Genset Controller GNS-2500 Series
Genset Controller GNS-2500 Series
Genset Controller GNS-2500 Series
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<strong>Genset</strong> <strong>Controller</strong><br />
<strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong><br />
Single Applications<br />
■■<br />
Advanced Control &<br />
Monitoring<br />
• Engine Start/Stop Control<br />
• Engine & Generator Monitoring &<br />
Protection<br />
• Remote Monitoring & Alerts<br />
• Comprehensive Metering<br />
• Auto Generator Start at Loss of Mains<br />
■■Expanded Offering of I/O<br />
• 9 Binary Inputs & 9 Outputs<br />
• 2 Form A and 2 Form C Relays<br />
• 4 Versatile ANALOGUE Input that<br />
Support:<br />
VDO, 5VDC, 10VDC, 0-20 mA,<br />
Resistive & Thermocouple<br />
■■Intuitive, Adaptable User<br />
Interface<br />
• Simultaneous Multi-Lingual<br />
Support<br />
• Local, Remote & No Display<br />
Support<br />
• Multiple Security Levels & Panel Lock<br />
• User-friendly SmartVU<br />
Configuration Software<br />
■■High Degree of Connectivity &<br />
Compatibility<br />
• SAE J1939<br />
• MODBUS<br />
• RS-232/485<br />
• SMS support<br />
• Ethernet (Via Serial to Ethernet<br />
Converter)<br />
AMF <strong>Genset</strong> <strong>Controller</strong><br />
GAC’s <strong>GNS</strong>-<strong>2500</strong> <strong>Genset</strong> <strong>Controller</strong> <strong>Series</strong> is a family of highly-flexible genset controllers for<br />
standalone applications that meets all the requirements for AMF functions.<br />
The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong>, designed for both ‘electronic’ and conventional engines, is ruggedly<br />
constructed with simple-to-use microprocessor technology.<br />
GAC’s new controller series provides superior genset control, protection, and metering; all<br />
at a reasonable cost.<br />
The series is available in 3 distinct configurations:<br />
Manufactured by:<br />
Governors America Corp.<br />
1. Black Box – for use with external buttons and gauges.<br />
2. Panel Mount – a conventional one box door-mounted design.<br />
3. Two Box – the Black Box connected by CANbus to a separate control panel<br />
■■Highly Developed Design<br />
• Robust 600V Design<br />
(min. 25% over voltage allowed)<br />
• CE Approved<br />
• NFPA110 Level Compatible<br />
• Industrial Temperature Range<br />
• Resistant to salt fog, humidity, dust,<br />
dirt, and chemical contaminants<br />
• Audible & Tactile F/B on Buttons<br />
for Gloved Fingers<br />
HUEGLI<br />
TECH<br />
SWITZERLAND
<strong>Genset</strong> <strong>Controller</strong><br />
<strong>GNS</strong>-<strong>2500</strong><br />
Description<br />
The <strong>GNS</strong>-<strong>2500</strong> monitors the mains voltage and frequency,<br />
to detect loss of mains power. Once one of these mains<br />
protections is tripped, the <strong>GNS</strong> will automatically start the<br />
generator, open the MCB, then close the GCB. The MCB<br />
can be configured to open at the immediate loss of mains<br />
or at “generator ready to load”. Upon the return of stable<br />
mains characteristics, the <strong>GNS</strong>-<strong>2500</strong>, using user-configurable<br />
timing, will open the GCB then close the MCB. The <strong>GNS</strong><br />
is also programmed to provide warnings of impending loss<br />
of mains and a test function.<br />
Programming the <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> with GAC’s enhanced<br />
SmartVU configuration software is both logical and<br />
straightforward. Apart from I/O allocation, all parameters<br />
can also be edited from the (PIN protected) front panel,<br />
without need for a laptop. The controller senses engine<br />
parameters directly via 4 analogue inputs and it can communicate<br />
with the engine’s electronic control unit via J1939<br />
CANbus protocol. The programmable inputs and outputs are<br />
engineered to allow the user to easily customise the operation<br />
as desired.<br />
The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> has been designed to offer excellent<br />
value by including features which are often considered<br />
‘extras’.<br />
Standard features include:<br />
• 9 programmable inputs and 9 programmable outputs;<br />
• 4 analogue inputs that support a wide range of senders;<br />
• 2 Form A and 2 Form C relays;<br />
• robust electronic protection;<br />
• fixed voltage detection schemes;<br />
• remote control and monitoring;<br />
• up to two built in RS-232/485 ports with expansion for field<br />
service laptop support;<br />
• Modbus and J1939 CANbus interface;<br />
• SMS support; multiple, memory-resident language:<br />
The standard temperature range is -20°C – 85°C but<br />
versions operating down to -40°C are also available.<br />
A cost-effective range of expansion modules is available<br />
including remote Displays, Gauges and Annunciators with<br />
logic control blocks, expandable I/O capabilities and additional<br />
relays, all connected via J1939 CANbus.<br />
As with all GAC products, the <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> can be<br />
easily and cost effectively adapted to provide customised<br />
solutions for OEMs.<br />
Operating Modes<br />
The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> can be operated in Manual, Auto, or<br />
Test modes, and has a full suite of engine and generator<br />
protections. When in Manual mode, the <strong>GNS</strong> will start and<br />
stop the engine based on user inputs. In Auto mode, the<br />
<strong>GNS</strong> will start and stop the engine when failure of the mains<br />
is detected. Test mode allows the user to test the genset<br />
without affecting the normal mains supply to the load. An<br />
Off mode is also included, to lock the controller and prevent<br />
genset operation.<br />
Alarms, Warnings, and Protections<br />
The <strong>GNS</strong> features alarms and warnings to alert the user<br />
while protecting the generator and engine. All protections<br />
can be individually enabled or disabled. Shutdown conditions<br />
include low oil pressure, low fuel level, high coolant<br />
temperature, under/over speed, under/over voltage, under/<br />
over current, under/over frequency, sensor failures, over<br />
crank, and generator voltage unbalanced.<br />
Engine Control<br />
• Cranking control provides pre-lube, up to 4 pre-start<br />
stages, adjustable number of crank attempts, duration,<br />
pause delay and crank disconnect. Also provided is an<br />
engine start counter.<br />
• Engine timers include cool down, maintenance, pre-crank,<br />
crank and several protections.<br />
• Adjustable protection thresholds and delays for speed, oil<br />
pressure, coolant temperature, and fuel level.<br />
Metering<br />
• Metered generator parameters include line voltage, line<br />
to line voltage, current, frequency, reactive power, power<br />
factor and actual power.<br />
• Metered engine parameters include RPM, oil pressure,<br />
coolant temperature, battery voltage, fuel level, service<br />
hours, run hours, and number of starts. RPM, oil pressure,<br />
and coolant temperature can be integrated via J1939<br />
Inputs<br />
The <strong>GNS</strong> is equipped with dedicated inputs for mains and<br />
generator voltage, generator current, and a speed sensor.<br />
The unit is also equipped with 4 configurable analogue<br />
inputs and 9 configurable binary inputs. The analogue inputs<br />
allow a wide range of sensors including voltage, current,<br />
and resistive senders. Though easily reconfigured, three of<br />
the analogue inputs are configured for Fuel Level, Engine<br />
Temperature, and Oil Pressure. The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> can<br />
use J1939 messages for oil pressure, engine speed, and<br />
coolant temperature in combination with the analogue inputs<br />
for control and protection operations, thereby, freeing<br />
up analogue inputs for other sensors.<br />
2<br />
HUEGLI<br />
TECH<br />
SWITZERLAND
<strong>Genset</strong> <strong>Controller</strong><br />
<strong>GNS</strong>-<strong>2500</strong><br />
Outputs<br />
The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> is equipped with 5 discrete binary<br />
outputs and four relays. The discrete outputs can sink up<br />
to 500mA of current to battery ground and support up to<br />
32VDC. The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> has four relays, two Form C<br />
and two Form A. Though reconfigurable, the first Form C<br />
relay is configured to control the fuel solenoid, the second<br />
is configured to control the starter. By adding a jumper<br />
(located on the back of the <strong>GNS</strong>), the fuel relay can be<br />
configured to be directly controlled by the emergency stop<br />
input – when the emergency stop input is activated, power<br />
to the fuel solenoid is removed, thereby depriving the engine<br />
of fuel.<br />
All <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> analogue inputs, binary inputs, relays<br />
and binary outputs assignments can be configured by the<br />
user.<br />
RS232/485, SAE J1939, Ethernet, Modbus<br />
The standard <strong>GNS</strong> is equipped with a SAE J1939 port and<br />
one serial port. The serial port can be configured for RS232<br />
or RS485 operation. The RS232 can connect the <strong>GNS</strong> to an<br />
external modem, external I/O, remote display, Ethernet converter<br />
or PC using the industry standard MODBUS protocol.<br />
A factory installed modem can be provided. The modem can<br />
support pager and SMS functions. Note: the <strong>GNS</strong>-<strong>2500</strong>BE is<br />
a stand-alone controller equipped with two RS232 ports and<br />
can be operated without a display<br />
Remote Annunciator, Output Relays, &<br />
Programmable Logic<br />
The optional GAC Remote Annunciator (RA20) and Contact<br />
Relay Module (CRM20) provide external programmable<br />
logic and annunciation for the <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong>. The RA20 is<br />
equipped with 20 x 3 colour LEDs and can be panel mounted.<br />
The CRM20 is similar to the RA20 with the inclusion 20<br />
Form C relays. Both of these devices have 30 blocks for<br />
logic programming and can source data via Modbus over<br />
two RS-232/485 ports and CANbus.<br />
Start and Stop are used when the <strong>GNS</strong> is in Manual Mode;<br />
as a safety feature, the <strong>GNS</strong> is programmed to require the<br />
user to press the Fault Reset to resume operation of the<br />
genset after a protection function has been activated. This<br />
action acknowledges the shutdown condition. The Arrows<br />
and Enter buttons are used to navigate the menu system.<br />
<strong>GNS</strong> Display Real Time Information<br />
• Operating Mode<br />
• Line Voltage<br />
• Line to Line Voltage<br />
• Current<br />
• Frequency<br />
• Oil Pressure<br />
• Engine Temperature<br />
• Generator State<br />
• Active Alarms and<br />
Warnings<br />
SmartVU<br />
• Binary Inputs<br />
• Binary Outputs<br />
• Analogue Metering<br />
• Power Metering<br />
• Generator Metering<br />
• History<br />
• Power (Real Power, Apparent<br />
Power, Power Factor)<br />
• Mains Voltage<br />
The <strong>GNS</strong>-<strong>2500</strong> <strong>Series</strong> is configured using the accompanying<br />
SmartVU PC configuration, control and monitoring tool.<br />
This program allows the user to set and modify security,<br />
operating set points, assign I/O, establish warning and alarm<br />
thresholds, and control overall system behavior. Once configured,<br />
the settings can be saved to a file for easy replication.<br />
While connected to a <strong>GNS</strong>, SmartVU can be used to<br />
monitor genset performance (see Figure 1).<br />
Within SmartVU, the layout of the display is highly customisable.<br />
The user chooses which meters are to be displayed,<br />
and the location on the screen. The screen configuration<br />
can be stored for later use.<br />
SmartVU is capable of simultaneously communicating<br />
with multiple <strong>GNS</strong> controls, and the layout of the screen is<br />
customisable.<br />
<strong>GNS</strong>-<strong>2500</strong> Display<br />
The <strong>GNS</strong>-<strong>2500</strong> is equipped with a 64 x 128 graphical display,<br />
10 LEDs, 11 buttons (with the exception of <strong>GNS</strong>-2504BE).<br />
Depending on the configuration the display can support<br />
multiple languages simultaneously. The user can switch<br />
between the languages on the fly.<br />
The LEDs represent Ready/Auto, Not in Auto, Running,<br />
Warning, Supplying Load, Shutdown/Alarm, Mains and<br />
Generator Status and MCB/GCB Open/Close. The display<br />
has 11 contact switches for Start, Stop, Horn Silence, MCB/<br />
GCB Open/Close and Fault Reset buttons, Directional Arrow<br />
Keys, a Back Button and an Enter Button.<br />
3<br />
Figure 1<br />
HUEGLI<br />
TECH<br />
SWITZERLAND
<strong>Genset</strong> <strong>Controller</strong><br />
<strong>GNS</strong>-<strong>2500</strong><br />
Diagram 1. System Wiring/Outline<br />
LB178-2<br />
L S H<br />
CAN<br />
G 8 9 6 G 7 5 2 G 4 3 G G 1<br />
BINARY<br />
ANALOG INPUTS<br />
OUTPUTS<br />
RS232/485<br />
BATTERY<br />
8-32 VDC<br />
+D+<br />
BINARY INPUTS<br />
MAG<br />
P/U<br />
2 3 5 6 8 G +<br />
BO1<br />
RELAYS<br />
BO2 BO3 BO4<br />
G<br />
-<br />
1<br />
4<br />
7<br />
9<br />
-<br />
LB178-3<br />
LB178-1<br />
NOTE:<br />
1. U.O.S. ALL WIRES TO BE 22AWG TWISTED PAIR.<br />
SINGLE LINE BREAKER CONTROL / FEEDBACK SHOWN.<br />
2<br />
L3<br />
L2<br />
18 AWG<br />
N C B A<br />
MAINS VOLTAGE<br />
3<br />
GENERATOR<br />
CURRENT<br />
A G B G C<br />
RS-232 3-WIRE NULL MODEM CABLE.<br />
4<br />
N C B A<br />
GENERATOR VOLTAGE<br />
4<br />
10 amp Fuse<br />
D+<br />
+<br />
12/24VDC<br />
Battery<br />
ALTERNATOR<br />
3<br />
-<br />
REMOTE START/STOP<br />
ESTOP<br />
MAGNETIC<br />
PICK-UP<br />
DIESEL/GAS ENGINE<br />
STARTER<br />
FUEL SOLENOID<br />
MAINS<br />
GENERATOR<br />
G<br />
L3<br />
L2<br />
L1<br />
N<br />
FUEL LEVEL<br />
PRESTART<br />
3<br />
B+<br />
3<br />
3<br />
ENGINE TEMP<br />
OIL PRESSURE<br />
B+<br />
ALARM<br />
READY TO LOAD<br />
N<br />
L1<br />
3<br />
MCB<br />
GCB<br />
2<br />
L<br />
FUEL SOLENOID<br />
STARTER<br />
FUEL LEVEL<br />
ENGINE TEMP<br />
OIL PRESSURE<br />
4<br />
HUEGLI<br />
TECH<br />
SWITZERLAND
<strong>Genset</strong> <strong>Controller</strong><br />
<strong>GNS</strong>-<strong>2500</strong><br />
Specifications<br />
Environmental<br />
Ambient Operating Temperature:<br />
<strong>GNS</strong>-2504E............................................................Temp:-40 to +85°C<br />
<strong>GNS</strong>-2502E............................................................Temp:-20 to +85°C<br />
Relative Humidity...........................................95% non-condensing<br />
Agency Approvals...........................................................................CE<br />
Input Parameters<br />
Power..............................................................................8VDC-32VDC<br />
Polarity Negative....................................................................Ground<br />
Speed Sensor Signal..............0.5 – 30 Volts RMS, 30-1200 ohms<br />
9 Assignable Binary Inputs.................................................0-32VDC<br />
4 Analogue Inputs ..........Wide range of senders, includingVDO<br />
.......................(e.g.,OilPressure,CoolantTemp)<br />
......................................5VDC, 10VDC, 0-20mA,<br />
...................................Resistive Thermocouple<br />
Generator Voltage ....................................480VAC RMS Nominal -<br />
...........................600VAC Max phase to phase<br />
........277VAC RMS Nominal phase to neutral<br />
Mains Voltage............................................480VAC RMS Nominal -<br />
...................................600VAC Max phase to phase<br />
................277VAC RMS Nominal phase to neutral<br />
Generator Current (CT Secondary).............................5A Nominal<br />
Output Parameters<br />
2 Form A Relay...................................................250VAC, 30VDC, 3A<br />
2 Form C Relay.................................................125VAC, 28VDC, 12A<br />
5 Binary Outputs..................................................0-32VDC,0-500mA<br />
Display I/O<br />
LEDs........................Ready/Auto, Not in Auto, Running, Warning,<br />
..........................................Supplying Load, Shutdown/Alarm,<br />
....................................................Mains and Generator Status<br />
.......................................................and MCB/GCB Open/Close<br />
Switches.................................Start, Stop, MCB/GCB Open/Close<br />
......................................Horn Silence, Fault Reset, Enter,<br />
...................................... 4Arrows (Up, Down, Left, Right)<br />
Communications<br />
PC Configuration & Monitoring...............Modbus on RS-232/485<br />
ECU...............................................................................................J1939<br />
Remote Devices..............................Modbus on RS-232 or RS-485<br />
Reliability<br />
Vibrations.......................................................................................TBD<br />
Testing......................................................100% Functionally Tested<br />
Physical<br />
Overall Dimensions....................................................6” x 9” x 1.75”<br />
...............................152mm x 229mm x 445mm<br />
Panel Opening Size........................................................4.45” x 6.89”<br />
................................................113mm x 175mm<br />
Weight..........................................................................................1.3lbs<br />
.........................................................................................0.59kg<br />
Mounting.........................................................Front Panel Mounted<br />
<strong>GNS</strong>-2504BE.....................................................Back Panel/DIN Rail<br />
SmartVU Minimum Requirements<br />
Microsoft Windows 2000-<br />
Windows 7...................................Pentium II, 64M RAM, 10M Disk<br />
...............................................................VGA, Serial Port<br />
Options<br />
• <strong>GNS</strong>-2502DE & 2504DE Remote Display<br />
• EAM Ethernet Adapter<br />
• <strong>GNS</strong>-2504BE Black Box Non-Display Control<br />
• External Modem<br />
• Custom Displays (up to 65 LEDs, up to 24 Switches)<br />
• Remote Contact Relay Module<br />
• Remote Annunciator Panel<br />
• Remote Analogue Gauge Drivers<br />
Local Distributor / Partner:<br />
HUEGLI<br />
TECH<br />
SWITZERLAND<br />
HUEGLI TECH AG (LTD)<br />
Murgenthalstrasse 30<br />
4900 Langenthal Switzerland<br />
Phone: +41 62 916 50 30<br />
Fax: +41 62 916 50 35<br />
e-mail: sales@huegli-tech.com<br />
www.huegli-tech.com<br />
<strong>GNS</strong>-<strong>2500</strong>_DS_EN_04.2011<br />
Features and specifications are subject to change without prior notice<br />
© HUEGLI TECH