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Mecc Alte SMARTECH GC250 Technical Manual

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GC250
CONTROLLER
TECHNICAL MANUAL

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Summary of Contents for Mecc Alte SMARTECH GC250

  • Page 1 GC250 CONTROLLER TECHNICAL MANUAL...
  • Page 2 GC250 Technical Manual This Page Intentionally Left Blank ENGLISH Code: EAAM057616EN Rev. 16 | Date: 1/03/2023 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 3 Valid for firmware version 1.17. 5.6.4, 5.7.2, 5.7.3, 5.8.4, 7.2, 7.4.8.8, 7.4.8.10, 7.4.8.11, 7.4.8.12, 7.4.8.13, 7.4.8.14, 9.6.5, 9.6.7, 11.3, 11.13 01/03/2023 Valid for firmware version 1.19. 7.2, 7.4.1, 9.5.3.1 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 4: Table Of Contents

    5.8.4 Digital inputs configuration ................45 T.22...T.28 Connection to the mains ..............50 5.9.1 Measurement of the mains neutral ............... 50 5.10 T.30...T.36 Connection to generator ............. 51 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 5 9.3.1 Genset frequency ..................104 9.3.2 Genset voltages ..................105 9.3.3 Generator status..................107 9.3.4 Communication and events ................ 107 Automatic intervention of the generator inhibited..........107 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 6 29 – High fuel level (from contact) ................. 133 30 – High fuel level (from analogue sensor) ............133 31 – High coolant temperature (from contact) ............133 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 7 Other functions ....................150 11.1 Fuel pump ....................150 11.1.1 Use with an analogue level transducer ..........151 11.1.2 To use this function requires: ..............151 11.1.3 Level evaluation ..................152 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 8 Using a contact level transducer ............163 11.13.3 Evaluation of the level ................163 11.13.4 Automatic pump control ................ 164 11.13.5 Manual pump control................164 11.13.6 Protections .................... 164 11.13.7 Signalling ....................164 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 9: Introduction

    The message can also be used only for minor dangers that may cause damage to equipment ATTENTION! and/or people. This term indicates that the message includes useful information for the development of the operation or procedures clarifications. INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 10: Introduction And Prerequisites

    Although most configurable parameters are accessible from the front panel, some particular features or configurations, due to their nature, can only be set or edited through the Mecc Alte Board Programmer4 PC Software (hereinafter called “BoardPrg4”), which can be downloaded for free from the Mecc Alte website www.meccalte.com...

  • Page 11: Definitions

    Several parts of this manual refer to the controller's software revisions. These revisions are marked with the assigned Mecc Alte code (shown on the rear panel of the controller). The format of the code is: EB0250256XXYY, where “XX” is the main version and “YY” is the minor version. Thus, the code EB02502560100 refers to the controller software release "1.00".

  • Page 12: Views Of The Device

    Controller GC250 Technical Manual ENGLISH Code: EAAM057616EN GC250 Rev. 16 | Date: 1/03/2023 2 Views of the device GC250 Front view Rear GC250 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 13: Technical Features

    (siren, LCD lamp, digital inputs active; 110mA @ 27 VDC communicating CANBUS; 132mA @ 13.5 VDC analogue inputs to GND; static outputs and +D not active) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 14 4mA for T.16 and 4.6mA for the other three inputs. Maximum voltage applicable: 60VDC Minimum voltage applicable: -24VDC The input T.16 can be configured as analogue input for the measurement of the voltages (see below) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 15 Self-regulating contrast with the temperature and with possibility of manual correction. Operating conditions From -30°C to +70°C, 95% not condensing humidity Stock conditions From -35°C to +80°C Size 141(L)x113(H)x39(P)mm Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 16: Measurement Resolution

    Min. 0.1 kW/kVA/kVAr (it depends on the CT ratio) Power Factor 0.01 Energy 1 kWh/kVArh Engine speed 1 rpm Oil pressure 0.1bar (below 10bar) Cooling liquid temperature 0.1°C Fuel level 0.1% Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 17: Installation

    The device can operate in CAT.III only if the negative supply terminal of the device and the neutral terminal of the generator are connected to the protective earth. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 18: In/Out Connections And Configuration

    2 screw terminals 0...10V Configurable digital inputs T.17 Digital input 2 T.18 Digital input 3 T.19 Digital input 4 T.20 CAN_H CANBUS connection and ECU engine T.21 CAN_L Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 19: Correspondence Input/Output And Their Logic Functions

    T.16 DI_CONTROLLER_T16 N.U. Available T.17 DI_CONTROLLER_T17 N.U. Available T.18 DI_CONTROLLER_T18 EMERGENCY STOP EMERGENCY STOP T.19 DI_CONTROLLER_T19 START INHIBITION START INHIBITION T.09 DI_CONTROLLER_T09 N.U. Available T.13 DI_CONTROLLER_T13 N.U. Available Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 20: Application Type

    ST.336: Auto Start application ST.337: Auto Mains Failure application • • ST.346: DRIVE application According to the application type, the connection diagram changes, as indicated in the following paragraphs. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 21: Principle Connection Diagram For Auto Mains Failure Applications

    Controller GC250 Technical Manual ENGLISH Code: EAAM057616EN GC250 Rev. 16 | Date: 1/03/2023 5.2.1 Principle connection diagram for Auto Mains Failure applications Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 22: Principle Connection Diagram For Auto Start Application

    Controller GC250 Technical Manual ENGLISH Code: EAAM057616EN GC250 Rev. 16 | Date: 1/03/2023 5.2.2 Principle connection diagram for Auto Start application Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 23: And T.02 Device Supply

    Also, the identification is carried out every time that the unit is switched the related logics and alarms. to the OFF/RESET mode. During the installation, open all the fuses in the panel before connecting the battery positive. WARNING! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 24: Engine Commands Outputs T.03 And T.04

    For currents above the nominal value or for inductive loads with values higher than 500mH it’s necessary to use an external relay. ATTENTION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 25: Fuel Solenoid Fuel Solenoid Command

    T.03, as shown before, to cut the power to the starter motor and one NO between battery plus and valve/stop command with no intermediate fuses which, when activated, delivers positive voltage to the stop valve by bypassing the controller command. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 26: D+ Energizing And Checking The Operation Of The Recharge Alternator

    +D voltage of the recharge alternator drops below 0V or if it does not rise after start, once the P.0349 time is up, it is assumed that the belt is broken or at least that there is a malfunction and the controller activates the Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 27: D+ Input Used As Analogue Input

    With inductive loads (power relays, electromagnetic actuators), although some are already present inside, it is advisable to use diodes for damping opening over voltages. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 28: Load Switching Commands Auto Mains Failure Applications

    DOF.2034 - “GCB steady closing command”. The GCB command is used to connect the loads to the generator. The MCB command is used to connect the loads to the mains. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 29: Load Switching Commands For Auto Start Applications

    The wiring diagram provides a circuit breaker GCB in mains voltage commanded by means of a relay; it is also possible to use a circuit breaker in battery voltage observing the limits of current of the output used. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 30 The default configuration of the device provides a use of the output T.08 that is specifically configured as default. It is by the way possible to use any digital output configured with the function. DOF.2034 - “GCB steady closing command”. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 31: Digital Outputs Configuration

    By default, all bits are set to zero. The digital outputs can be used directly as command for devices outside the controller, or for reporting certain operating conditions. Functions configurable on the digital outputs Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 32 It is activated in OFF/RESET mode by pressing the STOP key: it can be used to turn on possible external led to the controller, and have one only procedure to test the warning lights Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 33 037: Start battery low voltage. 038: Start battery high voltage. 039: Service required. 041: Minimum oil pressure (from contact). 042: Minimum oil pressure (from analogue sensor). Continued overleaf… Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 34 It is activated in case of faults of the GCB and MCB breakers, i.e.: 013: Mains circuit breaker not closed 014: Genset circuit breaker not closed 023: Mains circuit breaker not open 024: Genset circuit breaker not open Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 35: And/Or Logics

    ST_XXX: internal statuses of the controller.  AT_XXX: statuses concerning the thresholds on ANALOGUE measures (see par. 5.7.3In fact, every digital input can  have an AND/OR logic associated, which determines its status. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 36 Clock/Calendar start inhibition ST_088 Inhibition of the GCB closing from contact ST_090 Inhibition of the GCB closing from serial port ST_096 Ready to supply ST_104 Supply ST_112 Synchronization every second Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 37 DPF status: regeneration needed - lowest level (spn3701=1) ST_373 DPF status: regeneration needed - moderate level (spn3701=2) ST_374 DPF status: regeneration needed - highest level (spn3701=3) ST_998 Always active ST_999 Always not active Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 38: Analogue Inputs

    The three inputs are between themselves electrically identical. Each input can be singularly configured for the measure of the resistive signals; by default, the analogue measures are not enabled. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 39: Input T.12 Analogue Reference (Analogue Reference)

    The measure of the voltage with respect to the GND terminal is displayed on page S.07, under item T.12; the measuring range of the system, and therefore the value indicated, can be higher than the one useful for compensation, mentioned above. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 40: Configuration And Functions Of Analogue Inputs

    One parameter, which configures the checking options and the actions in case of “out of threshold” (P.4013 and  P.4016 for input T.13). The thresholds defined here do not depend on any threshold set within the menus “Protections”; INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 41 The following table shows the list of functions that can be associated to the ANALOGUE inputs: Inputs Functions Thresholds T.16 T.13 T.09 T.14 T.15 AIF.0000 Not used AIF.0100 Used as digital input AIF.1000 Oil pressure (VDO) AIF.1001 Oil pressure (general) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 42: Conversion Curves

    The conversion curves cannot be configured directly from the panel of the controller board, but through a PC equipped with the BoardPrg4 software. INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 43: Digital Inputs

    BoardPrg4. The virtual inputs can be configured as feature and can be used the same way as the physical inputs. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 44: Digital Inputs

    T.18 must remain connected with GND through a NC contact in the emergency WARNING! button; when the contact opens, the relative alarm is generated (see wiring diagram par. 0) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 45: D+ Input Used As Analogue Input

    A parameter that configures a possible delay of the function activation (P.2002 for the input T.16, the consecutive  parameters for the other inputs). See documents [1] for the parameters list. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 46 When the input “activates” (only in MAN mode), the controller tries to start (only once) in the same way of an automatic start, that is commanding the motor up to the start success or failure. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 47 GCB status. It is used to detect the actual status of the KM/MCB circuit breaker. In case of discordance between status and command, a signalling will outline it. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 48 (JH_03) is active, a warning is activated. DIF.4033 Deactivation (if FUEL is When the input is active, if the fuel solenoid valve control is enabled). active, a deactivation is commanded. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 49 When the input is “active”, if the time set by means of the temperature P.0216 parameter from engine start has elapsed, a fixed description (language-dependant) warning is activated. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 50: Measurement Of The Mains Neutral

    5.9.1 Measurement of the mains neutral The device, in three-phase connection, can function both with the neutral connection and without it; selection is performed through the P.0129 parameter. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 51: Measurement Of The Generator Neutral

    5.10.1 Measurement of the generator neutral The device, in three-phase connection, can function both with the neutral connection and without it; selection is performed through the P.0128 parameter. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 52 The TA measuring the three currents have a sole terminal T.41 for the return current. The measurement is carried out by shunt. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 53: Communication Resources

    With supply by USB, the light if the LCD display can be reduced compared to the normal operation; this is normal, and it is not to be considered a device fault. INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 54: Rs485 (Optional)

    The download of the history logs can be realised by means of special software tools. Loading/replacing the firmware of the device is a specific operation of Mecc Alte; in addition to the operating FW to be loaded, it requires a particular procedure and specific programs and normally this procedure must not be carried out by the person who performs the installation, except in specific situations previously agreed on with Mecc Alte.

  • Page 55: Can-Bus Connections

    CAN_H and CAN_L terminals of the control unit. NOTE: the termination must always be enabled, unless the connection proceeds to other devices and the Controller is not one of the two ends. INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 56: Command And Indications

    Fig. 1 – GC250 Front Panel 1 - Push-button 2 - Indicators The controls consist of 5 buttons (1a, 1b). The front panel also has 5 luminous indicators (2a, 2b). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 57: Pushbuttons

    By pressing the button for around half a second, the controller provides for the automatic management of the generator, which will be started when the plant AUTO conditions require it. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 58 MCB opening and GCB closure. When the controller is turned on, keeping it pressed at the same time as the STOP button, it allows access to the special functions. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 59: Indicators

    Indicates the presence of at least one lockout, one deactivation or  power-off ALARM There is at least one active warning.  No anomalies.  Indicates engine running  ENGINE RUNNING Indicates engine idle  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 60: Multifunctional Display

    Fig. 2 - Mode navigation menu Mode Icon Description Page Identifier PROGRAMMING Programming P.XX STATUS Status information S.XX MEASURES Electrical measurements M.XX ENGINE Engine measurements E.XX HISTORY History logs H.XX Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 61: Structure Of Display Areas

    DOWN Ref. 1c 7.4.4 Structure of display areas E.01 AUTO KEY: 1 - Status bar 2 - Data area °C Fig. 4 - Display areas Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 62: Top Status Bar

    The view of the operation mode doesn’t change when the pages change. The view mode identifier (1a), and the page identifier (1b) identify and refer to the page so there is no chance of error. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 63: Status Information (S.xx)

    The status of the generator voltage (absent, low, high etc.)  : Lack of voltage on the generator. : Generator voltage present, but “out of tolerance” (low). : Generator voltage present, but “out of tolerance” (high). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 64 If multiple diagnostic codes are active at the same time, they will be cyclically alternated on the display every 2 seconds. The diagnostic codes are stored (even if the external device deactivates them) until the yellow/red Can-Bus indicator light warning is acknowledged with the “ACK” button. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 65 Pressing and holding the digit ▼ it is possible Page S.06 to display the turning inputs in two different ways: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 66 T.12, of T.09 (D+) and of the analogue input T.16. For each input the measure in Volt is displayed, for terminals T.13, T.14, T.15 the measure in ohm is also displayed. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 67: Electrical Measures (M.xx)

    The arrow flashes (to indicate a faulty situation) in case of reversed power on the generator and in case of negative power to the loads. The active power measure and that of the power factor.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 68 This page is only shown for the three-phase systems and only if the system is configured to use the neutral connection (see par. 5.10.1). In fact, every digital input can have an AND/OR logic associated, which determines its status. The three Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 69 (login) in parameter P.0000 (" Access code"). To the bottom right there is an icon that allows immediate identification of the fact that the page is related to the GENERATOR measures. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 70 2521 - Load type L3 (0=leading, 1=lagging) • spn 2468 - Exported active energy spn 2469 - Imported active energy • • spn 3380 - Excitation voltage Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 71 (usually when they do not follow the J1939-75 standard). The controller offers up to six pages. The configuration file defines the number of measurements shown and their description. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 72: Engine Measurements (E.xx)

    If some of these measures are not available, they are hidden. 7.4.8.4 E.04 COUNTERS This page contains various counters (managed by the controller board), which concern the engine: Start-up counter (resettable to zero).  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 73 (fixed or flashing, like red lamp). It is linked to SPN 3697 (“DIESEL PARTICULATE FILTER LAMP COMMAND”) or 6915 (“SCR SYSTEM CLEANING LAMP COMMAND”). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 74 Information not available is not displayed. The number of pages displayed therefore depends on the actual information transmitted by the engine control unit. The information shown on this page are: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 75 1135: Engine Oil Temperature 2.  spn 1136: Engine ECU Temperature.  spn 1172: Engine Turbocharger 1 Compressor Intake Temperature  spn 1180: Engine Turbocharger 1 Turbine Intake Temperature  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 76 The parameter can be modified directly from page E.20. As an alternative to the parameter, it is possible to use two digital inputs configured with the following functions: DIF.2071: inhibits regeneration.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 77 SPN 3715 (“DIESEL PARTICULATE FILTER ACTIVE REGENERATION INHIBITED DUE TO PERMANENT SYSTEM LOCKOUT”) SPN 3716 (“DIESEL PARTICULATE FILTER ACTIVE REGENERATION INHIBITED DUE TO ENGINE NOT WARMED UP”) SPN 3750 (“AFTERTREATMENT 1 DIESEL PARTICULATE FILTER CONDITIONS NOT MET FOR ACTIVE REGENERATION”) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 78 SPN 5963 ("AFTERTREATMENT 1 TOTAL DIESEL EXHAUST FLUID USED") • SPN 6563 ("AFTERTREATMENT TRIP DIESEL EXHAUST FLUID") • SPN 4360 ("AFTERTREATMENT 1 SCR INTAKE TEMPERATURE") • SPN 4363 ("AFTERTREATMENT 1 SCR OUTLET TEMPERATURE") Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 79 The controller provides up to six pages. The configuration file defines the number of measures shown and their description. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 80 The controller shows one measure per line: it shows the text configured for analogue input (P.4010 analogue input T.13), followed by the measure. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 81: History Logs (H.xx)

    Keeping button ▼ pressed, the selected function activates (the one highlighted in negative); keeping button ▲ pressed you return to page “H.03”. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 82 1.00 Generator in tolerance EVT.1030 1.00 GCB Close command EVT.1031 1.00 GCB Open command EVT.1032 1.00 GCB closed (from digital input) EVT.1033 1.00 GCB open (from digital input) Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 83 Anomalies are themselves saved as events. They are registered with their own alarm code summed to: EVT.2000: if they are warnings.  EVT.4000: if they are deactivations.  EVT.5000: if they are interlocks.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 84 With a configurable rhythm through parameter P.0442 (interval in seconds) and P.0443 (in minutes) the controller records the following analogue magnitudes: Mains phase-to-phase voltages and frequency.  Generator frequency and phase-to-phase voltages.  Generator currents.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 85 30 minutes. This archive can store up to 64 records. Every following record overwrites the older one. The controller records the analogue values described in par. 0. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 86 The more recent record is the one associated to the highest number. Using the ▲ and ▼ pushbuttons it is possible to scan all the records. The controller uses only one page of the display for this type of recordings. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 87 To reset an archive to zero, it is necessary to display it first and then to keep the digits ▲ and ▼ for 5 seconds, until when the controller shows a message of reset to zero. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 88: Parameter's Programming

    [1] where they’re described in detail. Some functions or particular configurations can be set or modified only through the PC program Mecc Alte Board Programmer4. The use of BoardPrg4 is recommended as it simplify a lot the programming operations. ATTENTION! In this paragraph the general programming structure and the operating procedure to read and/or modify parameters are described.

  • Page 89: Menu Selection

    Pressing digit AUTO, you enter the sub menu selected (highlighted); pressing STOP you leave the menu (back to the previous menu or to the base screen if exiting programming in the main menu). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 90: Parameter Organization

    To confirm the new value, press again the AUTO button; to abort and return to the original value, press STOP button. Parameter types are the following: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 91: Set Up Limits

    The operator has not to worry about verifying that the set-up value is acceptable for the controller since it is not possible to set up not acceptable values. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 92: Exit From Programming

    In case you lose the “manufacturer password” it is necessary to contact Mecc Alte service centre. The following examples show all combinations of passwords assignation. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 93: Password For Commands From Serial Port (Usb)

    USB with Modbus protocol. To send commands via Modbus to the device, it is necessary that each command is preceded by the password contained in P.0004. The default password is “123”. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 94: Operation Sequence

    AUTO mode, and when it is deactivated, the controller remains in AUTO mode, but you can use the buttons to change-over to MAN or OFF/RESET. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 95 Configuring a digital input of the controller to acquire the “Remote start request” with code DIF.2032. If input is  active, the controller passes to REMOTE START mode, if it deactivates, it returns to AUTO. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 96: Recording Of Mode In Event Archive

    9.1.2 Operation modes and logics AND/OR The controller makes available its own operation mode for the AND/OR logics by means of the following internal statuses: ST.000 - “OFF/RESET”.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 97: Mains

    P.0203: low mains voltages threshold (percentage respect to P.0116); under this value mains is considered  anomalous. P.0204: high mains voltages threshold (percentage respect to P.0116); over this value mains is considered  anomalous. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 98 P.0237 = 200 %.  P.0236 >= P.0237  Let us see a practical example upon how thresholds work, with default values for the parameters we have seen. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 99 The hysteresis on the various thresholds is calculated as half the difference between P.0204 and P.0203. However, it is limited by the maximum value set with parameter P.0201. The hysteresis applies to: Downwards, to mains availability threshold (i.e., between 70 V and 80 V).  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 100 In case a “clockwise” rotation direction is required, please set “2” in P.0239; in case the rotation direction is “counter- clockwise”, the mains is seen as “Out of tolerance”. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 101 If we have an unusually high asymmetry on the voltages, the global status is “Low”.  If the direction of rotation of the mains is different from the one configured, the global status is “Low”.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 102: External Mains Sensor

    “mains presence delay” (to re-power the loads as soon as possible, since they are not powered by the generators). By setting bit 0 of P.0250 to “1”, the controller manages the "mains presence delay". Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 103: Communication And Events

    (the percentage values are calculated with respect to the rated engine speed). Set parameters P.0331 and P.0332 correctly (over-speed protection). • Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 104: Genset Frequency

    P.0307: high voltage threshold (percentage related to P.0105) above this value the generator cannot be connected  to the loads. P.0202: hysteresis applied to all the thresholds related to generator frequency. It is a percentage value of P.0105.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 105: Genset Voltages

    P.0227: threshold (percentage of P.0102) over which the engine is considered started.  P.0301: low generator voltage threshold (percentage of P.0102); under this value the generator cannot be  connected to the loads. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 106 Thresholds P.0301 and P.0303 are used also to manage the generator protections on voltage. These protections can be individually disabled setting to zero the relevant parameter that specifies the delay (respectively P.0302 and P.0304). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 107: Generator Status

    When there is an inhibition active, a flashing lock is displayed in the top right corner of the display. The inhibition status does not affect TEST and REMOTE START modes. INFORMATION! Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 108: Inhibition From Contact

    If the command for the starter motor is not active, the controller impedes the starting (as the engine is rotating). Running: the controller deactivates the command of the starter motor and impede its restart.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 109 In movement, if at least one of the previous checks show “in movement” or “running”.  Running, if at least one of the previous checks show “running” consecutively for at least 0,2 seconds.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 110: Engine Commands

    (P.0004) which has to be sent before any command. To send the command, it is necessary to write in sequence (within 5 seconds):  HOLDING REGISTER 101: write the password configured with the parameter P.0004. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 111 MAN mode also. This status is necessary to wait that the genset reaches the full speed. The engine could, in effect, turn off (the controller could have diagnosed it only because it is the engine control unit Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 112 STOP in AUTO mode acting on bit 0 of parameter P.0495 INFORMATION! (keyboard options). The stop phase also can be performed when the engine is already stopped. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 113: Communication And Events

    The controller records any change of the engine's status in the events log, if it is enabled with bit 3 of the P.0441 parameter: EVT.1040: Engine stopped  EVT.1041: Starting cycle  EVT.1042: Engine running.  EVT.1043: Cooling cycle  EVT.1044: Stopping cycle  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 114: Circuit Breakers Management

    It is therefore necessary to use a contact which is normally closed, so that when the controller is not supplied, the under-voltage coil is enabled and the breaker can be closed. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 115: Acquiring Breakers Status

    The delay associated to the input (P.2002 for input 1 or equivalent parameter for the other inputs) is used as maximum time for opening or closing the breaker. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 116: Off/Reset Management Logic

    Alternatively, it is also possible to connect some external buttons NO of breakers opening/closing to the digital inputs of the controller. The controller will use these inputs (only in MAN) exactly as: DIF.1001 - “GCB close command”.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 117: Automatic Power Delivery Of The Generator Inhibited

    MCB, even if the mains is present and the generator is stopped. The opening of MCB will not result in the start of the generator and in the GCB closure. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 118: Events And Signalling Related To The Breakers

    There is also signalling of specific events in the plant management. Before describing them in detail, some definitions are required. We define three typologies of anomaly: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 119: Silencing The Horn

    HOLDING REGISTER 101: write the password configured with the parameter P.0004.  HOLDING REGISTER 102: write value “51”.  Parameter P.0491 (Horn duration) influences the management of the controller's horn. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 120: Acknowledging Anomaly

    DOF.3151 (“reset of anomalies”). The board activates this output for one second when the internal sequence for  the cancellation of anomalies is carried out. With this procedure, it is also possible to reset externally managed anomalies. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 121: Anomalies Connected To Digital Inputs

    [1] contain a table showing the code per each input). Using the parameter which configures the function (P.2001), it is possible to select the type of anomaly (warning, deactivation or block) and also to define the conditions in which the anomaly has to be managed. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 122: Anomalies Connected To Analogue Inputs

    (P.4005 or P.4008). The parameter that configures the actions is managed through bits (every bit enables/disables a function connected to the threshold). A description for these parameters follows 5.7.3 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 123: Anomalies List

    P.0301 for the time P.0302. * In MAN it is only enabled if the GCB breaker is closed or if the Bit2 of parameter P.0249 is set to "1". Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 124: Maximum Generator Voltage

    Generator/Loads protection Category: Related parameters: P.0105 Rated frequency P.0307 Threshold for maximum frequency P.0308 Delay for maximum frequency To disable: P.0308=0 Enabled in: MAN, AUTO, TEST, REMOTE START Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 125: Belt Break (Alternator Battery-Charger Failure)

    As engine protection, the maximum power protection must be used, that is independent from the load type. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 126 The following graph shows the curve used for enabling protection, with a value of P.0310 set to 60 seconds (I is the maximum current): Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 127: Manual Stop While In Auto

    It is activated when pressing the “STOP” button on the front panel or sending a stop command via USB, while in AUTO, TEST or REMOTE START 08 – Operating conditions failure Icon: Type: Alarm Category: General Related parameters: P.0217 Maximum time for full speed conditions P.0217=0 To disable: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 128: Mains Circuit Breaker (Mcb) Not Closed

    16 – Short circuit on the generator Icon: Configurable (Block/Deactivation) Type: Category: Generator protection Related parameters: P.0101 Number of generator phases P.0102 Generator rated voltage P.0106 Generator rated power P.0311 Threshold for short circuit Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 129: Overspeed (From Measure, Only For Drive Applications)

    Related parameters: P.0331 Threshold of maximum speed from frequency (in %) P.0332 Delay for maximum speed from frequency To disable: P.0332=0 MAN, AUTO, TEST, REMOTE START Enabled in: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 130: Engine Not Stopped

    Deactivation/Warning General Category: Related parameters: P.2001 Function of input T.16 or equivalent for other inputs P.2002 Delay for input T.16 or equivalent for other inputs To disable: P.2002=0 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 131: Genset Circuit Breaker (Gcb) Not Open

    (parameter P.2002 or equivalent). Active if the configured input remains continuously active for the associated time. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 132: Minimum Fuel Level (From Analogue Sensor)

    It activates if the level measure remains continuously below or equal to threshold P.0345 (in percentage) for time P.0346. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 133: High Fuel Level (From Contact)

    (if the command for the fuel solenoid is activated) and is disabled in the engine start/stop phases. It activates if the input configured is continuously “active” for the time configured, but Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 134: High Coolant Temperature (From Analogue Sensor)

    P.0216 (oil mask) from engine start has elapsed (this is to allow you to start the engine idle, to cool it off) 34 – Maximum coolant temperature (from analogue sensor) Icon: Type: Alarm Engine protection Category: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 135: Maximum Oil Temperature (From Analogue Sensor)

    The threshold P.0362 is expressed as a percentage of the rated battery voltage which is not configurable but is automatically selected by the controller between 12 e 24 Vdc. Selection is made when the controller is powered and Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 136: Starter Battery Voltage, High

    To be programmed, parameters P.0424 and P.0425 require “installer” access level: this function can be used for genset rental in order to lock the genset when the established hours are elapsed. 41 – Minimum oil pressure (from contact) Icon: Type: Alarm Category: Engine protection Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 137: Minimum Oil Pressure (From Analogue Sensor)

    (parameter P.2002 or equivalent). It is only enabled if the controller has been started by the controller (if the command for the fuel solenoid is activated) and is disabled in the engine Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 138: Low Oil Pressure (From Analogue Sensor)

    (P.2008 or equivalent). It is possible to force the emergency stop alarm manually with a control through the serial ports writing (within 5 seconds) the Modbus registers in sequence: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 139: Maximum Power

    (absolute value) is continuously over the threshold P.0315 for time P.0316. 53 – Generator current unbalance Icon: Alarm Type: Generator protection Category: Related parameters: P.0101 Number of generator phases P.0102 Generator rated power Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 140: High Oil Temperature (From Analogue Sensor)

    In addition, the generator voltages and frequency must be within the tolerance range and the load must be changed-overt to the mains (it prevents load Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 141: Low Generator Voltage

    (P.0418 and P.0420) or the operation enabling time (P.0421, P.0422, P.0423). To deactivate it, you need to set the clock. 58 – Low generator frequency Icon: Type: Warning Loads protection Category: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 142: High Generator Voltage

    Threshold P.0397 is expressed as a percentage of the generator rated frequency. The protection activates when the generator frequency rises continuously over threshold P.0397 for time P.0398. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 143: Faulty Engine Can-Bus 0 Link

    (T.15, P.4025 suitably configured) or from CAN-BUS (P.0700 other than zero). It activates if the coolant temperature remains continuously below threshold P.0353 for time P.0354 (even with engine shut down). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 144: Adblue Pump Failure

    NMT ALIVE PDU for the set time. For the other types of engines, it is activated if the controller does not continuously receive messages from the engine for time P.0711. With P.0709 the protection is configured as warning, deactivation or alarm. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 145: Minimum Engine Speed (From Measure, Only For Drive Applications)

    This protection is enabled only if the board is connected to the engine via the CAN BUS (P.0700 different from zero). It is activated when the engine signals the overspeed state over the CAN-BUS. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 146: High Coolant Temperature From Can-Bus

    CAN BUS 136 – Low coolant level from CAN BUS Icon: Type: Warning Category: Engine protection Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 147: Low Battery Voltage From Can Bus

    This protection is enabled only if the board is connected to the engine via the CAN BUS (P.0700 different from zero). It is activated when the engine signals the low oil pressure state over the CAN BUS. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 148: High Oil Temperature From Can Bus

    CAN BUS. 198 – Warnings cumulative – Yellow lamp from CAN-BUS Icon: Type: Warning Category: Engine protection Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 149: Alarms Cumulative - Red Lamp From Can-Bus

    CAN BUS. Using bit 13 of P.0704 it is possible to configure the protection as warning or alarm. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 150: Other Functions

    In order for this feature to be usable, the DOF.1032 code – “Fuel pump” must be set in one of the configurable outputs. Another possibility is to configure a digital output to command and interception solenoid on the pump line (DOF.1034 – “Fuel pump solenoid command”). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 151: Use With An Analogue Level Transducer

    Stop contact (input with feature DIF.3302) closed if the level is below the pump stop threshold.  High level contact (input with feature DIF.4213): closed if the level is over the pump stop threshold.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 152: Level Evaluation

    Associate a delay to that input (in parameter P.2002 or in the equivalent parameters).  If the input remains active for the time configured, the controller issues a warning and stops the pump (without changing the command mode). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 153: Load Thresholds

    The output is activated in a maximum power condition, and can directly be used as control for disconnecting loads. Ensure to pay attention to the thresholds: when a part of the loads is disconnected, the power will decrease. If the lower Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 154: Alternative Parameters Configuration

    This function is usually used with multiple-voltage and/or multiple-frequency panels: wiring the cams of a selector to the panel on the inputs of the controller, you can manually switch voltages and frequency without having to use the parameters of the controller. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 155: Ejp Function

    Configure a second digital input with feature DIF.2502 – “Loading inhibition) (in parameter P.2004 or the  equivalents). Then connect the NO contact of signal A to first configured input and the contact NC of signal B to second input. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 156: Maintenance

    2. Load working time with GCB closed (hours) counter (resettable to zero) Total active power meter (kWh), with power measured when the loads are connected to the generator; it measures only the supplied power and does not measure in case of power reverse. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 157: Counters Reset

    The resetting procedure is common for all the counters, but it only applies to some of them, based on the page displayed on the multifunctional display. See in paragraph 7.4.8.3 the description of the display page that contains the counter to be reset to zero. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 158: Clock

    I.e., the engine may have been used just few minutes before but test will anyway start at due time. In addition to the dates, it is also possible to select a start time and duration. This time interval is common to all the days selected. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 159: Weekly Scheduling Of Engine Operating Time Intervals

    P.0422: allows to configure the start of the time interval during which the engine can start automatically (in hours  and minutes). P.0423: allows to configure the end of the time interval during which the engine can start automatically (in hours  and minutes). Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 160: Non-Volatile Memory

    “AUTO + STOP”, when you turn it on next you will get again the signalling of not valid memory. 11.9 Plant name It is possible to assign a name to the plant, including it into parameter P.0456. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 161: Power Saving Mode

    ECU. This operation requires the BoardPrg4 software, which allows you to select the ECU from the list of all those for which Mecc Alte has developed a configuration file. It is then possible to decide whether to receive information only from the engine ECU or whether to also send commands (P.0703, described in the documents mentioned above): by setting P.0703 to “0”, GC250 does not transmit anything on...

  • Page 162: Can-Bus Connection With Voltage Regulators (Avr)

    ▼ button pressed or cancel the modification by keeping ▲ pressed. Through parameter P.1496 it is possible to select which is the power source of the pump between: Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 163: Using An Analogue Level Measurement

    If the level is below the pump start threshold, assign the "start" position.  If the level is higher than the pump stop threshold, assign the "stop" position.  Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...

  • Page 164: Automatic Pump Control

    In addition, the activation and deactivation of the pump are recorded in the event log if bit 7 of parameter P.0441 is active: • EVT.1072: pump activated. • EVT.1073: pump deactivated. Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 165 GC250 Technical Manual ENGLISH This Page Intentionally Left Blank Code: EAAM057616EN Rev. 16 | Date: 1/03/2023 Mecc Alte S.p.A. - Full or partial reproduction prohibited, if not authorized...
  • Page 166 UNITED KINGDOM SPAIN CHINA INDIA Mecc Alte U.K. LTD Mecc Alte España S.A. Mecc Alte Alternator Mecc Alte India PVT LTD 6 Lands’ End Way C/ Rio Taibilla, 2 (Nantong) Ltd Plot NO: 1, Talegaon Oakham Polig. Ind. Los Valeros 755 Nanhai East Rd Dhamdhere S.O.

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