRun counts. User password may be required.
MEASURE
ENGINE
Battery Volts: 13.8 Maximum reading is 40 volts

MPU: 1513rpm 50.39Hz Pickup reading. See SET-UP\BASICS Pick-up Teeth.
kW Hours: 00,001,234 Non-volatile count! See COMMAND\SET-kWH
HoursRun: 000,150:10 Non-volatile count! See COMMAND\SET-HOURS
Seite 16 von 43
GENERATOR
OVERVIEW
Gen Volts Amps Hz
ΦA 221 115 Phase-A RMS voltage, current and frequency
50.07 Phase-B…
ΦB 222 117 Σ Phase-C…+ total 3-phase TRUE power
kW
ΦC 220 125
69.9
POWER+PF
Total-Power COSφφ (PF) Generator

Total apparent power, Phase-A power factor
Σ kVA: 78.9 Φ A:
0.91 Total true power, Phase-B power factor
Total reactive power, Phase-C power factor
Σ kW: 69.9 Φ B:
0.88
Σ kVAr: 36.4 Φ C:
0.87
GEN Φ A, GEN Φ B and GEN Φ C

Phase-A (L-N) display example. Phase-B and phase-C are similarly displayed.
Gen Φ A Hz: Phase-A frequency
50.07 RMS voltage, % Total Harmonic Distortion
Volt: 221 %THD: 0.1 RMS current, Reactive Power
Amps: 115 kVAr: 10.5 Apparent Power, True power
kVA: 25.4 kW: 23.1
Note!
1. %THD is a measure of how "pure" the generator sine wave is. Consider Total Harmonic Distortion (THD)
above 2% as inappropriate for modern office equipment. Non-linear loads and ground faults at the generator
stator windings are major sources of harmonics.
2. Positive kVAr means that the current is lagging after the voltage. Normal.
3. Negative kVAr means that the current is leading the voltage. Abnormal!
GEN Φ Φ
Gen Volts Hz: 50.07 Generator phase-A frequency
Φ A: 221 Φ AB: 384 L-N voltage, L-L voltage
Φ B: 222 Φ BC: 383
Φ C: 220 Φ CA: 382
MAINS or BUS
This function displays V4 phase measurements.
Mains Φ A The caption is MAINS or BUS according to SET-
Frequency Hz: 50.14 UP\OPTIONS Mains Standby ATS
Voltage Vrms: 223
Distortion %THD: 0.1
SYNCscope
Synchroscope display example:
Gen Φ A v Mains Φ A V1 gen phase-A vs V4 mains phase-A
Freq Slip Hz: -0.07 V1 frequency - V4 frequency
Phase Shift °: 11 V4 to V1 angles: -180°..180°
Voltage Match: -2 V1 volts - V4 volts
Seite 17 von 43
IN 1..16
This function shows which IOB1 input channels are active. Use the left← and right→ push-buttons to move the
LCD cursor to any input channel column to find its name. The input channel type, "normally open" or
"normally closed", is defined by SET-UP\IN 1..16.
SYSTEM
This display function provides general system information. Function: Master
A "Master" function indicates that the genset, when in parallel with other Network IDs 12------
gensets, determines the bus voltage and frequency. ANALOG OUT (V): 1.50
PWM OUT (%): 50.0
A "Slave" function indicates that the genset, when in parallel with other
gensets, changes its governor speed and AVR voltage settings to make its active and reactive load-share match
those of the "Master" set.
Up to eight controllers can be connected to the RS-485 network. Each has a unique ID number (See
SET-UP\BASICS) in the range of 1..8. "Network IDs" identifies the controllers that are connected to the
network.
ANALOG OUT and PWM OUT respectively control the governor speed/fuel and the AVR voltage/excitation.
SET-UP
This menu defines the systems parameters: set-points, delays, etc. The parameters are non-volatile (unaffected
by battery disconnection). You need to know the installation engineer password to enter the menu. See Set-up
menu options for further details.
HELP
This function displays useful information.
• Press ENTER to browse through the display pages.
• Press ESC to exit.
The first line of display, "Standby V1.7h Aug 94", identifies the controller's operating software.
The SET-UP menu

You can set-up the system parameters from the front panel key-pad or from the remote PC console (running the
program REMOTE.EXE). The parameters are organized in several lists according to their type: Time-delays,
set-points, yes/no options, N/O or N/C definitions of the IOB1 inputs, basic definitions and factory calibration
data. Each parameter is presented with a brief text prompt. The parameters are stored on a non-volatile
memory. They are not affected by battery voltage disconnection.
Select a list and enter :
• The marker points to the parameter last examined.
• Use the left← and the right→ arrow push-buttons to get to the parameter that you want to edit.
• Press ESC to return to the SET-UP menu.
• Press ENTER to begin the parameter value editing. A cursor starts blinking at the value field. If you come
across the "Remove Write Protect" response, refer to the next paragraph ("Attention!").
• Press the left← and the right→ arrow push-buttons to move the LCD cursor across the value digits.
• Type any digit over a ± sign to invert it.
• Press ESC to quit parameter editing (this leaves the parameter value unchanged).
• Press ENTER to replace the parameter value with a new one. Choose different parameter value if you
come across the Value Outside Range! message.
Important! Begin the first SET-UP session with a careful review of the SET-UP\ BASICS parameters.
Attention!
There are two methods the installation engineer can protect the system parameters:
LEVEL 1: SET-UP entry password is ____. After typing the password you can leave and enter the SET-UP menu
for 15 minutes without being asked for the password again.
LEVEL 2: Parameters can be made "read-only" by SET-UP\OPTIONS Write Protect. This protection is
implemented in hardware -- IT IS RECOMMENDED TO USE THIS OPTION! To inhibit write
Seite 18 von 43
protect temporarily (ie effective until the battery voltage is removed) press the push-button 0 while
switching on GENCON II battery volts.
DELAYS
Time delay format is: xx'yy"z. xx denotes minutes, yy denotes seconds and z denotes tenths of a second.
Set Overspeed
The time delay from detecting engine overspeed to the declaration of fault.
Gen OverVolts
The time delay from detecting over-voltage in any gen phase (V1,V2,V3) to the declaration of fault.
Gen UnderVolts
The time delay from detecting under-voltage in any gen phase (V1,V2,V3) to the declaration of fault.
Gen OverFreq
The time delay from detecting over-frequency in gen phase A (V1) to the declaration of fault.
Gen UnderFreq
The time delay from detecting under-frequency in gen phase A (V1) to the declaration of fault.
G 2x OvCurr
The time delay before declaring an over-current fault in each channel
Τ · Is
I1, I2 or I3 is inversely proportional to the phase current I: Time-Delay =
I − Is
Is is the current level that is defined in SET-UP\SET-POINTS.
T, this parameter, is the time-delay that corresponds to I = 2⋅⋅ Is (substitute in the formula and check).
However, note that this formula is correct only for currents within the controller measurable range, which is
approximately 5.9 Amps ∗ CT RATIO maximum.
This resulting time-delay vs. current relationship is called "very inverse" and is widely in use.
G Revrse kW
The time delay from detecting reverse active power in any gen phase (V1,V2,V3) to the declaration of fault.
G Rvrs kVAr
The time delay from detecting reverse reactive power in any gen phase (V1,V2,V3) to the declaration of
fault, ie generator loss of excitation.
G Over %THD
The time delay from detecting "percentage of harmonic distortion" higher than the set-point level in any gen
phase (V1,V2,V3), to the declaration of fault.
SyncTimeout
Limit on the time it should take the genset to reach synchronization with the mains or the bus (ie match V1
with V4 in phase and in voltage). When this time delay expires, a warning fault is declared. Where load
transfer is required (Mains Standby ATS = 1, etc.), after this time delay expires transfer through paralleling
is discarded and "break→delay→make" transfer is made.
Sync Dwell Time
This is the minimum time that is required for the generator phase A (V1) and the bus or mains phase A
(V4) to stay within the phase and voltage match windows to recognize synchronization.
At least 1/2 sec Sync Dwell Time is recommended.
The contactor parameters that are relevant to the synchronizer are its 2 ⋅ θw
worst case closure time, Tc, and the maximal phase-shift it allows at θw + Tw
⋅ Tc < θ c
the moment of closure, θc.
Denote Sync Dwell Time by Tw and SYNC Window ° by θw. You should make sure that Tw is large
enough and θw is small enough to satisfy the above relation.
Example: Given a contactor with Tc=0.2 sec and θc=20°.
The default parameter values θw=10° and Tw=0.5 sec mean that the worst phase shift that the contactor
will be subject to at the moment of closure is 18°, which is acceptable.
kW
kW Surge Enable
When in parallel with the mains a sudden change in the active
power of the set is a likely sign of mains failure. However,
immediately when entering the parallel connection, fast kW Time
oscillations are common. To demand very soft connection with
the mains may call for an unacceptable synchronization time. To
increase the Parll kW Surge above the oscillations' peak is
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also undesirable as we lose the effectiveness of the PARALLEL LOAD SURGE protection. This time delay
provides a short term initial bypass.
Test Delay
The time delay from In#2 TEST W/O LOAD deactivation to genset stop.
V4 Volts Status
The time delay to reject transient abnormal status in the mains/bus phase A.
Standby On
The time delay between mains phase A (V4) failure to genset start in automatic mode. Mains Standby ATS
= 1.
Standby Off
The time delay from mains phase A (V4) return to removing the genset load in automatic mode. Mains
Standby ATS = 1.
Engine Preglow
The time delay for engine preglowing before cranking. See IOB1 K#1 relay.
Engine Crank
The time limit on engine cranking.
CrankFail Rest
The time delay between cranking attempts.
Set Stabil Max
The time limit after detecting "firing speed" (SET-UP\SETPOINTS CrankStop RPM) to reach genset
stabilization, ie reach normal voltage, frequency and oil pressure (In#5 OIL PRESS SHUT = OFF).
Set Stabil Min
The time delay between "firing speed" detection (SET-UP\SETPOINTS CrankStop RPM) to the connection
of load by IOB1 K#7 relay.
Coolin Down
The genset run time, without load, to cool off the engine.
Stoppin Max
The limit on the time from blocking fuel supply (through IOB1 K#2 FUEL SOLENOID relay) to reaching
genset standstill conditions.
AlarmOn Max
The time limit on R#3 AUDIBLE ALARM relay activity.
LubPump On
K#5 LUBRICATION PUMP cycle: On time.
LubPump Off
K#5 LUBRICATION PUMP cycle: Off time.
Load Break→ → Make
The minimal time delay before reconnecting the gen or mains power to the load. This delay is especially
important if there are synchronous motor loads.
Contactor Delay
Limit on the time from applying a command to the gen or mains contactors by the K#7 or K#8 relays to
sensing the expected response by In#15 or In#16 respectively. In#15 and In#16 are connected to auxiliary
contacts on the contactors. Exceeding this time limit is a shutdown fault. This test is optional, see SET-
UP\OPTIONS Check Contactors.
(ATS=0) K#7→ → K#8
When SET-UP\OPTIONS Mains Standby ATS = 0, ie K#8 is NOT driving the mains contactor it has an
alternative use:
When the relay K#7 GEN CONTACTOR is energized, after a time delay, K#8 is also energized.
When K#7 is de energized, K#8 immediately is de energized too.
K#8 is used in multiple genset paralleling systems to delay loading the generators bus. See Applications.
kW QuotaInc
When the controller is in config. #4 (paralleling with the mains) and In#16 is not active, this is the time
delay before the export kW quota is increased. See Dynamic export quota control in Applications.
kW QuotaDec
When the controller is in config. #4 (paralleling with the mains) and In#16 is active, this is the time delay
before the export kW quota is decreased. See Dynamic export quota control in Applications.
R#1 Off→ → On
When R#1: Trip|kW Load option is 1, this is the time delay before RELAY#1 is energized.
See Basic load control in Applications. Seite 20 von 43
R#1 On→ → Off
When R#1: Trip|kW Load option is 1, this is the time delay before RELAY#1 is de-energized.
See Basic load control in Applications.
Parll Start
When the Parall Auto Start option is active, in parallel genset systems, as the system load increases this is
the time delay before starting the next genset in the COMMAND\SEQUENCE. See Applications.
Parll Stop
When the Parall Auto Start option is active, in parallel genset systems, as the system load decreases this is
the time delay before removing and stopping one genset. See Applications.
LS SettlingTime
When the Parall Auto Start option is active, in parallel genset systems, this is the minimal time between
consecutive gensets start/stop in response to load changes. The load-sharing feedback loops should
re-distribute the load evenly within this time. See Applications.
SET-POINTS
User Password
The user must enter this 4 digit password to change the operating mode, change the run-time count, etc. No
password is required if this number is 0.
Cranking Attempts
This is the number of engine cranking attempts.
Overspeed RPM
This threshold applies to the speed read from the magnetic pickup. Make sure that a correct number of teeth
is defined in SET-UP\BASICS.
CrankStop RPM
Engine "firing" speed. This threshold applies to the speed read from the magnetic pickup. Make sure that a
correct number of teeth is defined in SET-UP\BASICS.
Bat OvVoltage
Battery over voltage threshold. Note, the battery equalize/recharge voltage, per cell is for lead-antimony
2.35, for lead-calcium 2.40 and for nickel-cadmium=1.65. Fault is declared after a 1 sec delay.
Bat UnVoltage
Battery under voltage threshold. The battery cell final voltage is dependent on the discharge rate. For a
lead-acid type at high discharge rate it may even be 1.0V. Typical value is 1.75V. Battery undervoltage is
ignored during engine cranking. Fault is declared after a 1 sec delay.
Gen OvVoltage
Over voltage threshold. Applies to each gen phase to neutral voltage.
Gen UnVoltage
Under voltage threshold. Applies to each gen phase to neutral voltage.
Gen OvFrequen
Generator phase A (V1) over frequency threshold.
Gen UnFrequen
Generator phase A (V1) under frequency threshold.
Gen OvCurrent
Overcurrent threshold, Is. It applies to each generator phase current separately. Is is usually selected as the
100% (nominal) generator phase current. The time delay before a fault is declared depends on the extent the
current exceeds Is. If the phase current is just a few amps higher than Is it will take very long time before
GEN OVERCURRENT is declared. See SET-UP\DELAYS G 2x OvCurr for more details. When in parallel
with the mains/bus, if the phase current exceeds Is, the controller reduces the generator excitation level --
this provides an effective generator current limiting.
Gen Revrse kW
Reverse (negative) true power kW threshold. Applies to each gen phase (V1/I1, V2/I2 & V3/I3). Fault
indicates a potential prime mover failure.
Gen Rvrs kVAr
Reverse (negative) reactive power kVAr threshold. Applies to each gen phase (V1/I1, V2/I2 & V3/I3).
Fault is reported as GEN EXCITATION LOSS since it usually indicates, in parallel mode, AVR failure.
Gen Over %THD
IEC55 standard for clean AC power suggests 2% as the maximal harmonics percentage acceptable.
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V4 Ov Voltage
Over voltage threshold for the mains/bus phase A (V4) input. If SET-UP\OPTIONS enables Mains
Standby ATS, voltage above this threshold is a mains failure condition.
V4 Un Voltage
Under voltage threshold for the mains phase A (V4) input. If SET-UP\OPTIONS enables Mains Standby
ATS, voltage below this threshold is a mains failure condition.
V4 Ov Frequen
Over frequency threshold for the mains phase A (V4) input. If SET-UP\OPTIONS enables Mains Standby
ATS, frequency above this threshold is a mains failure condition.
V4 Un Frequen
Under frequency threshold for the mains phase A (V4) input. If SET-UP\OPTIONS enables Mains Standby
ATS, frequency below this threshold is a mains failure condition.
Gov Volt Bias
ANALOG OUT voltage when the paralleling system is not active.
SYNC Window º
This ± value is the allowed phase shift between V1 and V4 during synchronization. Recommended 10° or
less. See SET-UP\DELAYS Sync Dwell Time.
SYNC Window V
This ± value is the allowed voltage difference between V1 and V4 during synchronization.
SYgainV/180º
Speed synchronizer gain "potentiometer". Adjusts ANALOG OUT reaction to the phase shift between the
generator phase A (V1) and the mains/bus phase A (V4). ANALOG OUT controls the governor speed
setting. It expresses the change in ANALOG OUT volts, as per 180° phase shift, in 0.1 second interval.
SYstbl V/Hz
Speed sync stability "potentiometer". Adjusts ANALOG OUT reaction to the frequency difference between
the generator phase A (V1) and the mains/bus phase A (V4). ANALOG OUT controls the governor speed
setting. The parameter expresses the change in ANALOG OUT volts, as per 1 Hz frequency difference, in
0.1 second interval. Important: A + sign indicates that to raise the genset speed setting it is required to
increase ANALOG OUT volts. A - sign indicates that to raise the genset speed it is required to decrease
ANALOG OUT volts.
SYgain %P/V
Voltage sync gain "potentiometer". Adjusts PWM OUT reaction to the voltage difference between the
generator phase A (V1) and the mains/bus phase A (V4). PWM OUT, through an appropriate interface
module (see AVRx), controls the AVR voltage setting. The parameter expresses the change in PWM OUT
duty-cycle as per 1 volt difference, in 0.1 second interval. Important: A + sign indicates that to raise the
generator voltage it is required to increase PWM OUT duty cycle. A - sign indicates that to raise the
generator voltage it is required to decrease PWM OUT duty cycle.
Parll kW Surge
When in parallel with the mains, any change in the consumers load is normally absorbed by the "infinite"
mains. If however a sudden change is measured, it is a likely sign of a mains failure. This parameter
determines the amount of power change that triggers off the PARALLEL LOAD SURGE protection. Note
that sensing a kW decrease is optional, see SET-UP\OPTIONS kW Drop=LoadSurge?.
In response to a PARALLEL LOAD SURGE, if a mains contactor is installed (ie Mains Standby ATS? 1) it
immediately opens (by energizing IOB1 K#8 relay) and the generator is left with the essential loads.
If the mains contactor is not used, the generator contactor opens (by de-energizing IOB1 K#7 relay).
The response time of this protection is about 100 ms, which is acceptable by most electricity boards. An
external loss of mains protection device can be installed, see PARALLEL MAINS FAIL.
LSgain V/Xre
Active load sharing gain "potentiometer". Adjusts ANALOG OUT reaction to the difference between the
active power (kW) output of the genset and the desired output level (the "error"). ANALOG OUT
controls the governor speed setting. The parameter expresses the change in ANALOG OUT volts, as per
Xre error, in 0.1 second interval. Xre denotes the kW rating of the genset.
LSstbl V/Xre
Active load sharing stability "potentiometer". Adjusts ANALOG OUT reaction to the rate of change in the
active power output of the genset (ie reacts to dKW/dt). ANALOG OUT controls the governor speed
setting. The parameter expresses the change in ANALOG OUT volts, as per Xre change in the genset
power output in 0.1 second interval. Xre denotes the kW rating of the genset.
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LSgain%P/Xap
Reactive load sharing gain "potentiometer". Adjusts PWM OUT reaction to the difference between the
reactive power (kVAr) output of the genset and the desired output level (the "error"). PWM OUT, through
an appropriate interface module (see AVRx), controls the AVR voltage setting. The parameter expresses
PWM OUT duty-cycle change as per an Xap error in 0.1 second interval. Xap denotes the kVA rating of
the genset.
LSstbl%P/Xap
Reactive load sharing stability "potentiometer". Adjusts PWM OUT reaction to the rate of change in
reactive power output of the genset (ie reacts to d kVAr/dt). PWM OUT, through an appropriate interface
module (see AVRx), controls the AVR voltage setting. The parameter expresses the change in PWM OUT
duty-cycle as per an Xap change in the genset reactive power output in 0.1 second interval. Xap denotes the
kVA rating of the genset.
Ramp +kW/Sec
Engine loading rate: After entering parallel connection with the mains the controller increases the active
power output of the set, at the selected rate, until it reaches the export quota.
Ramp -kW/Sec
Engine unloading rate: Before leaving parallel connection with the mains the controller reduces the active
power output of the set, at the selected rate, until it reaches zero.
Ramp+kVAr/Sec
Generator loading rate: After entering parallel connection with the mains the controller increases the
reactive power output of the set, at the selected rate, until it reaches the export quota.
Ramp-kVAr/Sec
Generator unloading rate: Before leaving parallel connection with the mains the controller reduces the
reactive power output of the set, at the selected rate, until it reaches zero.
kW Quota Inc.
When the controller is in configuration #4, paralleling with the mains, this is the increase step in the kW
export quota when In#16 is not active. See Dynamic export quota control in Applications.
kW Quota Dec.
When the controller is in configuration #4, paralleling with the mains, this is the decrease step in the kW
export quota when In#16 is active. See Dynamic export quota control in Applications.
%kW/Xre→ → R#1 On
When R#1: Trip|kW Load option is 1, this is the critical system load level (ΣkW/ΣXre) where RELAY#1
is, after delay, energized. See Basic load control in Applications.
%kW/Xre→ → R#1 Off
When R#1: Trip|kW Load option is 1, this is the critical system load level (ΣkW/ΣXre) where RELAY#1
is, after delay, de-energized. See Basic load control in Applications.
+%kW/Xre→ → Start
When the Parall Auto Start option is active, in parallel genset systems, this value specifies when it is
needed to start additional gensets. It is the least amount of extra power, specified as a percentage of the
Xre: Rated kW, which the system must be capable of generating. See Applications.
+%kW/Xre→ → Stop
When the Parall Auto Start option is active, in parallel genset systems, this value specifies when it is safe
to stop one genset. It is the least amount of extra power, specified as a percentage of the Xre: Rated kW,
which the system after stopping one genset must still be capable of generating. See Applications.
OPTIONS
ABBREVIATION SUMMARY Note that if the parameter prompt line ends with…
Question? 0 NO,1 YES '?' then 0 stands for no, 1 stands for yes.
Select A|B: 0 A, 1 B ':' then 0 stands for method A, 1 stands for method B.
S|W=Shutdown|Warning
WRITE PROTECT...!?
1 makes all SET-UP parameters read only! IT IS RECOMMENDED TO USE THIS OPTION TO
INCREASE THE SYSTEM RELIABILITY. See Attention!.
RMS use Harmonics?
Current and voltage RMS values can be calculated from the fundamental frequency only (0) or can include
the harmonic content (1). Recommendation: use 0.
NOT IN AUTO Warn?
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1 defines OFF and MAN modes to be illegal. Warning fault is declared.
Energize Run|Stop:
0 = fuel solenoid is "energize to run".
1 = fuel solenoid is "energize to stop".
Cool After NoLoad?
1 makes the engine cooling off delay mandatory. If 0 is defined, only if the genset contactor was closed
(active IOB1 K#7 relay) at the time genset stop command was issued, the genset enters cooling down
before it stops.
Bat OverVolts S|W:
0 = battery over voltage condition is a shutdown fault.
1 = battery over voltage condition is a warning fault. Fault is declared after 1 second delay.
Recommendation: 0.
Gen UnderVolt S|W:
0 = gen undervoltage fault is shutdown.
1 = gen undervoltage fault is warning.
Gen UnderFreq S|W:
0 = gen phase A under frequency fault is shutdown.
1 = gen phase A under frequency fault is warning.
LowWaterLevel S|W:
In#10 LOW WATER LEVEL fault is: 0 = shutdown, 1 = warning.
Ext. Overload S|W:
In#14 can be connected to an external overload protection relay. When In#14 is active, the gen contactor
immediately opens (ie IOB1 K#7 relay de-energizes). If shutdown option is selected (0) the genset is
shutdown after cooling off period.
GENCON LOW DC S|W:
Dangerously low DC voltage level can be defined as: 0 = shutdown, 1 = warning. Recommendation, enter
0. You may be tempted though to enter 1 to utilize 12V batteries to their end…
The following four parameters define the controller's configuration.
They are described in greater detail in the Applications section.
Generic Configure?
1 selects the generic configuration #0. Having selected this option discards the following parameters:
Parallelin System, Mains Standby ATS, Cogeneration Mode and Check Contactors. The controller's inputs
In#15 and In#16 and output relays K#7 and K#8 get a special meaning, as follows:
In#15 In#16 OPERATION
OFF OFF Synchronizing without load
OFF ON Paralleling with the mains (export quota ramp up/down)
ON OFF Paralleling with other gensets (load-sharing)
ON ON Synchronizing with load
Energized K#7 indicates that the genset is ready for load,
Energized K#8 indicates that the genset runs in sync with the bus/mains,
De energized K#8 while in parallel with the mains indicates PARALLEL LOAD SURGE detection.
Parallelin System?
1 enables the synchronizer, load-sharing, etc.
Mains Standby ATS?
1 = The relay K#8 drives the mains contactor. The transfer of the load from the mains to the genset, and
vice versa, is the controller's responsibility, as is the tradition in Europe: When abnormal AC level is
detected at V4, the genset is started after a time delay, etc. See Standby On and Standby Off. If the
paralleling system is enabled, a soft (synchronized zero-power) transfer is made whenever possible. If not
possible (SYNCHRONIZER TIMEOUT etc.) a standard break → delay → make transfer is made.
0 = The relay K#8 follows K#7 GEN CONTACTOR with an adjustable delay. It can be used to ensure
minimal time for multiple genset paralleling before taking the load. See the (ATS=0) K#7→K#8 delay.
Cogeneration Mode?
If Parallelin System = 1 and Cogeneration Mode = 1 (configurations #4 and #6) the genset runs in parallel
with the mains continuously, maintaining the user COMMAND\EXPORT quotas, as long as In#1 is active.
Seite 24 von 43
If the Parallelin System = 1, Mains Standby ATS = 1 and Cogeneration Mode = 0 (configuration #5) the
genset runs in parallel with the mains briefly in response to active In#1, just as needed to transfer the load
from the mains to the genset "softly". When In#1 is deactivated, after brief paralleling the load is "softly"
transferred back to the mains.
If the Parallelin System = 1, Mains Standby ATS = 0 and Cogeneration Mode = 0 (configuration #3) the
genset can be run in parallel with other generator-sets.
Parall Auto Start?
This option is relevant to controllers in configuration #3 that are used in multiple generator-set paralleling
systems. 1 enables starting of the genset when the system load increases, etc.
See the Applications section.
Generator Syn|Asy:
0 for synchronous (self-excited) generators, 1 for asynchronous (induction) generators.
Induction generators can be used only in parallel with the mains (config. #4) since no exciter or voltage
regulator is used. If left 1 in a different configuration it is automatically reset, Generator Syn|Asy:←← 0.
An induction machine, when driven above the synchronous speed by the engine, converts mechanical power
to electric power. When using this type of generator note the following differences:
♦ The V1, V2 and V3 input channels are connected directly to the mains. V4 is not used.
♦ The function of the synchronizer is ONLY to match the engine speed with the mains frequency. Hence,
only the parameter SYstbl V/Hz matters (ie SYgainV/180° and SYgain %P/V are not used).
Synchronization is achieved when the engine speed is held within a ± 0.5 Hz difference from the mains
continuously for the selected Sync Dwell Time.
♦ The reactive power (kVAr) is not under GENCON II control. Hence, the related LSgain%P/Xap and
LSstab%P/Xap parameters are not used.
♦ Negative kVAr is normal with asynchronous generators. Hence, set the Gen Rvrs kVAr large enough or
otherwise LOSS OF EXCITATION shutdown is declared.
In#3 Sleep|Bypass:
0 = Active In#3 in automatic mode stops the genset: "Sleep Mode".
1 = Active In#3 is a request to override shutdown faults (fire extinguishing applications).
SleepClearsFaults?
1 means that switching the operating mode from AUTO to SLEEP by In#3 clears all the pending faults.
Check Contactors ?
1 introduces testing of the generator and the mains contactors. Test failure causes a
CONTACTOR(s) FAILURE shutdown fault after a programmable Contactor Delay.
The test compares the auxiliary switches status, as read by the inputs In#15 and In#16, with the contactor
commands issued by the relays K#7 and K#8, respectively. If the mains contactor is not used, ie the Mains
Standby ATS option is 0, the test does not include In#16 and K#8. The testing method depends on the type
of the contactor drive, an electromagnet or a motor.
1 also indicates to the Parallelin System that switching between the synchronizer and the load-sharing
functions is determined by the contactors' auxiliary switches rather than by the contactors' commands.
Motor Contactors ?
0 indicates that the contactor(s) are driven by an electromagnet:
The gen contactor is powered by the gen ΦA, the phase that is monitored by V1.
The mains contactor, if enabled (ie the Mains Standby ATS option is 1), is powered by the mains ΦA,
the phase that is monitored by V4. Note: This type of contactor opens when its power is removed.
1 indicates that the contactor(s) are driven by a motor or by a spring charged by a motor:
The gen contactor is powered by the gen ΦA, if the Mains Standby ATS option is 0.
If the mains contactor is enabled, the contactors are powered by a common power source that is either the
gen ΦA or the mains ΦA -- whichever volts are high. This power source can be created by selecting the
phase of the gen or the mains by the relay K#6, when the K#6 Engine|Gen On option is 1.
Note: This type of contactor stays closed when its power is removed (if no undervoltage release).
R#1 Shunt|kW Load:
0 prepares RELAY#1 to drive a circuit breaker (shunt) trip coil. RELAY#1 is energized when a shutdown
fault is detected while the genset is running.
1 prepares RELAY#1 for basic load control applications. See Applications.
K#6 Engine|Gen On:
0 → K#6 is energized when the engine is running: RPM ≥ 60 or Hz ≥ 15.
1 → K#6 is energized when the generator voltage is high: V1, V2 and V3 ≥ Gen Undervoltage setpoint.
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kW Drop=LoadSurge?
If selected, a sudden decrease in the kW load, while the genset is running in parallel with the mains, also
triggers the PARALLEL LOAD SURGE protection. The same Parll kW Surge setpoint applies.
Smooth Mains→ → Gen ?
1 is effective with Parallelin System = 1 and Mains Standby ATS = 1 only (config's #5, #6). When the
controller measures less than 50% of the nominal voltage by V4 during paralleling with the mains, it
immediately opens the mains contactor and the genset remains with the plant load. The message
PARALLEL MAINS FAIL is logged UNLESS this option is chosen. This message may be confusing if V4
is disconnected by some external relay to achieve a smooth power transfer, that is a mains to genset load
transfer exactly when the genset power export during ramp up reaches the plant's demand.
Alter Sync Method?
1 introduces a slight modification to the synchronizer algorithm: Phase difference between the genset and
the bus/mains is ignored when the frequency difference is larger than 0.2 Hz. The significance of this
modification is debatable.
IN 1..16
Each IOB1 board input can individually be defined as a N/O ("normally open") or N/C ("normally closed").
Select by the left← and right→ push-buttons the In#. Change definition by ENTER .
BASICS
Always start system configuration with SET-UP\BASICS. They have side effects on several
SET-UP\SET-POINTS.
Controller ID No
A value between 1 to 8. A unique number should be assigned to each controller that is connected to the
RS485 communication line.
No of Alt Poles
The number of the rotor poles (always an even RPM × Number _ of _ Poles
number). Determines the number of electrical cycles
Frequency =
120
produced by each revolution of the shaft.
Pick-up Teeth
Number of teeth on the gear. Determines the number of magnetic pickup pulses generated per each
complete revolution of the shaft. On correct "teeth" assignment MEASURE\ENGINE Hz equals the
MEASURE\GENERATOR\OVERVIEW Hz!
CT Ratio
Current transformers ratio. For example, ratio = 160 for 800A:5A transformers.
Xap: Rated kVA
The apparent power rating of the set, denoted Xap. The COMMAND\EXPORT quotas legitimacy will be
tested against this value.
Xre: Rated kW
The true (active) power rating of the set (engine), denoted Xre. The COMMAND\EXPORT quotas
legitimacy will be tested against this value.
Adj Sec/Week
Real time clock adjustment specified in seconds per week.
FACTORY
Calibration parameters. The password is: _ _ _ _ _ _. It is recommended to note down the calibration
parameters in case they are accidentally damaged. See also SET-UP\OPTIONS WRITE PROTECT...!
Tuning up the paralleling switch gear

GENCON II has four feedback controls built in:
1. SY: Phase synchronizer -- operates by regulating the engine speed,
2. SY: Voltage matching -- operates by regulating the generator voltage,
3. LS: Active load (kW) sharing -- operates by regulating the engine fuel supply,
4. LS: Reactive load (kVAr) sharing -- operates by regulating the generator excitation level.
The SY prepares the genset for a "soft" entry into parallel connection with the mains or the bus.
When in parallel with the mains, the LS maintains the genset power output at the level set by the user
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COMMAND\EXPORT. When in parallel with other gensets, the LS maintains an equal genset load share (ie
equal genset-power/genset-ratings ratio).
GENCON II controls the engine speed and fuel supply by regulating its B2 ANALOG OUT DC voltage.
ANALOG OUT is connected to the engine electric governor. Its 0 to 7.5 Vdc range is compatible with most
electric governors. For example:
1. Woodward Governor Co., AUX INPUT 11+: Gov Volt Bias = 1.50 Vdc. Raising voltage increases speed.
2. Barber-Colman Company, ILS 8: Gov Volt Bias = 4.00 Vdc. Raising voltage increases speed.
3. Governors America Corp., AUX N: Gov Volt Bias = 1.50 Vdc. Raising voltage decreases speed.
GENCON II controls the generator voltage and excitation level by ON
regulating the duty-cycle of its B3 PWM OUT signal (Pulse Width
Modulated Output). A special interface module (see AVRx) OFF time
converts this digital signal into a floating DC voltage source. The
T1
DC voltage changes the generator Automatic Voltage Regulator T0 T1 Duty-Cycle =
T0+T1
(AVR) reference voltage.
Each one of the four feedback controls monitors the error E between a value that it measures (eg, phase-shift)
and the ideal one (eg, 0° phase-shift; or in other "λ" units -- volts, kW's or kVAr's -- according to the case) and
the error rate of change, ∆E ("λ"/sec). In response, the ANALOG OUT (Vdc) or the PWM OUT duty-cycle
(percentage) changes by: E ∗ gain + ∆E ∗ stability. The installation engineer can adjust the gain and the
stability levels. For most installations, setting the gain as high as possible, while keeping the system stable
with the stability adjustment, results in a satisfactory control.
Though these (PID) control loops operate in discrete steps, 10 steps per second, they are quick enough for their
behaviour to be identical to common analogue units.
Getting started
1. Check the measurement system thoroughly under load! Check SET-UP\BASICS Xap and Xre.
2. Run the generator-set with Parallelin System = 0. Make sure that by changing the Gov Volt Bias you change
the engine speed. If the speed increases when raising the Gov Volt Bias, the SYstbl V/Hz sign should be
positive (+). If the speed decreases, the sign should be negative (-). Set Gov Volt Bias to a value in the
middle of its effective control range. Adjust the governor speed potentiometer to the nominal generator
frequency (50Hz or 60Hz).
3. Adjust the AVR potentiometer to the nominal generator voltage. Disconnect B32. This is equivalent to a
PWM OUT duty cycle fall from 50% to 0%. The generator voltage must change to its lowest or highest
extreme. If the generator voltage also falls, SYgain %P/V sign should be positive (+), otherwise the sign
should negative (-).
Tuning up the feedback controls
To tune up a feedback control loop we use the appropriate display, SYNCscope for the SY controls and
POWER+PF for the LS controls, to examine how different gain and stability set points effect the error
behaviour: Too much gain causes fast oscillations. Too much stability may cause slow oscillations. It can also
be useful to look at the SYSTEM display to see how ANALOG OUT (V) and PWM OUT (%) change. The
following general tuning up procedure is recommended:
♦ Start with the gain at its midpoint value if you haven't worked with this type of governor or AVR before.
Otherwise, start with the values that you've found best last time. We don't expect that the new optimal values
to be much different -- the engine and the alternator size plays a secondary effect.
♦ Try to reach an acceptable level of oscillations by different stability values -- prefer minimal stability level.
♦ Successful → Increase the gain and try to stabilize it…
♦ Failed → Reduce the gain and try to stabilize it…
Don't waste time, make significant set point changes. If a gain or stability value is 0.0123 you will not notice
any change in the system's performance if you try 0.0124…
Moreover, the controller just approximates your keyboard entries to the nearest values that it can represent
internally!
If you come to the conclusion that the governor "SY" and "LS" gain/stability parameters are very small, consult
the section on ANALOG OUT to see if you can install a voltage divider between ANALOG OUT and the
electric governor control input to reduce the ∆speed/∆volts ratio. Check also if there is a trimmer on the
governor that can do the same.
Seite 27 von 43
The same applies to the AVR "SY" and "LS" parameters. Note also that AVRx, the AVR interface module, has
a built-in range trimmer -- use the minimal range that is acceptable.
Since new engines after a while change their characteristics, usually they respond faster to fuel injection, it is
recommend after finding the optimal LSgain V/Xre value to reduce it, say, by 30%.
Synchronizer tune up tips
1. Check that V4 Ov/Uv Voltage/Frequency limits are reasonably set.
Note: The synchronizer does not work when the voltage or the frequency measured by V4 are abnormal!
2. Run the set by IOB1 In#2 Test W/O Load. The synchronizer works but the generator contactor stays open.
3. An asterisk (*) appears in the OVERVIEW display each time the SYNC Window °, SYNC Window V and
Sync Dwell Time criteria are met:
Paralleling with the mains tune up tips
1. Tune up the LS gain/stability under config. #4 even if your application is #5 or #6, ie PARALLEL=1,
ATS=0 and COGEN=1. This will prevent unnecessary mains tripping.
2. Search for the optimal gain and stability set-points with the COMMAND\EXPORT quotas to 0. This is
when the genset is most unstable.
3. When tuning up the LS controls, dangerous kW and kVAr oscillations may develop. Hence, go through all
the controller's protections and set them up for their shortest delay. Make also sure that appropriate SET-
POINTS are selected for: Gen OvCurrent, Gen Revrse kW, Gen Rvrs kVAr, Parll kW Surge, etc.
4. Run the genset by In#1. If you come upon PARALLEL LOAD SURGE immediately when entering parallel
connection you have two options:
A. Delay introducing the PARALLEL LOAD SURGE protection by a suitable kW Load Surge Enable time.
B. Increase the Sync Dwell Time (eg 0.5 sec → 1 sec) and narrow the SYNC window º (eg 10° → 5°). This
will make the synchronization time longer but the parallel connection will be become "softer" (extending
SyncTimeout if necessary).
Example:
The following table lists the best parameters found for a 100 KVA, 80 KW, Perkins+Newage genset with
Woodward isochronous 8290-040 governor and STAMFORD SX440 AVR (no droop kit!). Engine flywheel
had 126 teeth. The current transformers were 5A:200A ie CT Ratio = 40.
Gov Volt Bias 1.50
SYgain V/180 deg 0.0020
SYstbl V/Hz +0.0700
SYgain %P/V +0.100
LSgain V/Xre 0.1013
LSstbl V/Xre 1.8995
LSgain %P/Xap 24.979
LSstbl %P/Xap 22.008
Multiple set paralleling tune up tips
1. Search for the optimal gain and stability set-points when the generator bus has no load. This is when the
system is most unstable.
2. In a "#3 Random access paralleling" application it is convenient to let another controller be in configuration
#1. This controller will always be the first to connect its genset to the bus and will run
3. isochronously. Using this controller MEASURE\GENERATOR\POWER+PF display you can also tell the
effect of the gain and stability parameters of your controller without leaving the SETPOINTS display.
3. The optimal (maximal) LS gain values when paralleling multiple sets are usually smaller than the optimal
values found when paralleling a set with the mains using the same governor and AVR models.
Rear panel
V1,V2,V3,V4 - Voltage inputs
These inputs measure line to neutral AC voltages. All these four inputs are internally and mutually isolated
and provide a very high degree of protection against electrical transients.
The software currently supports only wye (star) connected generators, as follows:
Connect A11 to gen phase A, A21 to gen phase B and A31 to gen phase C.
Connect A12, A22 and A32 to the generator Seite 28 point.
neutral von 43
The generator phase order should be "clockwise" or the ILL GEN PHASE ORDER warning fault is declared.
Connect A41 to the mains or bus phase A and A42 to the mains or bus neutral.
Note!
1. V4 can serve as a comprehensive single phase mains monitoring detector for automatic mains failure
applications, see config's #2, #5 and #6. For three phase mains monitoring an external relay should be
connected in series with V4, ie the relay disconnects the input of V4 on a mains failure.
2. If while paralleling with the mains the voltage measured by V4 is lower than 50% of its nominal level
PARALLEL MAINS FAIL is declared -- this is caused by an external protection relay. Note that loss of
mains during paralleling can also be detected by the in-built PARALLEL LOAD SURGE.
3. It is the installation engineer responsibility to make sure that the phase order of the bus/mains is identical to
the phase order of the generator. DIFFERENT ORDER ENDANGERS LIFE AND PROPERTY!
4. NEMA phase A, B and C designations are equivalent to IEC phase U, V and W designations.
I1,I2,I3 - Current transformer inputs
These inputs measure, through 5A current transformers, the generator phase currents. The CT ratio is defined
in SET-UP\BASICS, eg CT Ratio = 160 for a 800A : 5A transformer. The CT's burden at 5A is 2.5VA.
The diagram shows one measurement circuit. Note: A51 +
1. It is recommended not to ground the CT's externally since any A
voltage difference between A52/62/72 and C12 will result in CT I1 0.1 Ω −
TO A62, A72
reading spurious currents. A52
The voltage across the 0.1Ω resistor at 5A is only 0.5V! 100 Ω
2. Though A52/62/72 are connected internally, it is
recommended to connect the CT's by 3 pairs of wires to reduce
-BAT C12
"crosstalk" between the channels (twisted pairs preferably).
The phasing of the CT's should match the phasing of the corresponding voltage inputs. By MEASURE\
GENERATOR\GEN ΦA to ΦC it is easy to find the correct connection of the CT. Eg, inverse CT connection
will result in reading negative kW's.
BATTERY & Ground Noise Hazards!
GENCON II is designed for continuous operation from 8 to 40 Vdc. In addition, it withstands short voltage
dips during engine cranking and withstands the prolonged, even 100 Vdc high, transients during "LOAD-
DUMP" (may happen if the battery open circuits while the engine is running).
Electric governors pass high current pulses from the battery MPU
positive pole to the battery negative pole. As a result, because of

MPU+ B11 PICKUP
wiring impedance, considerable ground noise voltage develops at MPU- B12
the governor battery(-) terminal. GENCON II is connected to i i
EMI!
the governor directly. Any voltage difference between the BAT(-)

C12 BAT(-)
controller's battery(-) terminal (C12) and the governor's battery(-

GOVERNOR GENCON II
) terminal can lead to ground currents flowing through
GENCON II (see illustration) . Ground currents degrade the F
NOISE
system performance and can cause EMI (electromagnetic VOLTAGE
interference) errors!
This has two solutions: SYSTEM
BATTERY
Recommended: Make the governor battery(-) terminal the DON'T!
reference ground for the whole control system ie, connect
GENCON II C12 and the IOB1 BAT- directly to the governor battery(-) terminal and not to the system
battery negative pole.
Seite 29 von 43
MAGNETIC PICK-UP
#3 CABLE SHIELDS SHOULD BE CONNECTED AT ONE SIDE ONLY

CONTROL CUBICLE
IOB1 GENCON II GOVERNOR

PICK-UP
BAT -
ANALOG OUT
C12 BAT -
BAT -
#2 THE CONTROL CUBICLE GROUND IS

THE GOVERNOR BAT- TERMINAL
#1 GEN-SET
E NOISE VOLTAGE ACROSS THIS WIRE
#1 THIS CONNECTION MAKES THE METALLIC CUBICLE

A SHIELD AGAINST CAPACITIVELY COUPLED NOISE
- +
Easy: Disconnect B12 PICK-UP and B22 ANALOG OUT from the governor and leave just B11 and B21
connected.
Magnetic Pickup Input
The magnetic pickup produces an AC voltage with every flywheel/gear tooth passing next to its coil. The
magnetic pickup input, B11-B12 PICK-UP, detects AC signals starting from approximately 0.5 Vrms
(± 0.7 volts peak to peak).
The system calculates the engine speed (RPM) and the generator frequency (Hz) from the MPU frequency,
based on the number of flywheel teeth and the number of generator field poles defined in SET-UP/BASICS. The
MPU measurements are displayed by MEASURE\ENGINE. The system also measures the generator frequency
directly from the V1 phase input. It declares a warning fault if there is a difference between the two readings.
When the MPU is used only by GENCON II, use a twisted pair shielded cable as follows:
Connect B11 and B12 to the pick-up coil. Connect the shield to B13 only.
When the MPU is also used by the electric governor, if you did not make the governor battery(-) terminal the
reference ground for the controller leave B12 not connected. See Ground Noise Hazards.
IMPORTANT NOTE:
Controllers that were manufactured before
NOISE SIGNAL NOISE SIGNAL
20 Feb. 94 (last unit s/n A50 4 02 028) are
very sensitive to the pickup AC signals (their
circuit works by counting zero crossings). In ð AFTER ZERO CROSSING DETECTION
some cases this lead to detection of spurious
frequencies.
The simplest solution is to add a small DC
NOISE SIGNAL
offset to the magnetic pickup AC signal:
NOISE SIGNAL
+24V BAT
10K ohm
ð AFTER ZERO CROSSING DETECTION
B11 MPU+
Typical
Resistance The example uses the magnetic pickup coil intrinsic 85Ω resistance to
B12 MPU- 85 ohm
add a 0.2 Vdc bias to the pickup signal. AC signals smaller than ± 0.2
Magnetic Pickup
volts are ignored.
ANALOG OUT
This voltage source controls the engine speed and fuel through the electric governor external reference input:
Connect B21 to the positive reference input (there are sorts of names for it: "AUX", "ILS", etc.).
Seite 30 von 43
Connect B22 to the negative reference input (often simply the governor battery(-) terminal) ONLY if you've
made the governor battery(-) terminal the reference ground of GENCON II. See Ground Noise Hazards.
ANALOG OUT voltage swing is from 0 to 7.5 Vdc. It is produced by a 12 bit D/A converter, hence the
smallest voltage step that it is capable of is 1.8 mV. If this is too coarse, ie the governor ∆Speed/∆Volt is too
large, you may find it convenient to introduce a voltage divider circuit between GENCON II and the governor.
REF(ANALOG) = 3.5 + (ANALOG-3.5) * R2 / (R1+R2)
For example, an 0.1 Vdc increase in Cummins's EFC
R1
governor reference leads to a 3 Hz frequency increase. This is B21 ANALOG OUT (8) REF
still within the controller's resolution, however introducing the 120K
R2
following voltage divider made it easier to find proper gain GENCON II 5K EFC
and stability parameters.
(9) +3.5 VDC
PWM OUT REF(ANALOG) = 3.5 + (ANALOG - 3.5) / 25
The PWM controls the generator AC voltage level during
REF(0) = 3.5 - 0.14
synchronization and controls the generator excitation level REF(7.5) = 3.5 + 0.16
during paralleling. Read on the AVRx for further details.
UP TO 8 GENCON UNITS
RS-485 serial port 4000 FT MAX 120 Ω
This is an industry standard serial communication port. When
paralleling several generator-sets all the controllers' RS-485 ports RS485+ B41
MUST be connected. Each controller should have a unique Controller RS485- B42
ID No. There can be up to eight controllers in the network. The GROUND B43
TWISTED
SHIELDED
controllers can be supervised from a PC that is running REMOTE.EXE. GENCON II PAIR
The RS-485 port is also used for software maintenance.

RS485+ B41
When connecting the RS-485 ports, check that all the ports maintain the RS485- B42
same ± polarity. Connect the shield only to one controller B43. GROUND B43
GENCON II
The communication line can stretch up-to 1,200 meters. Long lines
:
should be made of a twisted pair shielded cable with 120Ω characteristic
impedance (eg BELDEN 9841). It is important to place 120Ω termination RS485+
resistors at each line end. RS485-
Inside the controller there is an optional 1K termination resistor for short- GROUND
distance non-shielded cables. This resistor is switched on by 120 Ω

SW1=DOWN (see Dip-switches). PC RS422/485 INTERFACE BOARD
AUXILIARY I/O
Connect B6 through the supplied cable to IOB1. The cable has 5 wires. If it has 6 wires (manufactured before
21 Mar '94) it is recommended to cut the green wire (signal ground, pin 3).
Route this cable as far away as possible from high AC voltage or current lines!
Dip-switches
UP
Locate the three dip-switches inside the controller, next to the AUXILIARY I/O B6
connector opening. Denote the highest switch by SW1, the middle by SW2 and the lowest
SW1
SW2 by SW3. UP position is when pointing to the "B6" inscription, DOWN position when
SW3 pointing to the "AUXILIARY I/O" inscription.
B6 AUX...
DOWN
SW1, Internal RS-485 1 KΩ termination resistor: DOWN→Connected, UP→Not connected.

SW2, Software mode: DOWN→Maintenance (see LOAD.EXE, READ.EXE & WRITE.EXE), UP→Normal.
SW3, Flash memory voltage: DOWN→High for loading software (see LOAD.EXE), UP→Normal.
RELAYS #1, #2 and #3
There are 3 relays in the main unit (plus 8 additional ones in IOB1). Each relay has a Single Pole Double
Throw (SPDT) contact configuration. The rating of each contact is 380 Vac / 10 Amps.
R#1 RELAY -- Circuit breaker trip coil or Load controller
The use of this relay depends on the SET-UP\OPTIONS R#1: Trip|kW Load parameter.
0→ R#1 N/O contact is closed if during genset operation a shutdown fault is detected. It activates the
Seite 31 von 43
generator circuit breaker (shunt) trip coil that avoids slow collapse of the voltage at the load side.
1→ It can be used for basic load control, non-essential load release and re-entry etc. See Applications.
R#2 RELAY -- Visual alarm
R#2, through a N/O contact, activates an external visual alarm when a warning or a shutdown fault is
detected. When the fault is acknowledged by the RESET button, R#2 RELAY is deactivated.
R#3 RELAY -- Audible alarm
R#3, through a N/O contact, activates an external audible alarm when a warning or a shutdown fault is
detected. R#3 is deactivated automatically after a time delay or by pressing the RESET button. See SET-
UP\DELAYS.
Error messages
The following section lists all the system error messages in alphabetic order. Use the REPORT function to
examine all the messages logged in memory.
AIR DAMPER CLOSED
The result of active In#13 AIR DAMPER SHUT. The air damper (flap) is activated by the relay K#4.
Normally the air damper lever needs reset too.
AUX I/O BOARD ERROR -- Check:
1. Is DC voltage available to the IOB1?
2. Is the GENCON II ó IOB1 cable fitted?
3. Is the GENCON II ó IOB1 cable routed far off high AC voltage and current lines?
BATTERY CHARGR FAULT
The result of active In#12 CHARGER FAULT.
CONTACTOR(s) FAILURE
Conflict detected between the status of the auxiliary contacts on the gen/mains contactors (see In#15/16)
and the status of K#7/8 relays.
EMI (NOISE) DETECTED
This error message indicates the presence of an Electro Magnetic Interference source.
EMI can be caused by an electric spark across a switch contacts when it interrupts the current flow through
an inductive load (the fuel solenoid for instance). Sparks can AND SHOULD be prevented by using
diodes in DC circuits and by using capacitors (or varistors) in AC circuits, as follows:
VARISTOR
DC AC
EMI can also be caused by closing a noisy ground path through the controller, as explained in the section
on Battery & Ground Noise Hazards.
Note! Each EMI causes a software restart with, in most cases, no apparent system disruption. In extreme
cases, where the EMI's come in streams, you may see the controller locked in trying to restart the software
but with no success. Prevention is the best defense in fighting electrical noise!
ENGINE OVERCRANK
All the engine cranking attempts have failed. See SET-UP\SET-POINTS.
ENGINE SHUTDOWN FAIL
Engine fuel supply was blocked yet, after delay (see SET-UP\DELAYS), "signs of life" are still detected.
Hint: Check In#5 OIL PRESS SHUT.
ENGINE SLOW CRANK
The speed, read by the magnetic pickup, 2 seconds after starting to crank the engine, was found to be lower
than 60 RPM.
EXTERNAL OVERLOAD
The result of active In#14 EXTERNAL OVERLOAD. This can be a shutdown or a warning fault. See
SET-UP\OPTIONS. Immediately on detecting active In#14 status the generator contactor opens (K#7 is de-
energized). Seite 32 von 43
FREQUENCY NOT BUILT
Following detection of engine firing speed, after delay, normal gen frequency was not reached (see SET-
UP\SET-POINTS & DELAYS).
GEN EXCITATION LOSS
Negative kVAr (reactive power) was detected. The generator is expected to supply kVAr! Is it an AVR
fault? See also SET-UP\SET-POINTS & DELAYS.
GEN HIGH HARMONICS
Heavy non-linear loads? Improper generator type or size? Stator short-circuit can also cause high
harmonics. See also SET-UP\SET-POINTS & DELAYS.
GEN OVER FREQUENCY
Generator frequency higher than SET-UP\SET-POINT existed for SET-UP\DELAY.
GEN OVERCURRENT
Note! The larger the overcurrent level is...the shorter gets fault declaration time delay. See SET-UP\SET-
POINTS & DELAYS.
GEN OVERVOLTAGE
Generator voltage higher than SET-UP\SET-POINT existed for SET-UP\DELAY.
GEN REVERSE POWER
Negative Watts (true power) detected. Engine failure? See also SET-UP\SET-POINTS & DELAYS.
GEN UNDER FREQUENCY
Generator frequency lower than SET-UP\SET-POINT existed for SET-UP\DELAY.
GEN UNDERVOLTAGE
Generator voltage lower than SET-UP\SET-POINT existed for SET-UP\DELAY.
GENCON LOW DC DANGER
Dangerously low DC voltage level was detected. A little bit lower and the controller would have ceased
functioning. This can be a shutdown or a warning fault, see SET-UP\OPTIONS.
GENCON MEMORY ERROR
Built-in test message. EEPROM data error (parameters memory). Contact nearest service facility.
GENCON PROGRAM ERROR
Built-in test message. FLASH data error (software memory). Try loading the the controller software again
under safe DC conditions. If the problem continues contact the nearest service facility.
GENCON UP: SET CLOCK
Reminds the operator to set the clock after switching on the controller.
Generator Syn|Asy:← ←0
The parameter Generator Syn|Asy can be set to 1, to select asynchronous (induction) generators, only in
configuration #4, paralleling with the mains.
GENERIC CONFIG ERROR
Applies to configuration #0 only (under a PLC command): The controller indicated that it cannot take any
load (K#7 was de energized), nevertheless either In#15 or In#16 was left active for more than
Contactor Delay time. Ie, the operating mode chosen by the PLC corresponds to "running with load".
HIGH BATTERY VOLTAGE
Battery voltage higher than SET-UP\SET-POINTS existed at least for 1 second.
HIGH WATER TEMP SHUT
The result of active In#7 HIGH TEMP SHUT.
HIGH WATER TEMP WARN
The result of active In#8 HIGH TEMP WARN.
ILL GEN PHASE ORDER
This warning indicates that the AC voltage connected to V1 is lagging after the voltage connected to V2.
Normally V1 is 120° ahead of V2.
LOW BATTERY VOLTAGE
Battery voltage lower than SET-UP\SET-POINTS existed for 1 second while the set was stationary or
running (ie not during start-up).
LOW FUEL LEVEL WARN
The result of active In#11 LOW FUEL WARN.
LOW OIL PRESS SHUTDN
The result of active In#5 OIL PRESS SHUT when the set is running.
LOW OIL PRESS WARNIN
The result of active In#6 OIL PRESS WARN when the set is running.
Seite 33 von 43
LOW WATER LEVEL
The result of active In#10 LOW WATER LEVEL. Can be shutdown or warning according to
SET-UP\OPTIONS.
LOW WATER TEMP WARN
The result of active In#9 LOW TEMP WARN.
NETWORK RS-485 ERROR
Report only. Indicates an error in transmitting or receiving data through B4 RS-485. Cause → Solution:
♦ Short circuit in the network cable or wrong polarity connection of some network member → …
♦ EMI noise → Use a twisted pair cable. Connect the cable shield, if used, to ground at one end only!
♦ Large difference in the ground potential between the network members → Use an isolated PC RS-485
port. Reduce members ground to ground resistance.
♦ Data reflections (long distance) → Use a cable designed for RS-422/485 applications. The typical
characteristic impedance of such a cable is 120Ω -- use two 120Ω end of cable termination resistors.
Verify that the PC RS-485 port can drive this load, ie maintain at least 2V while driving a 60Ω load.
NETWORK SET-UP ERROR
Report only. Another controller in the network is using the same ID no. Each controller should have a
unique ID no. See SET-UP\BASICS. Ignore this message if NETWORK RS-485 ERROR is also reported.
NOT IN AUTO MODE
The controller was taken out of AUTO mode. Not generated by "Sleep mode" (see In#3 SLEEP).
OIL PRESS NOT BUILT
Following detection of engine "firing" speed, after delay, normal oil pressure was not reached. Check In#5
OIL PRESSURE SHUT status. See also SET-UP\DELAYS.
PARALLEL LOAD SURGE
When in parallel with the mains, a sudden kW load change was detected. It can be a kW increase or,
optionally, a kW decrease (see kW Drop=LoadSurge?). This is a likely indication of a mains failure. In
response, the genset is isolated from the mains (by energizing K#8 if the ATS logic is enabled or by de-
energizing K#7 if not). See SET-UP\SET-POINTS Parll kW Surge parameter.
This error can also occur if the genset does not make a "soft" parallel connection with the mains. You
can make the parallel connection "softer" by increasing the Sync Dwell Time and narrowing the SYNC
Window or you may delay the introduction of this protection by a suitable kW Surge Enable delay.
PARALLEL MAINS FAIL

When in parallel with the mains, the voltage measured by V4 is less than 50% of the nominal. An external
protection relay disconnected the input of V4. The controller's immediate response is to isolate the generator
from the mains. It is done by energizing K#8 or by de energizing K#7 according to the Mains Standby
ATS? option. The Smooth Mains→Gen ? = 1option suppresses logging of this message.
REMOT EMERGENCY STOP
The result of active In#4 EMERGENCY STOP.
REVISE SETPOINTS
Following a change in SET-UP\BASICS or FACTORY parameters, the installation engineer is reminded to
revise the SET-UP\SET-POINTS.
RPM OVERSPEED SHUTDN
Engine speed higher than SET-UP\SET-POINT existed for SET-UP\DELAY.
RPM v FREQUENCY ERRO
Conflict between measured engine speed (pickup) and gen frequency (V1). Display MEASURE\ENGINE.
Hint: Check SET-UP\BASICS teeth & poles number.
SHUTDOWNS BYPASS ON!
The result of active In#3 BYPASS. Most shutdown faults become warning only!
STOP BUTTON PRESSED
GENCON II red STOP button was pressed. Shutdown fault was declared.
SYNCHRONIZER TIMEOUT
Failed to synchronize the genset with the mains within the allotted time. Check SET-UP\SETPOINTS &
DELAYS.
UNEXPECTED BUS VOLTS
Frequency is detected at V4 when logically it should have been dead.
VOLTAGE NOT BUILT
Following detection of engine firing speed, after delay, normal gen voltage level was not reached (see SET-
UP\SET-POINTS & DELAYS).
Seite 34 von 43
GENCON II dimensions
LEAVE CLEARANCE FOR VENTILATION ABOVE UNIT
ADDITIONAL CLEARANCE
FOR CABLE CONNECTION
& ROUTING 40 mm
6.3 mm FEMALE
DETACHABLE SCREW-TYPE CLAMP QUICK DISCONNECT
CAN BE PLACED ON BOTH SIDES

OR ON TOP AND BOTTOM
DIN 43700
PANEL CUTOUT
136 x 136 mm
IOB1 -- Auxiliary I/O board
Attention!
There are 2 IOB1 models: One for 12 Vdc batteries and one for 24 Vdc batteries.
Be sure that you are using the correct model!
General
IOB1 is an auxiliary input and output interface board. It adds to GENCON II 16 input and 8 output channels.
The input channels implement the set of alarms and pre-alarms that is specified in NFPA 110 level 1 (USA
code), control the diesel engine and control the generator and mains (when applicable) contactors.
IOB1 is mounted on a DIN rail inside the control cubicle. It is connected to GENCON II by a special 120 cm
symmetrical cable. Proper operation of the IOB1 is continuously monitored and shutdown fault is declared on
any malfunction. If the cable is removed all IOB1 relays are off.
Input channels
The 16 input channel terminals are connected through "normally open" (N/O) or "normally closed" (N/C)
contacts to the battery(-) potential. The type of contact to use with each input, N/O or N/C, is defined by SET-
UP\IN 1..16. The input channels activity is displayed by MEASURE\ IN 1..16.
In#1 RUN WITH LOAD
Active In#1 starts the genset in AUTO mode unless a shutdown fault exists. When the genset is ready it
takes the load or enters paralleling.
In#2 TEST W/O LOAD
Active In#2 starts the genset in AUTO mode unless a shutdown fault exists. When In#2 is deactivated,
following the Test Delay time, the genset stops.
In#3 SLEEP or BYPASS
In#3 can be used in two ways according to the In#3 Sleep|Bypass option:
SLEEP: Active In#3 inhibits genset startup in AUTO mode. When it is active OVERVIEW displays
"Mode=Sleep." It can be activated by a clock to disable standby operation after working-hours.
BYPASS: Active In#3 converts most shutdown faults to warnings (except In#4 EMERGENCY STOP).
Active In#3 is also a warning fault. It is typically used when powering fire extinguishing pumps.
In#4 EMERGENCY STOP
Active In#4 is a shutdown fault. It also activates the K#4 AIR DAMPER relay.
In#5 OIL PRESS SHUT
Active In#5 indicates low lubricating oil pressure (see In#6). In#5 passes 0.5 sec delay to filter out transient
contact statuses. When the engine is running it causes a shutdown fault. When the engine stops, after
Stoppin Max time delay, it causes an ENGINE SHUTDOWN FAIL warning.
Seite 35 von 43
In#6 OIL PRESS WARN
Active In#6 indicates low lubricating oil pressure. When the genset is running it causes a warning fault.
In#7 HIGH TEMP SHUT
Active In#7 that is detected when the genset is running is a shutdown fault. It is ignored if detected when the
engine stops since temperature in that case tends to rise.
In#8 HIGH TEMP WARN
Active In#8 that is detected when the genset is running is a warning fault. It is ignored if detected when the
engine stops since temperature in that case tends to rise.
In#9 LOW TEMP WARN
Active In#9 is a warning fault.
In#10 LOW WATER LEVEL
Active In#10 is a warning or a shutdown fault. See SET-UP\OPTIONS.
In#11 LOW FUEL WARN
In#12 CHARGER FAULT
In#13 AIR DAMPER SHUT
Active In#13 is a shutdown fault. K#4 AIR-DAMPER does not operate if In#13 is already active.
In#14 EXTERNAL OVERLOAD
Active In#14 causes a warning or shutdown fault according to the Ext. Overload S|W option. The genset is
taken off load immediately.
In#15 GEN CONTACTOR
Active In#15 indicates that the generator contactor is closed. In#15 status is expected to follow that of the
K#7 GEN CONTACTOR relay within a Contactor Delay time. This time limit, if exceeded, is a shutdown
fault condition. Under the Generic Configure? option this input has a special function.
In#16 MAINS CONTACTOR or kW QUOTA LIMIT
When SET-UP\OPTIONS Mains Standby ATS is 1,
an active In#16 indicates that the mains contactor is closed. In#16 status is expected to follow the K#8
MAINS CONTACTOR relay command within a time limit (see SET-UP\DELAYS). This time limit, if
exceeded, is a shutdown fault condition.
Under the Generic Configure? option this input has a special function.
When SET-UP\OPTIONS select configuration #4, and the genset is in parallel with the mains,
an active In#16 indicates that the export kW quota has to be decreased. An inactive In#16 input indicated
that the export kW quota has to be increased. See Dynamic export quota control in Applications.
Output channels
There are 8 output relays, K#1 to K#8, driving 24 output terminals. The relays have Single Pole Double Throw
(SPDT) contact configuration. 3 terminals belong to each relay: Pole, N/C Throw, N/O Throw. Follow the PC-
board marking. Each contact rating is 380 Vac / 10 Amps.
K#1 PRE-GLOW
K#1, through a N/O contact, energizes an electric heater before cranking the engine. Use SET-
UP\DELAYS to define the pre-glow time.
K#2 FUEL SOLENOID
K#2, through a N/O contact, operates the fuel solenoid. The fuel solenoid can be defined as either "energize
to run" or "energize to stop", see SET-UP\OPTIONS. The genset should stop within a predetermined time
after blocking its fuel supply (see SET-UP\DELAYS) or otherwise a fault is declared. If it just the oil
pressure not falling fast enough (In#5 OIL PRESS SHUT), it is a warning fault only. However, if speed
and voltage are measured, shutdown fault is declared and the K#4 AIR DAMPER relay is also activated.
K#3 CRANK
K#3, through a N/O contact, energizes the starter motor solenoid. Use SET-UP\DELAYS to define the
maximal cranking time and the delay between the cranking attempts. Use SET-UP\SET-POINTS to define
the number of cranking attempts and the minimal speed to stop cranking (ie engine "firing" RPM).
K#4 AIR DAMPER
K#4 is active for 2 seconds following an engine overspeed or following failure to stop the genset by K#2
FUEL SOLENOID. K#4 is inhibited if In#13 AIR DAMPER is already active.
K#5 LUBRICATION PUMP
K#5, when the genset is stationary, activates an auxiliary lubrication pump repetitively, with a
predetermined on and off duration. See SET-UP\DELAYS.
Seite 36 von 43
K#6 SET RUNNING
If the K#6 Engine|Gen On option is:
0 → K#6 is active when the engine is running: RPM ≥ 60 or Hz ≥ 15.
1 → K#6 is active when the generator voltage is high: V1, V2 and V3 ≥ Gen Undervoltage setpoint.
K#7 GEN CONTACTOR
K#7, through a N/O contact, operates the generator to load contactor. In conjunction with K#8, complete
automatic transfer switch (ATS) logic is provided. If the genset parallel operation with the mains is enabled,
the ATS contactors should not use a mechanical or electrical interlock mechanism. It is recommended,
especially when paralleling is used, to bring to In#15 GEN CONTACTOR an auxiliary contact from the
gen contactor, to compare K#7 command with the contactor status.
Under the Generic Configure? option this relay indicates that the genset is ready for load.
K#8 MAINS CONTACTOR
If Mains Standby ATS = 1, K#8, through a N/C contact, operates the mains to load contactor. In
conjunction with K#7, complete automatic transfer switch (ATS) logic is provided. If the genset parallel
operation with the mains is enabled, the ATS contactors should not use a mechanical or electrical interlock
mechanism. It is recommended, especially when paralleling is used, to bring to In#16 MAINS
CONTACTOR an auxiliary contact from the mains contactor, to compare K#8 command with the
contactor status.
If Mains Standby ATS = 0, K#8 follows K#7 with a programmable delay. See (ATS=0) K#7→K#8.
Under the Generic Configure? option this relay indicates that the genset runs in sync with the bus or mains.
IOB1 dimensions
AVRx -- A universal voltage regulator interface 50 cm long wires 0.7 cm
It is required to adjust dynamically the reference point of the Automatic BROWN AC1
Voltage Regulator (AVR) to achieve voltage matching when synchronizing BROWN AC2
the generator and to regulate the reactive power (VAR) output when running
the generator in parallel. WHITE B31
min max
5.0 cm
In many AVRs it is possible to adjust the reference point by applying a DC PURPLE B32
voltage bias signal. The AVRx is an interface module that provides the RED A2
BLACK GND
genset controller with an isolated analogue output voltage channel for AVR
GREEN A1 Rev. 1
control.
3.4 cm
Seite 37 von 43
AVRx dimensions
Block diagram
BUFFER
B31 PWM OUT (WHITE) FILTER A2 (RED)
GENCON AMPLIFIER
OPTO
GND (BLACK)
B32 PWM OUT (PURPLE) ISOLATOR
PWM OUT BUFFER
FILTER A1 (GREEN)
AMPLIFIER
B34
AC1 (BROWN)
PHASE ADJUSTABLE
GEN AC/DC VOLTAGE
NEUTRAL
AC2 (BROWN) LEVEL: α
AVRx
Transformer: 30 Vac max, 100 mA min
Seite 38 von 43
Pulse Width Modulation (PWM)
Operation Constant: Tcycle = Ton + Toff
The AVRx is a simple digital to analogue converter. The digital input, Variable: Duty-cycle = Ton / Tcycle
PWM OUT, has a variable duty cycle D. D is under software control On
(0 ≤ D ≤ 1). Off time
Ton Toff
The analogue output is related to D as follows:
α VA1 VA2 The voltage between A1 to GND is: VA1=α α ∗(1-D).
The voltage between A2 to GND is: VA2=α α ∗D.
The voltage between A1 to A2 is: VA1→A2=VA2-VA1=α α ∗(2∗D-1),
VA1→ A2 α volts BIPOLAR OPERATION.
ie ±α
α can be adjusted by the AVRx potentiometer from 3 to 9 volts
D approximately.
50% 100%
The A1, A2 terminals maximal current load is 20 mA.
Examples:
1. When the paralleling functions are not active, PWM OUT produces a "square" wave, ie D = 50%:
VA1= α / 2, VA2= α / 2 and VA1→A2= 0. Note that under this condition the AVR reference point should
be set to the nominal AC volts of the system.
2. When the PWM OUT duty-cycle D is 0, VA1 = α volts, VA2 = 0. Hence, VA1→A2 = -α α volts. This
AVRx input can be simulated by disconnecting the B31 or B32 wires.
Notes:
1. For NEWAGE AVRs (eg SX440, MX341), set α to 3 volts (min position). Connect A1 & A2 to the AVR
A1 & A2 terminals respectively. GND is not used. The transformer can be 16 Vac.
2. Contact WEXLER for further information on interfacing the AVRx module with AVRs of other
manufacturers.
Remote control and monitoring

The RS-485 network connects up-to eight GENCON II controllers with an IBM compatible PC. The program
REMOTE.EXE simultaneously builds eight control panels on the PC screen, "LCDs + Keypad."
NEW: The program VIEW.EXE builds one large control panel on screen (requires a graphic screen).
Prerequisites: PC DOS operating system. RS-485 serial communication port.
The RS-485 port transmitter (TX) enable signal should be DTR, RTS or OUT1. The RS-485 port should have
preferably in built voltage isolation. It is useful to have a mouse and a printer (with PC 8-bit symbol-set).
Run the program by REMOTE SET. The program will ask the following:
RS485 port COM number: 1..4 (↵ = 3) ? COM device codes: 1/3F8, 2/3E8, 3/2F8, 4/2E8
RS485 port IRQ number: 0=None, 2..7 (↵ = 5) ? IRQ use#1: 2/HDD-LAN, 3/COM2,4/COM1,5/LPT2
Number of gensets: 1..8 (↵ = 2) ? In the example the controllers ID numbers are 1 & 2
Screen: 1=Color, 0=Monochrome (↵ = 1) ? Any IBM display adapter
Printer: 0=None, 1=LPT1, etc. (↵ = 0) ?
Software character: 1=Spanish, 0=Swedish (↵ = 1) ? Either ¿ or å
If you omit the argument SET, your last set of answers is used.
Each one of the display windows mimics one controller LCD. The Controller ID No determines the screen
position of the LCD mimic. If there is no communication with a controller, the display window is blank.
The mouse keypad on the screen and the PC keyboard are linked to the controller shown with a double
borderline window. Pressing a function key, F1 … F8, links the keys with the corresponding controller.
Alternatively, by clicking the mouse anywhere within a display window, automatically links the keys with the
controller. Operating a controller through the PC console is identical to operating the controller through its own
front panel. Operating the program through a mouse has the following additional advantages:
♦ Clicking a menu function by the mouse automatically activates the function. Clicking the lowest display line
selects a higher menu level.
♦ When a function is active, clicking the mouse left button is equivalent to ESC and clinking the right button
is equivalent to ENTER .
Press the PC ò arrow key to print a parameter value. The ñ key prints a carriage-return/line-feed.
#1 Without an IRQ, REMOTE is slower. Your computer may not be fast enough to handle the RS485 IRQ's.
Seite 39 von 43
Software maintenance
Text editing
You may wish to change the name of an input alarm channel, or you may wish to translate all the commands
and messages from English into another language. You can do this by yourself using the PC program ED.EXE.
After editing the texts by ED.EXE, load the revised software into GENCON II using the procedure described
in the following section.
Run the program by ED SET to define the program input and output files. If you omit the argument SET,
ED.EXE will use the file names that it used in its previous execution. You can edit an existing software file by
specifying the same input and output file names.
The layout of your PC keyboard may be different from the USA English standard. ED.EXE allows you to re-
define the keyboard "stroke to font" linkage. You can link a font with a single key, with a function key or with a
common key combination (ie Ctrl-key, Shift-key, Alt-key).
To link a key with a font, use the arrow keys first to point to the desired font and then strike the ENTER key,
the blue font background turns to red. Strike the desired key to establish linkage. The PC beeps if you strike an
unlinked key. If you strike a linked key, the blue "highlight" moves to the corresponding font. Strike Esc to end
the keyboard definition phase.
The text editing process is straightforward: Type over the existing text (the PC left, right, insert and delete keys
are at your disposal). Skip text line editing by striking the down arrow key.
Backtrack by striking the up arrow key. To introduce your text changes strike the ENTER key. End ED.EXE
by striking the Esc key. Be careful not to place text where measured values are displayed!
Software down loading

It may be required to load GENCON II with a new software version to enhance its capabilities, or it may be
required to load GENCON II with software having modified texts (see Text Editing). The software is stored in
a non-volatile Flash memory. The Flash memory is programmed (written to) by GENCON II itself. Flash
memories can undergo 10,000 re-programming cycles. You can identify the version of the software resident in
GENCON II using the COMMAND\HELP.
Prerequisites:
1. The PC should have an RS-485 serial communication port, preferably isolated from the PC ground. The
RS-485 transmitter (TX) enable signal should either be DTR, RTS or OUT1. No IRQ line is required.
2. Minimum 15 volt DC power supply for GENCON II. The DC supply should be well regulated or loading
the software may fail. It is advised to avoid electrical transients while loading software!
3. New software disk.
Procedure:
UP
1. Using a long and thin screw-driver prepare the dip switches for Flash programming
by: SW2=SW3=DOWN. You don't have to open the instrument cover!
SW1
See also Dip-switches. SW2
2. Connect GENCON II to the PC RS-485 serial port. Only one controller can now be SW3
connected to the PC! B6 AUX...

DOWN
3. Run LOAD.EXE by LOAD SET. Change RS-485 communication port as necessary.
If you type LOAD only, the program uses the set of arguments it used last.
4. Turn on GENCON II power supply.
5. Press ENTER to begin the software transfer. '>'s appear on the PC screen to indicate transfer progress.
PROG message appears on the GENCON II LCD. Wait for successful programming completion message.
6. Turn off GENCON II power supply.
UP
7. Prepare GENCON II dip-switches back for normal operation by: SW2=SW3=UP.
8. Turn on GENCON II power supply. Press 0 if you are asked to do so. SW1
SW2
Automatic text translation SW3
TRAN.EXE is a utility program which picks up translations made for an earlier B6 AUX...
DOWN
GENCON II software version and automatically introduces them to a newly released
English software version. Run the program for further details.
Seite 40 von 43
Reading the EEPROM
All GENCON II parameters (time-delays, set-points, calibration values, etc.) are kept on a non volatile
EEPROM memory. READ.EXE is a utility program for copying the EEPROM data to a disk file.
Procedure:
1. Set the dip-switch SW2 DOWN. The position of SW1 and SW3 is irrelevant.
2. Connect GENCON II to the PC RS-485 serial port. Only one controller can be connected.
3. Run READ.EXE by READ SET to define the program arguments as follows:
RS485 port COM number: 1..4 (↵ = 3) ?
EEPROM file name (↵ = EEPROM) ?
Software ID (↵ = s17h) ? 's' stands for 'standby'. You can read EEPROMs of earlier software versions, as
early as 's14a', and have them subsequently converted to 's17h' automatically by WRITE.EXE.
4. Turn on GENCON II power supply. The minimal power supply voltage is 8 volts.
5. Press ENTER.
7. Prepare GENCON II dip-switches for normal operation by: SW2=SW3=UP.
Writing the EEPROM -- The Fast Way!

WRITE.EXE is a utility program for copying a file created by READ.EXE to the EEPROM memory. If the
EEPROM file was read from an earlier software release, as early as 's14a', its data is automatically converted
to the latest 's17h' format.
Procedure:
1. Set the dip-switch SW2 DOWN. The position of SW1 and SW3 is irrelevant.
2. Connect GENCON II to the PC RS-485 serial port. Only one controller can be connected.
3. Run WRITE.EXE by WRITE SET to define the program arguments as follows:
RS485 port COM number: 1..4 (↵ = 3) ?
EEPROM file name (↵ = EEPROM) ?
4. Turn on GENCON II power supply. The minimal power supply voltage is 8 volts.
5. Press ENTER.
7. Prepare GENCON II dip-switches for normal operation by: SW2=SW3=UP.
EMC questions for the control panel builder

Electromagnetic interference (EMI) poses serious threats to the correct functioning of modern microprocessor
based systems. GENCON II was tested under extreme EMI conditions to reduce the risk of erratic control
behavior. Nevertheless, the panel designer should make his system electromagnetically compatible (EMC) to
reduce the risk that GENCON II, even for a brief moment, gets out of control. No effort should be spared if the
error message EMI (NOISE) DETECTED is registered even once. Here are the questions that should be asked:
1. Were all the switched inductive loads transients properly suppressed by placing diodes across the DC coils
and capacitor-resistors (or varistors) across the AC coils… ?
2. Is GENCON II ground "riding" above the governor ground (the recommended method)? If not, choosing the
easy method, one should not close noisy ground current paths through B12 and B22.
3. Are the GENCON II and IOB1 ground terminals (bat-) connected by a short wire to the cubicle for
electrostatic shielding?
4. Is the GENCON II ↔ IOB1 cable separately routed, ie not loomed with high AC voltage & current wires?
and in general…
5. Were all the cables in the system segregated? Cables carrying high frequency interfering currents should be
kept away from other cables, even within shielded enclosures. AC power and return, DC power and return,
analog controls, digital controls…
Seite 41 von 43
Installation Diagram
CT GEN C.B.
P1 P2
PHASE A
A1 A1 AC1 P1 CT P2
S1 S2
AUTOMATIC A2 AC2 PHASE B
A2 G
VOLTAGE P1 CT P2
REGULATOR GND S1 S2
MAGNETIC PHASE C
PICK-UP B31
UNIT AVRx B32
S1 S2 NEUTRAL
C.B. TRIP COIL
rev 1
A1 & A2 vs GND range: 3 ÷ 9 Vdc adj. 16 ÷ 24 Vac PHASE A
MAINS or BUS
A1 vs A2 range: ±3 ÷ ±9 Vdc adj. 100 mA
NEUTRAL
A11 A12 A21 A22 A31 A32 A51 A52 A61 A62 A71 A72 A41 A42
V1 V2 V3 I1 I2 I3 V4
B11 +
B12 PICK-UP
B13
B21 +
B22 ANALOG OUT
B23
SHIELDED WIRES TO BE TWISTED PAIRS
GROUNDED AT ONE END ONLY. B31 + ®
B32
PWM OUT
GENCON II
B33
6 5 11 12
B34
MPU AUX
ELECTRIC B41 H
GOVERNOR B42 L RS-485

+BAT -BAT B43
1 2 RELAY #1 RELAY #2 RELAY #3
NOTE! THE ELECTRIC GOVERNOR BAT- B6 AUXILIARY I/O BATTERY

TERMINAL IS THE "SIGNAL GROUND". +
DON'T ROUTE THIS CABLE C11 C12 C21 C22 C23 C31 C32 C33 C41 C42 C43
ALONG AC POWER LINES!
LOAD (kW) C.B.

CONTROL OR TRIP VISUAL AUDIBLE
COIL ALARM ALARM
DRIVER DRIVER DRIVER
P3
+ -
P4 K1 PRE-GLOW
BATTERY P1 K2 FUEL SOLENOID

+BAT
-BAT K3 CRANK
P2
RUN WITH LOAD I01 K4 AIR DAMPER
IN INDUCTION (ASYNCHRONOUS) NORMALLY
OPEN
TEST W/O LOAD
SLEEP OR BYPASS
I02
I03
WIRING DIAGRAM FOR
EMERGENCY STOP
OR OIL PRESS SHUT
I04
I05 IOB1 K5 LUBRICATION PUMP
GENERATORS V1, V2 AND V3 ARE NORMALLY

OIL PRESS WARN
HIGH TEMP SHUT
I06
I07 12V OR 24V K6
SYNCHRONOUS GENERATORS
SET RUNNING
CLOSED HIGH TEMP WARN I08
CONNECTED TO THE MAINS.

LOW TEMP WARN
LOW WATER LEVEL
I09
I10 K7 GEN CONTACTOR
AS PER GENCON II SOFTWARE:
LOW FUEL WARN I11
CHARGER FAULT I12
AIR DAMPER SHUT I13
V4 IS NOT USED. EXT. OVERLOAD
GEN CONTACTOR
I14
I15
K8 MAINS CONTACTOR
STANDBY V1.7h
MAINS CONTACTOR I16
Seite 42 von 43
Warranty limitation
Wexler warrants each unit it manufactures to be free from defects in material and workmanship under normal
use and service for the period of 1 year from date of purchase. This warranty shall not apply to damages caused
by lightning or any product or parts which have been subject to misuse, neglect, accident or abnormal
conditions of operations.
In the event of failure of a product covered by this warranty, Wexler will repair the instrument returned to an
authorized Service Facility within 1 year of the original purchase; provided the warrantor examination discloses
to its satisfaction that the product was defective. The warrantor may, at its option, replace the product in lieu of
repair. With regard to any instrument returned within 1 year of the original purchase, said repairs or
replacement will be made without charge. If the failure has been caused by a lightning, misuse, neglect, accident
or abnormal conditions of operations, repairs will be billed at a nominal cost. In such case, an estimate will be
submitted before work is started, if requested.
ANY IMPLIED WARRANTIES OF MERCHANDISING OR FITNESS FOR A PARTICULAR PURPOSE
OR USE SHALL BE LIMITED TO A PERIOD OF TWELVE MONTHS FROM THE DATE OF
PURCHASE. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES.
WEXLER SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, WHETHER IN CONTRACT, TORT, OR OTHERWISE.
If any failure occurs, the following steps should be taken:
1. Notify Wexler or the nearest Service Facility, giving full details of the difficulty, and include the serial
number. On receipt of this information, service data or shipping instructions will be forwarded to you.
2. On receipt of the shipping instructions, forward the instrument (in a suitable container that is rigid and of
adequate size), transportation prepaid. Repairs will be made at the Service Facility and the instrument
returned, transportation prepaid.
CLAIM FOR DAMAGE IN SHIPMENT TO ORIGINAL PURCHASER
The instrument should be thoroughly inspected immediately upon original delivery to purchaser. All material in
the container should be checked against the enclosed packing list. The manufacturer will not be responsible for
shortages against the packing list unless notified immediately. If the instrument is damaged in any way, a claim
should be filed with the carrier immediately. (To obtain a quotation to repair shipment damage, contact
Wexler). Final claim and negotiations with the carrier must be completed by the customer.
Seite 43 von 43

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Discontinued Product

Schiricksweg 2 41751 Viersen Tel.: +49 2162-40025 Fax: +49 2162-40035

Tolerance: Ground or earth, analog or analogue, emergency generator-set or standby

Disclaimer: We believe that this document is a faithful description of the system. We

The GENCON® II control system, whilst so light and small,…

Control Equipment + Design/Installation/Commissioning Man-Hours

The result: Paralleling is no longer the realm of heavy kW genset projects.

Abbreviation SET-UP\OPTIONS Description

Single generator-set applications

+ kW/Sec Ramp - kW/Sec Ramp + kVAr/Sec Ramp - kVAr/Sec Ramp

In#1 ON In#1 OFF In#1 ON In#1 OFF

- kW/Sec Ramp + kW/Sec Ramp - kW/Sec Ramp

with one power cut only as in configuration #5. Mains Contactor

Multiple generator-set applications

"master" genset governor and AVR independent

required to start and stop gensets automatically according to C.In#1 G3

G1: α = A/X2 = 20%, β = (X1−X2+2∗B) / (X1+X2) = 69%.

to the generators bus. Controller B then synchronizes the G2 B.K#7

#1 Unless it is not in AUTO mode or faulty.

maximal flexibility in the design of V1 V4

overrides In#1 RUN and In#2 TEST

An active In#16, after a kW QuotaDec time-delay,

set-point value. An inactive In#16, after a

The time-delays can be adjusted from 0 to 100

Basic load control

This type of contactor has two notable characteristics:

removed from the motor.

GENCON II -- The main unit

Common menu options

Battery Volts: 13.8 Maximum reading is 40 volts

Total-Power COSφφ (PF) Generator

GEN Φ A, GEN Φ B and GEN Φ C

The SET-UP menu

Tuning up the paralleling switch gear

positive pole to the battery negative pole. As a result, because of

the governor directly. Any voltage difference between the BAT(-)

controller's battery(-) terminal (C12) and the governor's battery(-

#3 CABLE SHIELDS SHOULD BE CONNECTED AT ONE SIDE ONLY

IOB1 GENCON II GOVERNOR

#2 THE CONTROL CUBICLE GROUND IS

E NOISE VOLTAGE ACROSS THIS WIRE

#1 THIS CONNECTION MAKES THE METALLIC CUBICLE

The RS-485 port is also used for software maintenance.

distance non-shielded cables. This resistor is switched on by 120 Ω

SW1, Internal RS-485 1 KΩ termination resistor: DOWN→Connected, UP→Not connected.

PARALLEL MAINS FAIL

CAN BE PLACED ON BOTH SIDES

IOB1 -- Auxiliary I/O board

AVRx -- A universal voltage regulator interface 50 cm long wires 0.7 cm

Remote control and monitoring

Software down loading

connected to the PC! B6 AUX...

Writing the EEPROM -- The Fast Way!

EMC questions for the control panel builder

GOVERNOR B42 L RS-485

NOTE! THE ELECTRIC GOVERNOR BAT- B6 AUXILIARY I/O BATTERY

LOAD (kW) C.B.

BATTERY P1 K2 FUEL SOLENOID

GENERATORS V1, V2 AND V3 ARE NORMALLY