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GCU-5K
Ver1.0
Automatic Control &
Protection Module for Generator
＊Support Electronic Engine (SAE J1939) parameter reading and display
KUTAI ELECTRONICS INDUSTRY CO., LTD.
TEL : +886-7-8121771
FAX : +886-7-8121775
Website : www.kutai.com.tw
Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 806037, Taiwan
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Summary of Contents for Kutai electronics GCU-5K
- Page 1 Ver1.0 Automatic Control & Protection Module for Generator ＊Support Electronic Engine (SAE J1939) parameter reading and display KUTAI ELECTRONICS INDUSTRY CO., LTD. TEL : +886-7-8121771 FAX : +886-7-8121775 Website : www.kutai.com.tw Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 806037, Taiwan...
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Page 2: Table Of Contents
3.1.3 Precautions for Assembly Wiring ......................9 3.2 Wiring Installation of the GCU-5KC and DP-70G ..................9 3.3 Wiring Assembly of the GCU-5K and Generator ..................10 3.3.1 Schematic Diagram of GCU-5KC Wiring Terminal and Number Positions ........... 10 3.3.2 GCU-5KC Connection Terminals, Communication Ports, and Connectors .......... 11 3.3.3 Recommended Wiring Diagram ...................... - Page 3 6.4.2.2 Applying for an account from GenOnCall® APP ................29 6.4.3 Control Unit Binding ..........................29 6.4.4 Edit Operator and Viewers ........................30 6.4.5 Establishing a connection With the GCU-5K Controller ................ 30 6.4.6 Unbinding............................... 31 6.4.7 Editing Push Notification ........................31 6.4.8 GenOnCall®...
- Page 4 7.5.2.1 Payment on KUTAI Website ....................... 40 7.5.2.2 Payment via GenOnCall® APP ......................40 7.5.2.3 Counter Cash Payment ........................40 SECTION 8 : INTRODUCTION TO GCU-5K 8.1 Product Overview ............................. 41 8.2 Function and Features ..........................41 8.3 Color LCD Displayed Contains ......................... 41 8.4 System Protections and Fault Alarms ......................
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Page 5: Section 1 : Safety Precautions
Failure to follow the correct procedures may result in personal injury or death. This manual contains information on the installation, wiring, application, operation, and maintenance of the GCU-5K Auto Start Control & Ptorection Module for Generator. It should be thoroughly read before operation. -
Page 6: Dp-70G Overview
Unit is successfully positioned Remote login connection Control unit settings allowed Firmware update prompt Front View Emergency Stop Button 7’’ Color LCD Panel Screen resolution 800480 Multi-function Rotary Knob Rear View Waterproofing Gasket DB9 Port Sound Outlet Mounting Holes x 6 ___________________________________________________________________________________________ GCU-5K... -
Page 7: Gcu-5Kc Overview
2.3 GCU-5KC Overview Mounting Holes AC Voltages Inputs Current Transformer Inputs Battery Power Inputs Output Signals 4G/5G Wi-Fi Router USB Power Supply Wiring Fixture Input Signals Owner Button CAN bus Status Indicators Terminals KCU-Module DB9 Port Expansion Slot ___________________________________________________________________________________________ GCU-5K... -
Page 8: Section 3 : Product Installation
155.0 [6.10"] 153.0 [6.02"] 280.0 [11.02"] Panel Cut-out 35.0 [1.38"] Metal door 42.7 [1.68"] Unit : mm [inch] 3.1.2 GCU-5KC 161.5 [6.36"] 53.0 [2.09"] 4xM4 37.0 [1.46"] 271.0 [10.67"] 283.0 [11.14"] 100.0 [0.18"] [3.94"] Unit : mm [inch] ___________________________________________________________________________________________ GCU-5K... -
Page 9: Precautions For Assembly Wiring
2. A loose DB9 connector will result in a disconnection between the GCU-5KC and DP-70G. The DP-70G will not function properly and remote monitoring operations cannot be performed. ___________________________________________________________________________________________ GCU-5K... -
Page 10: Wiring Assembly Of The Gcu-5K And Generator
1. Complete all wiring connection (except the battery cables). 2. Check whether all wiring connections are correct. 3. Connect the battery power. 4. Set the GCU-5K to the "STOP" position. 3.3.1 Schematic Diagram of GCU-5KC Wiring Terminal and Number Positions... -
Page 11: Gcu-5Kc Connection Terminals, Communication Ports, And Connectors
AWG 18 Input Signal must be Battery B- Input Signal User Configurable Input H AWG 18 Input Signal must be Battery B- Input Signal User Configurable Input J AWG 18 Input Signal must be Battery B- Input Signal ___________________________________________________________________________________________ GCU-5K... -
Page 12: Recommended Wiring Diagram
User Configurable Output E Oil Pressure Sender CAN-L Temperature Sender CAN-H Fuel Level Sender Shield Remote Start User Configurable Input F User Configurable Input G User Configurable Input H User Configurable Input J User Configurable Input K MPU+ MPU- DB9 Cable ___________________________________________________________________________________________ GCU-5K... -
Page 13: Section 4 : Front Panel Configuration
Section 6 and 7) Front Panel Configuration 4.1.1 Enabling On-Site Parameter Configuration Permissions Implementing the system parameter configuration, the GCU-5K must be in Stop mode and hold the Owner button on. The screen will display the following options: ● Onsite Configuration Enable ●... - Page 14 Oil Pressure Sender Failure Warning or Shutdown Shutdown Options: None / Warning / Shutdown Oil Pressure Sender Failure Permitted Delay 10 Sec Adjustment range: 1 ~ 99 s Active Value of Low Oil Pressure Warning 25 Psi Adjustment range: None / 10 ~ 50Psi ___________________________________________________________________________________________ GCU-5K...
- Page 15 Adjustment range: None / 8 ~ 25 Vdc Charge Alternator Fault Warning or Shutdown Warning Options: Warning / Shutdown Charge Alternator Fault Permitted Delay 10 Sec Adjustment range: 1 ~ 99 s Pre-Heat or Crankings Interval Timer 6 Sec Adjustment range: 2 ~ 99 s ___________________________________________________________________________________________ GCU-5K...
- Page 16 Adjustment range: 1 ~ 31 Day of Week Current Time Options: Monday to Sunday Hour Current Time Adjustment range: 0 ~ 23 (24Hr) Current Time Minute Adjustment range: 0 ~ 59 Restore Factory Configuration Options: Yes / No ___________________________________________________________________________________________ GCU-5K...
- Page 17 Level Switch Input/User Define Input/Utility Power Outage/Forced to Idel Checked User Configurable Input G when Engine is running Options: Yes / No User Configurable Input G Failure Warning or Shutdown Function Closed Options: Function Closed / Warning / Shutdown ___________________________________________________________________________________________ GCU-5K...
- Page 18 User Configurable Input K Signal NO or NC Normal Open (NO) Options: Normal Open (NO) / Normal Close (NC) 10 Sec User Configurable Input K Failure Permitted Delay Adjustment range: 1 ~ 99 s Detect Engine Startup Using Oil Pressure Switch Options: Yes / No ___________________________________________________________________________________________ GCU-5K...
- Page 19 Adjustment range: None / 1 ~ 99 38400 KCU-XX Baud Rate Options:115200 / 57600 / 38400 / 19200 / 14400 / 9600 / 4800 / 2400 KCU-XX Parity Bit Options: N81 / N82 / E81 / O81 WPS Location Service Options: Yes / No ___________________________________________________________________________________________ GCU-5K...
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Page 20: Section 5 : Generator Operational Test
The generator will be locked in at OFF state until the “Emergency Stop Button” is pressed again to unlock it. When Ethernet control is activated, GCU-5K will execute STOP / START / Auto modes based on the most recent command received (through Ethernet or On-Site). -
Page 21: Shutdown Procedure
Display operating status and Messages Steady = Stop Rotating = Operating ： Time delay countdown Running Hours Operating Mode ： Fault warning message AUTO / STOP / START Maintenance Reminder Countdown timer ： Shutdown message Power measurement Readings Battery Voltage ___________________________________________________________________________________________ GCU-5K... -
Page 22: Power Measurement Readings Display
The power measurement reading display includes generator's total phase voltage, current, frequency, KVA, KW, KVAR, RPM, KWH, and power factor (PF). 6.1.3 Event Log Display The GCU-5K provides the latest 250 event history records. Each fault record includes the Event Type, Occurrence Time, and Event Content. Event Type： Event type include Failure Warning, Shutdown, Engine Start, Operation mode changed, and other event records. -
Page 23: Ecu (Sae J193) Electronic Engine Parameter Display
ECU (SAE J1939) Electronic Engine Electronic Engine measurement Value Parameter SPN KUTAI GCU-5K can display up to 53 electronic engine parameters. Actual displayable items may vary based on the permissions of the installed ECU brand. 6.1.5 Location Map Display ®... -
Page 24: Overview Of Remote Monitoring And Control Functions
● Delete Event Log, reset Engine Running Hours, and KWH meter to zero (only Owner has this permission) When GCU-5K is set to "Remote Enable" or "AUTO" mode, the GCU-5K can accept remote control to start the generator. The following instructions must be followed, otherwise, it may lead to personnel injury or death: 1. -
Page 25: Controller Connection To Kutai Server
● WPS Mode: The Wi-Fi router with a WPS button can automatically pairs to obtain Wi-Fi domain name and password. ● AP Mode: If the Wi-Fi router used does not have a WPS auto-pair button, since GCU-5K does not have keyboard ®... -
Page 26: Ap Mode Wi-Fi Connection Setting
WPS button and its location. 6.3.1.2 AP mode Wi-Fi connection setting GCU-5K Front Panel Operation: Step 1： 1. Set GCU-5K at STOP mode, then press multi-functionn rotary knob 2. Enter Main function menu then click Other Setting Step 2： Select Wi-Fi AP Setting Step 3：... - Page 27 Once GCU-5K Wi-Fi set up is completed, the information bar on GCU-5K should show (connected with KUTAI Server). User can also enter the GCU-5K “About” for details on the eonnected Wi-Fi, ex. MAC SSID and IP information. Since Kutai-xxxxxxxxxxxx is a local Wi-Fi without internet capabilities, it's solely for setting up Wi-Fi. If a "No internet connection.
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Page 28: Installation Of 4G / 5G Wireless Wi-Fi Router
1. Securely install and fasten the KCU-31 and RJ45 network connector as shown in the left image to prevent poor contact due to vibrations, which could cause the GCU-5K to fail to connect to the internet. 2. If a symbol appears in the Information Bar of the DP-70G, it indicates that a connection has been established with KUTAI Server. -
Page 29: Downloading The Genoncall® Application
Control Unit Binding All GCU-5K units to be remotely monitored must first go through the binding process. The account used for binding will be considered the Owner of the device. The device must be actively connected to the server during binding. If the control module is not connected or if the entered product serial number is incorrect, the system will display a device offline message. -
Page 30: Edit Operator And Viewers
Open and log-in to the GenOnCall App ► Click Devices ► Enter Device Serial Number or scan the Serial Number on GCU-5K ► Press Confirm ►Enter Device Name ► Press Confirm Android Operation ： ® Open and log-in to the GenOnCall App ►... -
Page 31: Unbinding
GCU-5K is set at Remote Enable. 6.4.6 Unbinding Once the GCU-5K is bound, it cannot be re-bound by other account unless the unbinding process is performed first. The unbinding can be done by local GCU-5K controller or remotely by Owner’s mobile phone through GenOnCall ®... -
Page 32: Genoncall Settings On Mobile Device
2. Click Alarm Sound to turn on or off the mobile fault alarm sound. 3. Wi-Fi module setting ： Execute Wi-Fi settings on GCU-5K. ® 4. App Usage Guide ： Instruction for using the GenOnCall 5. Log Out ： User account logout... -
Page 33: Section 7 : Remote System Parameter Settings
Has the authority to remotely operate the GCU-5K to change system parameter settings, and Operator monitor all information of the Generator. The GCU-5K only allows one operator to log in. Only has the authority to monitor all information of GCU-5K which allow up to seven viewers Viewer to log in and monitor simultaneously. -
Page 34: Voltage Paramaters Setting
► Press System Setting ► Press Voltage Setting ► Press Under Voltage Setting ► Turn ON Under Voltage Warning or Under Voltage Shutdown ► Click on setting boxes ► Use the keypad to input the Under Voltage Protection values ► Press to enter. ___________________________________________________________________________________________ GCU-5K... -
Page 35: Abnormal Voltage Permitted Delay
► Press MPU Failure Warning or MPU Failure Shutdown ► Press setting boxes ► Use Magnetic Pick-Up Use the keypad to input the MPU Failure Permitted Delay time and Teeth of Flywheel ► Press to enter the values. ___________________________________________________________________________________________ GCU-5K... -
Page 36: Fuel Level Parameter Settings
► Press System Setting ► Press Oil Pressure Setting ► Press Oil Pressure Sender Malfunction Protection ► Turn ON Oil Pressure Sender Malfunction Protection ► Select Oil Pressure Sender Malfunction Warning or Shutdown ► Press setting boxes ► Use the keypad to input Permitted Delay time ► Press to enter the value. ___________________________________________________________________________________________ GCU-5K... -
Page 37: Low Oil Pressure Setting
7.2.8.2 User Configurable Output A to E Settings When the Generator requires additional control features beyond the GCU-5K standard output, or when a specific fault alarm signal output is needed from the GCU-5K, the User Congigurable Output A to E can be set for use. Press ►... -
Page 38: Engine Start / Stop Settings
Refer to the generator operation manual before setting. 7.2.9.8 Detect Engine Startup Using Oil Pressure Switch Press ► Press System Setting ► Press Engine Start / Stop Setting ► Press Detect Engine Startup Using Oil Pressure Switch ► Click on Yes or No. ___________________________________________________________________________________________ GCU-5K... -
Page 39: Battery And Charge Alternator Parameter Settings
Finding Longitude and Latitude Coordinates with Google Maps: Open Google Maps Application ► Move Map to Find Accurate Installation Location of GCU-5K ► Long Press on the Map at that Position ► Longitude and Latitude Coordinates are displayed at the Top or Bottom of the Screen Finding Longitude and Latitude Coordinates with Apple Maps: Open Apple Maps Application ►... -
Page 40: About This Unit
® KUTAI will aperiodically provide updated firmware programs for GCU-5K or updated versions of the GenOnCall APP for users to download and upgrade. When a smart device is connected to the GCU-5K, if the firmware update icon is displayed in the top information bar, user can click on the firmware update icon in STOP mode to remotely execute the local GCU-5K firmware update. -
Page 41: Section 8 : Introduction To Gcu-5K
SECTION 8 : INTRODUCTION TO GCU-5K 8.1 Product Overview The GCU-5K provides comprehensive protection for generator, along with functions like remote monitoring, location services, and push notifications for fault message. Users can directly operate from the local end (On-site) or access remote monitor or setting through GenOnCall ®... -
Page 42: Electrical Characteristics
VDO 0 to 150 PSI SECTION 9 : OPTIONAL ACCESSORIES Modbus-RTU communication module (KCU-05) SNMP communication module (KCU-06) Modbus-TCP/IP communication module (KCU-07) Ethernet (Dynamic IP) communication module (KCU-31) For installation instructions, refer to the user manual of related KCU communication module. ___________________________________________________________________________________________ GCU-5K...
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