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Harsen JNH GU640B Operation Manual

Automatic control module for single genset
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GU640B 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.
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  • Page 1 GU640B 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 GU640B 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. The engine or other type of prime mover should be equipped with an over speed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage.

  • Page 3: Table Of Contents

    GU640B Controller Operation Manual Contents Description ............................4 The Outline Dimension Drawings and Controller Wiring.............5 Panel Operation..........................8 Control and Operation Instruction....................10 Measure and Display Data......................16 Pre-alarm and Shutdown Alarm ....................17 Parameters Setting........................21 Installation Guide ..........................38 LCD displays and Menu System ....................47 10.

  • Page 4: Description

    GU640B Controller Operation Manual 1. Description GU640B is a new generation Automatic control 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

    GU640B 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 GU640B Controller Operation Manual 2.2 Terminal Connections: Pin no. 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 Not used Not used Not used Not used I1 Gen current input (S1) 0-5A...
  • Page 7 GU640B 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

    GU640B 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 GU640B 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

    GU640B 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. Press and hold the “MAN”...
  • Page 11 GU640B Controller Operation Manual NOTE: The start motor will power off while cranking if there are one of the following conditions occur: A. The generator’s frequency reaches the preset value (configurable cranking cutout value); B. The AC Engine speed reaches crank cutout value; C.
  • Page 12 GU640B Controller Operation Manual Generator shutdown sequence: When remote start signal is inactive, GCB close/open relay opens, Gen is off load, the timer for cool down is activated, when it times out, the fuel relay de-energises, generator stops and recovers to its standby status.
  • Page 13 GU640B Controller Operation Manual 4.4 TEST Control Sequence: When the controller is running in “TEST” mode means it simulates remote start is active and starts the generator. 4.5 The start and stop sequence of engine whose fuel solenoid is N. O. type: There are two kinds of fuel solenoids for an engine, one is N.C.
  • Page 14 GU640B 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 15 GU640B 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. If T4 is shorter than T5, oil pressure protection becomes effective after T4 in...

  • Page 16: Measure And Display Data

    GU640B Controller Operation Manual 5. Measure and Display Data Gen V L1-N L2-N L3-N Ph-N Gen 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 Gen total active power ∑P Gen power factor PF (AV) Engine speed RPM (signal derived from magnetic pick-up or generator Hz) Engine oil pressure Bar (signal from engine LOP sensor)

  • Page 17: Pre-Alarm And Shutdown Alarm

    GU640B Controller Operation Manual 6. Pre-alarm and Shutdown Alarm 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. When Pre-alarms occur, the Pre-alarm LED illuminates, but failure will not be locked out and the unit will not shutdown.
  • Page 18 GU640B Controller Operation Manual GEN. OVER VOLT: If controller detects that any phase output 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, “rated ph-voltage” preset as: 220V, “GEN-V over preALM” preset as: 115%, when any phase output voltage exceeds this value, LCD flashing high value icon for corresponding phase.
  • Page 19 GU640B Controller Operation Manual 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 attempt has been made, the Shutdown alarm LED illuminates and buzzer sounds, LCD displays start failure icon:...
  • Page 20 GU640B 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” preset as: 90%, when the generator active power exceeds this value, LCD flashing icon for corresponding high value.

  • Page 21: Parameters Setting

    GU640B 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 Voltage Type 1 to 5 Comm.
  • Page 22 GU640B 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 23 GU640B Controller Operation Manual 3— 3P3W (3 phases 3 wires): 4— 1P3W (single phase 3 wires): 5— 1P2W (single phase 2 wires):...
  • Page 24 GU640B 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. When parameter is configured as “1”, the controller will be in Automatic mode when it is powered When parameter is configured as “2”, the controller will be in the mode which is the same as last time when it is powered up.
  • Page 25 GU640B 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 GEN-V over Alarm 20 to 200% / 999 not used KW Overload preALM...
  • Page 26 GU640B Controller Operation Manual Alarm delay: Use a timer for confirmation of the alarm or pre-alarm. Overcurrent level: Used to configure the over current value of the Gen or the load, the overcurrent alarm is inactive when parameter configured as “999”. Expressed by percentage, use “Rated current”...
  • Page 27 GU640B 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 28 GU640B 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 29 GU640B 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 30 GU640B 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 Datcon 7 bar Murphy 7 bar Pre-set 1...
  • Page 31 GU640B 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 32 GU640B Controller Operation Manual 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. When parameter is configured as “0”, this function is inactive, and the conditions of judging stop failure and not implementing crank process are inactive.
  • Page 33 GU640B Controller Operation Manual Under SP Alarm: Used to configure the under speed alarm value for the engine. When parameter is set as “0”, this function is inactive. Over SP preALM: Used to configure the over speed pre-alarm value for the engine. When parameter is set as “9999”, this function is inactive.
  • Page 34 GU640B Controller Operation Manual 7.4 Configurable Inputs and Outputs: Items Preset Value Range D-Input 1 1 to 20 / 0 not used D-Input 2 1 to 20 / 0 not used D-Input 3 1 to 20 / 0 not used D-Input 4 1 to 20 / 0 not used...
  • Page 35 GU640B Controller Operation Manual D-Input * delay: Used to configure the timer for confirmation of the configurable digital input, total 5 corresponding to 5 D- Inputs. User relay *: There are 4 configurable output relays. Optional functions as following: Code Alarm mode defined not used Over current trip...
  • Page 36 GU640B Controller Operation Manual 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 Configurable D-input1 active Configurable D-input2 active Configurable D-input3 active Configurable D-input4 active Configurable D-input5 active...
  • Page 37 GU640B Controller Operation Manual 7.5 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% Pressure offset...

  • Page 38: Installation Guide

    GU640B 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 39 GU640B 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 40 GU640B 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 earth point.
  • Page 41 GU640B 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 Gen 3 phases V L1-N L2-N L3-N Ph-N Gen 3 phases V L1-L2 L2-L3 L3-L1 Ph-Ph Gen frequency Hz (L1) Gen 3 phases current I1 I2 I3...
  • Page 42 GU640B Controller Operation Manual 3P3W (3 phases 3 wires) Measure and Display Data Gen 3 phases V L1-L2 L2-L3 L3-L1 Ph-Ph Gen frequency Hz (L1) Gen 3 phases current I1 I2 I3 Gen apparent power ∑A Gen active power ∑P Gen power factor PF...
  • Page 43 GU640B Controller Operation Manual 1P3W (single phase 3 wires) Measure and Display Data Gen V L1-N L2-N Ph-N Gen V L1-L2 Ph-Ph Gen frequency Hz (L1) Gen phase current I1 I2 Gen apparent power ∑A Gen active power ∑P Gen power factor PF...
  • Page 44 GU640B Controller Operation Manual 1P2W (single phase 2 wires) Measure and Display Data Gen V L1-N Ph-N Gen frequency Hz (L1) Gen current I1 Gen phase apparent power A Gen phase active power P Gen power factor PF...
  • Page 45 GU640B Controller Operation Manual 8.2.6 The 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. NOTE: The terminal #31 is the common port for the configurable inputs and it is short connected to power negative (terminal #33) inside the controller.
  • Page 46 GU640B Controller Operation Manual 8.2.7Connection 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 47: Lcd Displays And Menu System

    GU640B 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 48 GU640B Controller Operation Manual For example: (configure CT ration at 500/5, then CT should be configured as100) Operation Description Press and hold “ ” 2sec, enter into parameters setting menu, then LCD displays: Press “√” button, then LCD displays: Press “+” or “-” button, it prompted to key in password: 2213, (press “→”...
  • Page 49 GU640B Controller Operation Manual For example: (resume parameters of controller to factory default) Operation Description Press and hold “ ” 2sec, enter into parameters settings menu, then LCD displays: Press “+” 9 times, then LCD displays: Press “√”, it prompted to key in password: 2213, (press “→”, move to desired modify number).

  • Page 50: Technical Specification

    GU640B 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: Input frequency 3 to 70Hz (voltage ≥15VAC) Accuracy...
  • Page 51 GU640B 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 Accuracy error 10.9 Magnetic pickup:...

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