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Harsen GU641A Operation Manual

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GU641A Controller Operation Manual
The clarification of notation used within this manual:
WARNING:
A WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death, serious personal injury or property damage.
CAUTION:
A CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in damage to equipment or property.
NOTE:
A NOTE provides other helpful information that does not fall under the warning
or caution categories.
1

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Summary of Contents for Harsen GU641A

  • Page 1 GU641A Controller Operation Manual The clarification of notation used within this manual: WARNING: A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death, serious personal injury or property damage. CAUTION: A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property.
  • Page 2 GU641A Controller Operation Manual WARNING: Read this entire manual pertaining to the work to be performed before installing, operating, or servicing this controller. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage.

  • Page 3: Table Of Contents

    GU641A Controller Operation Manual Contents 1. Description ........................4 2. The Outline Dimension Drawings and Controller Wiring ........5 3. Panel Operation ......................8 4. Control and Operation Instruction ................10 5. Measure and Display Data ..................18 6. Pre-alarm and Shutdown Alarm................19 7.

  • Page 4: Description

    GU641A Controller Operation Manual 1. Description GU641A is a new generation Automatic Mains (Utility) Failure module for single Genset, which adopts bran-new outline configuration, focus on the requirements of customers, and perfectly improves the performance of controller. It fully meets the auto control requirements of different kinds of Genset for user or special assembly factory.

  • Page 5: The Outline Dimension Drawings And Controller Wiring

    GU641A Controller Operation Manual 2. The Outline Dimension Drawings and Controller Wiring 2.1 Following Details: Module Dimensions W192mm×H144mm Panel Cutout W174mm×H126mm Thickness D56mm (without connection)
  • Page 6 GU641A Controller Operation Manual 2.2 Terminal Connections: Function Description Signal GEN. V input 0-346Vac 1mm² L1-N GEN. V input 0-346Vac 1mm² L2-N GEN. V input 0-346Vac 1mm² L3-N GEN. Neutral 1mm² Not used MAINS V input 1mm² 0-346Vac L1-N MAINS V input 1mm²...
  • Page 7 GU641A Controller Operation Manual 2.3 Typical Wiring Diagram A fuse with the rating of 1A shall be provided external to the equipment.

  • Page 8: Panel Operation

    GU641A Controller Operation Manual 3. Panel Operation The operation panel consists of 3 sections: LCD display indicating measurement parameters, LED indicator for common failure, and push buttons for Genset and selection of control modes. LCD can display 3-row data in the same time. LCD also has a backlight so that the operator can clearly read information day or night.
  • Page 9 GU641A Controller Operation Manual STOP / RESET Button / “→” Move Setting The Push button is used for manually stops the Genset. No matter what mode the controller is running, press and hold this button for 2sec to stop the generator, the mode of the controller will be default to “MAN”...

  • Page 10: Control And Operation Instruction

    GU641A Controller Operation Manual 4. Control and Operation Instruction The controller has 3 modes: AUTO, MANUAL and TEST. 4.1 Operation Modes Setting: Operation Description Press and hold the “AUTO” button for 2sec, the LED above the button is illuminated; the controller is running in “AUTO” mode.
  • Page 11 GU641A Controller Operation Manual Generator Auto Start Sequence: Controller implements following procedure when Mains voltage failure occurs (it means that the controller detecting either the voltage or the frequency of Mains is over the range of preset values and delay confirmed), or Mains fail to load, or remote start signal is active and Mains failure;...
  • Page 12 GU641A Controller Operation Manual CAUTION: If magnetic pickup is not used, to avoid damage to the start motor please make sure the generator’s voltage is higher than the measurable value of controller while cranking, since the crank cutout signal is sensed from the generator voltage and frequency.
  • Page 13 GU641A Controller Operation Manual Stop Failure: When cool down times out, the fuel relay opens and the timer for Stop delay begins. If the controller detects that the voltage of the generator or oil pressure or the speed of engine is greater than the cutout values or LOP switch is open, when it times out, the failure LED illuminates and the LCD displays Fail to stop.
  • Page 14 GU641A Controller Operation Manual Generator starting sequence: Pressing “START” button the fuel relay energises, and operates the fuel solenoid of engine, After 300ms delay, the start relay output is energised, the start motor engages and begins to crank, when the engine speed reaches the crank cutout RPM, the start relay output is de-energised and the safety-on delay starts.
  • Page 15 GU641A Controller Operation Manual Stop control sequence for N.O. type: During the controller’s stop sequence, the fuel relay energises, fuel solenoid is on power, the fuel solenoid closes the fuel valve and the engine begins to stop. After a delay (same as Stop delay) fuel relay de- energises, disconnecting the supply from the fuel solenoid.
  • Page 16 GU641A Controller Operation Manual 4.8 The function of forcing start Reason to add this function to the controller is that when the engine under abnormal conditions, e.g. the battery voltage is too low or ambient temperature is too low, or generator only outputs voltage at a high speed when magnetic pick-up is not used, the Genset cannot be started successfully when it implements the build-up cranking process of controller.
  • Page 17 GU641A Controller Operation Manual 4.9 Flow chart for start and stop T1－ start delay T4－ safety-on delay T2－ crank time T5－ idle time T3－ pre-heat time T6－ Stop delay NOTE: If T4 is longer than T5, oil pressure protection is ignored during T5.

  • Page 18: Measure And Display Data

    GU641A Controller Operation Manual 5. Measure and Display Data Mains 3 phases V L1-N L2-N L3-N Ph-N Mains 3 phases V L1-L2 L2-L3 L3-L1 Ph-Ph Mains frequency Hz (L1) Gen 3 phases V L1-N L2-N L3-N Ph-N Gen 3 phases V...

  • Page 19: Pre-Alarm And Shutdown Alarm

    GU641A Controller Operation Manual 6. Pre-alarm and Shutdown Alarm 6.1 Pre-alarm (warning) (NOTE: Pre-alarms are non-critical failure conditions and do not affect the operation of the generator system, they serve for drawing the operators’ attention to an undesirable condition so they can remove it to ensure continuous running of the system.
  • Page 20 GU641A Controller Operation Manual GEN. OVER VOLT: If controller detects that any phase voltage of generator has exceeded the “GEN-V over preALM” after the safety-on timer has expired, the pre- alarm LED illuminates and the buzzer sounds, LCD displays For example, “rating voltage” preset as: 220V, “GEN-V over preALM” preset as: 115%, when the generator output voltage exceeds this value, LCD flashing high value icon for corresponding phase.
  • Page 21 GU641A Controller Operation Manual 6.2 Shutdown Alarm (NOTE: shutdown alarm failures immediately lock out the system and stop the Genset. The failure must be removed and the controller reset before restarting the Genset.) Shutdown Alarm / Description LCD displays START FAILURE: if engine does not fire after the preset number of crank...
  • Page 22 GU641A Controller Operation Manual OVERLOAD: After safety-on delay times out, if controller detects the active power is higher than “KW Overload Alarm”, Genset stops, the Shutdown alarm LED illuminates and buzzer sounds: For example, “rating active power” preset as: 300KW, “KW Overload Alarm”...

  • Page 23: Parameters Setting

    GU641A Controller Operation Manual 7. Parameters Setting 7.1 SYSTEM: Items Preset Value Range CT Ratio 1 to 1200 VT Ratio 1.0 to 25.0 Rated ph-voltage 45 to 9999VAC Rated current 1000 0 to 6000A Rated active power 0 to 3000KW...
  • Page 24 GU641A Controller Operation Manual Voltage type: There are 5 kinds of voltage input type: “Y” 3P4W, “△” 3P4W, 3P3W, 1P3W, 1P2W. 1— “Y” 3P4W (3 phases 4 wires star): 2— “△” 3P4W (3 phases 4 wires angle):...
  • Page 25 GU641A Controller Operation Manual 3— 3P3W (3 phases 3 wires): 4— 1P3W (single phase 3 wires): 5— 1P2W (single phase 2 wires):...
  • Page 26 GU641A Controller Operation Manual Comm. Address: Used to configure ID address for MODBUS. Each controller on the same MODBUS has a unique communication address. Startup mode: Used to configure the Startup mode of controller when it is powered up. When parameter is configured as “0”, the controller will be in Manual mode when it is powered up.
  • Page 27 GU641A Controller Operation Manual 7.2 GENERATOR: Items Preset Value Range GEN-V under preALM 20 to 200% / 0 not used GEN-V under Alarm 20 to 200% / 0 not used GEN-V over preALM 115% 20 to 200% / 999 not used...
  • Page 28 GU641A Controller Operation Manual KW Overload Alarm: Used to configure the over load alarm value, the KW Overload Alarm is inactive when parameter configured as “999”. Expressed by percentage, use “Rated active power” as factor. Alarm delay: Use a timer for confirmation of the alarm or pre-alarm.
  • Page 29 GU641A Controller Operation Manual 7.3 ENGINE: Items Preset Value Range Rated speed 1500RPM 99 to 9999 RPM MPU input 0 NO / 1 YES Fly wheel teeth 5 to 300 Set pickup now Pair of Poles 1 to 4 Fuel mode 0 N.C.
  • Page 30 GU641A Controller Operation Manual MPU input: Used to configure whether magnetic pick-up is used or not. When parameter is configured as “1”, magnetic pick-up is used for the signal source of the engine speed. When parameter configured as “0”, the magnetic pick-up is not used, the engine speed is calculated from the frequency of the generator.
  • Page 31 GU641A Controller Operation Manual CAUTION: The HET-sensor is used to measure the coolant temperature, its accuracy is very important to the protection of the Genset, so please match the right type of the sensor or configure the right curve of the senor. Otherwise it may cause engine damage.
  • Page 32 GU641A Controller Operation Manual P-sensor type: Used to configure the type of LOP sensor. Optional kinds of built-in LOP sensors in controller. Code Mode Note close for low oil pressure open for low oil pressure VDO 5 bar VDO 10 bar...
  • Page 33 GU641A Controller Operation Manual Pre-set 3: 10.3 P(Bar) R(Ω) Pre-set 4: P(Bar) R(Ω) NOTE: “Configurable” means user can input the data manually according to the sensor curve. It can be done only through PC software. When configuring, please input the “resistance- measured value” from small to big one by one.
  • Page 34 GU641A Controller Operation Manual Crank cutout Oil-P: The crank cutout engine oil pressure, signal is from LOP sensor. Crank cutout P-delay: Used to configure the period from engine LOP switch opened or oil pressure reaches oil pressure Crank cutout value to crank disconnection.
  • Page 35 GU641A Controller Operation Manual Under SP preALM: Used to configure the under speed pre-alarm value for the engine. l When parameter is set as “0”, this function is inactive. Under SP Alarm: Used to configure the under speed alarm value for the engine.
  • Page 36 GU641A Controller Operation Manual EX. Crank permit: Used to configure the permit of external crank. Refer to 4.8 for details. 7.4 Configurable Inputs and Outputs: Items Preset Value Range D-Input 1 1 to 20 / 0 not used D-Input 2...
  • Page 37 GU641A Controller Operation Manual Low level is active. Used for preheat mode 4, as the Preheat condition of preheat relay output is energised or not. Low level is active. In crisis mode, all shutdown alarms Crisis mode are changed to pre-alarm (warning), it means the Genset would not be shutdown when shutdown alarm occurs.
  • Page 38 GU641A Controller Operation Manual Reserved Reserved Reserved Reserved Over current alarm Reserved Low oil pressure alarm High engine temperature alarm Under speed alarm Over speed alarm Reserved Reserved GEN. under voltage alarm GEN. over voltage alarm KW overload alarm P-Sensor open alarm...
  • Page 39 GU641A Controller Operation Manual 7.5 ATS CONTROL Items Preset Value Range Mains-V low Alarm 20 to 200% / 0 not used Mains-V High Alarm 115% 20 to 200% / 999 not used Mains-Hz low Alarm 45.0Hz 10.0 to 100.0Hz / 0 not used Mains-Hz High Alarm 57.0Hz...
  • Page 40 GU641A Controller Operation Manual 7.6 CALIBRATION MENU Items Preset Value Range GEN. V1 offset -9.9% to 9.9% GEN. V2 offset -9.9% to 9.9% GEN. V3 offset -9.9% to 9.9% Current I1 offset -9.9% to 9.9% Current I2 offset -9.9% to 9.9% Current I3 offset -9.9% to 9.9%...
  • Page 41 GU641A Controller Operation Manual Mains V2 offset: Used to modify the measured value display of Mains Phase 2 Voltage. Reference to the Rated voltage. Mains V3 offset: Used to modify the measured value display of Mains Phase 3 Voltage. Reference to the Rated voltage.

  • Page 42: Installation Guide

    GU641A Controller Operation Manual 8. Installation Guide 8.1 The cutout dimensional drawing installed on panel as above follows: Cutout dimension: 174mm (W) x 126mm (H). The controller is fixed by 6 special fittings. NOTE: The shock-proof equipment must be mounted if the enclosure is mounted on Genset or other heavy vibrant device.
  • Page 43 GU641A Controller Operation Manual 8.2.2 Power supply: Power specification: 8-35Vdc continuous DC voltage range Max. operating current @12V, 300mA; @24V, 150mA 0V for 80ms, assuming dc supply was at least 10V before Cranking dropouts dropout and recovers to 5V, controller can be normally operated dispenses with additional aux.
  • Page 44 GU641A Controller Operation Manual NOTE: For ensuring the accuracy of sensor please reduce the cable resistance between controller and sensor as much as possible, the cross section area of cable should not be less than 2.5mm When single pole sensor is used, the terminal #16 must be directly connected to the generator’s earth point, but not to the control panel or other...
  • Page 45 GU641A Controller Operation Manual 8.2.5 Typical connection for voltage input and current that corresponding to difference generator winding: 3P4W (3 phases 4 wires) Measure and Display Data Mains 3 phases V L1-N L2-N L3-N Ph-N Mains 3 phases V L1-L2 L2-L3 L3-L1...
  • Page 46 GU641A Controller Operation Manual 3P3W (3 phases 3 wires), CT measure at Gen side Measure and Display Data Mains 3 phases V L1-L2 L2-L3 L3-L1 Ph-Ph Mains frequency Hz (L1) Gen 3 phases V L1-L2 L2-L3 L3-L1 Ph-Ph Gen frequency Hz (L1) Gen 3 phases current I1 I2 I3 Gen total apparent power ∑A...
  • Page 47 GU641A Controller Operation Manual 1P3W (single phase 3 wires), CT measure at Gen side Measure and Display Data Mains V L1-N L2-N Ph-N Mains V L1-L2 Ph-Ph Mains frequency Hz (L1) Gen V L1-N L2-N Ph-N Gen V L1-L2 Ph-Ph...
  • Page 48 GU641A Controller Operation Manual 1P2W (single phase 2 wires), CT measure at Gen side Measure and Display Data Mains V L1-N Ph-N Mains frequency Hz (L1) Gen V L1-N Ph-N Gen frequency Hz (L1) Gen current I1 Gen phase apparent power A...
  • Page 49 GU641A Controller Operation Manual 8.2.6The connection of configurable digital inputs There are 5 configurable Inputs, which used for monitoring and control status, all of the inputs adopt electrical isolation, and controller internal provides 8vdc power supply, no need an additional power.
  • Page 50 GU641A Controller Operation Manual 8.2.7 Connection for the configurable output relays There are 6 relay outputs, except fuel and crank relays which are fixed function, other relays’ function all can be configured by user. NOTE: Terminal #17 is the common port for RL1 to RL6, and it is connected to power positive.

  • Page 51: Lcd Displays And Menu System

    GU641A Controller Operation Manual 9. LCD displays and Menu System LCD displays measuring parameters: Use a back-light TN LCD to display data and information. Each page can display multi-row information simultaneously, and the corresponding icon displays each status and data clearly. Display all status data and information needs several pages.
  • Page 52 GU641A Controller Operation Manual For example: (configure CT ration at 500/5, then CT should be configured as 100) Operation Description Press and hold “ ” 2sec, enter into parameters setting menu, then LCD displays: Press “√” button, then LCD displays: Press “+”...
  • Page 53 GU641A Controller Operation Manual For example: (resume parameters of controller to factory defaults) Operation Description Press and hold “ ” 2sec, enter into parameters setting menu, then LCD displays: Press “+” 9 times, then LCD displays: Press “√” button, it prompts to key in password, the password is 2213, (press “→”, move to desired modify number).

  • Page 54: Technical Specification

    GU641A Controller Operation Manual 10. Technical Specification 10.1 AC voltage: Measurement True RMS Phase to Neutral 15 to 346VAC Phase to Phase 25 to 600VAC Max power wastage per line <0.1W Accuracy Display 0 to 9999V 10.2 AC voltage frequency: 3 to 70Hz (voltage ≥15VAC)
  • Page 55 GU641A Controller Operation Manual 10.7 Charge failure input: Range 0 to 35Vdc Accuracy Max output current @12V 120mA, @24V 240mA 10.8 Analog Inputs: Number Sensor type resistance Resolution 10 bits Range 0 to 1KΩ When full scale, except for sensor...

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