Operating Manual

GC12 Generator Controller

GC12 v3.0

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Introduction
GC12 is a highly reliable Auto Mains Failure controller with automatic
generator start, stop and load switching suitable for a wide variety of diesel
generators.
GC12 monitors engine and 3-phase mains parameters and displays them on
the LCD screen. When a mains failure occurs, GC12 starts the generator and
transfers the load after a user defined time, and switches it back to the mains
supply when mains power is back. It can also be programmed to start the engine
when a backup battery drops below a certain voltage. It ensures the generator runs
in a healthy condition. If an abnormality occurs, it shuts the DG down
automatically and displays the fault on the LCD screen along with an LED
indication.
Enhanced features include Real Time Clock based operation, with a
scheduler, so that the generator can be operated only during the desired time
interval. It can also be operated in a cyclic run-rest pattern.
Configuration parameters can be set with an interactive menu, which has an
optional password protection. The generator can be set to work in automatic,
manual or remote mode operation. The operations are easy with a 9-key keyboard.
Alarm extension card from Simcons, AL12, can be used with GC12, to
provide potential free contact for alarms, viz. Mains Failure, DG running, Backup
Battery Low, Low Fuel, DG Battery Low, High Cabin Temperature and Common
Fault. It does need any other connections other than the one from GC12.

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GC12 v3x

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Features
3 phase mains and DG voltage monitoring with DG run time
Can be configured to work with single phase DG/MAINS
Potential free outputs for Mains Contactor, DG contactor, start, stop and
hooter outputs.
40 programmable parameters, easy navigation
Optional Alarm extension
Two line LCD display, LED indications
Easy user interface with 9 key keyboard and LCD screen.
User friendly menu with optional password protection
DG protection features: LLOP, under voltage, over voltage, overload, high
temperature, fuel, emergency stop, under speed, over speed etc.
Warning for crank failure, low battery, stop failure, battery low/high etc.
Analog fuel input
Auto, manual and remote mode operation
Scheduler based on Real Time Clock
Programmable run/rest time
Backup battery monitoring (can be programmed to start DG on low battery
overriding timers) with range 20VDC-70VDC (20VDC to 300VDC range
available upon special request)
Last 60 event records (20 different events/faults) with date, time stamp and
duration.
Easy mounting on panel

Specifications

Operating voltage: 8-30VDC continuous, with reverse polarity protection

Able to survive operating supply voltage dip to 0 V for 500ms.
Voltage range (DG/MAINS): 50-300VAC (L-N), 30-70Hz
Maximum display error: +/- 1% of full scale reading
Power consumption: less than1W @12VDC with mains contactor on
Operating Temperature: 0-70oC
Dimension: 96x96x110mm
Panel cut-out dimension: 92x92mm

SIMCONS
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GC12 v3x

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Front Panel Diagram

emergency stop will be detected and

is identified as a fault.
MAINS:
Open/Close
Mains
Contactor. Press for at least 2
seconds(until the LED changes). For
manual mode operation only.
DG: Open/Close DG contactor.
Press for at least 2 seconds(until the
LED changes). For manual mode
operation only.
RESET: Silence hooter, reset fault.
If a fault exists, a RESET
FAULT? popup will be shown
upon pressing the key. Change to
YES using up/down keys and
press SET to reset the fault.

Keyboard Functions

LED Indications

SET : Enter Menu, save changes.

UP : Increment/scroll up
DOWN: Decrement/scroll down
EXIT : Exit menu/settings, switch
between manual/auto mode(Press
for at least 3 seconds to change
mode. Press until the yellow LED
changes)
START: Crank DG (in manual
mode). Press the start key until the
generator starts.
STOP: Stop DG. Keep pressing the
stop key until the DG stops. If the
stop key is pressed in auto mode,

MANUAL
MODE
(Yellow
Indication):
The yellow LED
indicates the controller is in
Manual/remote mode.

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LOAD
ON
DG
(Green
Indication): Generator Contactor is
Closed
LOAD ON MAINS (Green
Indication): Mains Contactor is
Closed
FAULT
(Red
Indication):
Generator fault condition/warning.
Refer the LCD display to identify
the fault.
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GC12 v3x

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Wiring Diagram

*Max potential that can be applied on pins DCCOM, MCIN or GCIN in is 40V AC/DC. Use
external relay card to switch 230V.
*Max current into or out of DCCOM:4A. Max current into or out of MCIN/GCIN:1A

Connector Description
Digital Outputs (Relay Outputs)
1.
2.
3.
4.
5.
6.

Manual Mode Relay Output(on select versions)

No Connection
Preheater/Fan(on select versions)
Hooter
Stop/Fuel Solenoid
Start Solenoid

Input for Digital signal relay output

7. DC Common Input. This input powers the output pins 1-6.
8. No Connection

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GC12 v3x

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Contactor Input/ Output

Inputs

9. Mains Contactor
Output(Normally Open)
10.Mains Contactor Signal
Input(Common)
11.DG Contactor Output(Normally
Open)
12.DG Contactor Signal
Input(Common)

24.No Connection
25.Remote Mode (Negative
Sensing). This input activates
the remote start and stop
features
26.Fuel (Analog/Negative sensing)
27.Emergency/Remote stop
(Negative Sensing)
28.LLOP (Negative Sensing)
29.High Coolant/Oil Temperature
(Negative Sensing)
30.Fault1(Negative Sensing)
38.Remote Start(Negative
Sensing)

Auxiliary Input
13.No Connection
14.Battery +VE
15.Battery VE

DG Voltage
Alarm Extension Port

16.DG B phase
17.DG Y phase
18.DG R phase
19.DG Neutral

31.RX
32.TX
33.GND
34.BOUT

Mains Voltage
Backup Battery Input
20.Mains B phase
21.Mains Y phase
22.Mains R phase
23.Mains Neutral

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35.Backup Battery Negative

36.Backup Battery Positive

GC12 v3x

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Programmable Parameters
Run - Rest Cycle

MainsUndrvoltHgh

Enabled/Disabled

MAINS UNDER VOLTL-220 Volts

If enabled, Run Time and Rest Time

The voltage below which mains

failure is detected when mains
contactor is open
Default: 170 Volts

can be programmed. RUN time and

REST time can be set from 10
minutes to 15 hours. Scheduler cannot

MainsOverVoltage

be enabled if RUN-REST timer is

enabled.

220-300 Volts

Default: Disabled

Mains Over Voltage

Default: 270 Volts

MainsSinglePhase
Mains Imbalance

Enabled/Disabled

Enable/Disable
0-30%

Enable or Disable Mains single phase

operation. In single phase operation,

Default: Enabled

If enabled, Mains Voltage Imbalance

tolerance can be programmed.
Default: Disabled

MainsUndrvoltLow

DG Single Phase

90-220 Volts

Enabled/ Disabled

The voltage below which mains

failure is detected when mains
contactor is closed
Default: 160 Volts

Enable or Disable DG Single phase

operation
Default: Enabled

only the phase R is monitored.

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GC12 v3x

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LLOP must be connected to the AMF

controller.
Default: Enabled

DG UnderVoltage
90-220 Volts
Generator Under Voltage. If a UV
condition occurs, the load is tripped
for 10 seconds. If UV occurs again in
a short time interval, the generator is
shut down automatically.
Default: 160 Volts

MainsFailDelay
0-250 Sec
Mains Fail Delay- Delay between
mains failure and crank attempt.
Default: 10 Sec

DG OverVoltage

FailDelyExtended

220-300 Volts

0:00 to 15:00 Hr:Min

Generator over Voltage

Default: 270 Volts

Mains fail delay extended. Delay

between mains fail and crank attempt.
It can be set from 0 minutes to 15
hours.
Default: 00:00 HR: MIN

DG UnderSpeed
30-60Hz
Generator Under frequency/speed

DG Preheat Time

Default: 45 Hz

0-250 Sec

DG OverSpeed

DG Preheat time The duration

preheating is done before cranking
DG.
Default: 0 Sec

50-70 Hz
Generator Over frequency/speed
Default: 55Hz

Cranking Time

LLOPCheckToCrank

1-20 Sec
Enabled/Disabled
Generator cranking time- Generator is
cranked for the specified duration.
Default: 2 Sec

Enable or Disable LLOP check. The

feature checks for the LLOP signal
before attempting to crank. If enabled,

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Delay between opening of Generator

Contactor and stopping DG. During
this time the generator runs on no
load.
Default: 10 Sec

Crank Attempts
1-5
Generator crank attempts. If generator
did not start after cranking, it is again
cranked to the number of crank
attempts.
Default: 3

SolnoidOnToStart
Enabled/Disabled
Configure fuel solenoid. Enabled fuel solenoid energized when running
DG. Disabled solenoid is energized
to stop the engine

DG BuildUp Delay
1-250 Sec
DG build-up delay delay during
which DG voltage, frequency and oil
pressure build up
Default: 10 Sec

Default: Disabled

DG Stopper Time
1-99 Sec

MainsRestorDelay

Stopper time The time to stop the

generator
Default: 20 Sec

0-250 Sec
Mains Restore Delay- Delay between
mains recovery and mains contactor
closing.
Default: 5 Sec

LowFuelTripLevel
0-60 %
Low fuel percentage Fuel level
below which generator will be
stopped
Default: 10 %

Fault Trip Delay

1-99 Sec
DG Contactor trip delay in case of
occurrence of any fault condition.

LowFuelWarning
0-60 %

DG Recool Delay

Low fuel warning level Fuel level

below which a warning will be
displayed on the screen.
Default: 30 %

0-250 Sec

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GC12 v3x

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The generator operates only between

SCHEDULED
START
and
SCHEDULED STOP time when
mains failure occurs. If Run-Rest
Timer is enabled, scheduler cannot be
enabled.
Default: Disabled

HooterResetTime
4-99 Sec
Hooter reset time The time in which
the hooter will be turned on when a
fault condition occurs.
Default: 10 Sec

DG Bat Low Level

Time-24Hr Clock

7-24 Volts
00:00 to 23:59 Hr:Min

DG battery Low level The low

battery level at which an alarm is
triggered
Default: 11 Volts

The time in 24 hour format.

Date Settings

DG Bat HighLevel

Set day, month and year

BATT LOW LEVEL -30 Volts

FactoryDefaults?

DG battery level The low battery

level at which an alarm is triggered
Default: 14 Volts

Yes/No
Factory default settings Selecting
YES and pressing SET will cause all
the settings to be reset to factory
defaults.

Engine RPM/Hz
5-99
Engine RPM/frequency ratio. The
engine RPM is frequency*RPM ratio.
Default: 30

Calibration
Reserved. Factory calibration is done.

Scheduler

Password Options

Enabled/Disabled
If enabled, scheduler start time and
end time can be programmed. The
scheduled operating time must lie
within the 0-24 hours of a day. If
enabled, the Scheduled start time
and Scheduled stop time can be set.

The password options include Enable

Password (to enter menu) and
Change password. The default
password is 1234.

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GC12 v3x

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battery voltage. This feature is used to

bypass delay between mains failure
and engine start when low backup
battery voltage is detected.
Default: Disabled

Fan Output
Yes/No
Selecting Yes will configure the
PREHEATER relay output(PIN 3) to
FAN output for air cooled engines

Bts Bat LowLevel

Event Log

20V to 240V

Lists the last 60 events with duration

of at least 20 Sec. Use up/down key
for navigation. Press SET key for
event start and clear time. The latest
event has the numbering 1, and the
oldest 60.

Backup battery voltage below which

low battery is detected.

Calibrate BtsBat
0000 *10mV to 3000*10mV
Calibrate the backup battery voltage.
For example, if the backup battery
voltage is 48.5V, enter 0485*10mV
and press SET.

Clear Event Log

Yes/No
Selecting Yes and pressing SET will
cause all the event logs to be cleared.
Password is required to clear the log.

BypasRestOnLoBat
Enabled/disabled

BtsBatMonitoring

Enabling this option will bypass

programmed DG rest time when the
backup
battery
is
below
BtsBatLowLevel2. BtsBatLowLevel2
is programmable from 20V to 240V.

Enabled/Disabled
Enabling
BTSBAT
Monitoring
monitors and displays the Backup

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Indian Telecom Innovation Hub, KINFRA Hi-Tech Park, HMT Colony PO,
Kalamassery, Cochin 683503
Email: contact@simcons.in
Web: http://simcons.in

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GC12 v3x