Document: MAN-6000 Series

Data: 04/99
Part No. 276-947

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 TABLE OF CONTENTS
1. SYSTEM OVERVIEW.................................................................................................................................................................................................. 1
1.1. Scope of this Document.................................................................................................................................................................................... 1
1.2. General Description........................................................................................................................................................................................... 1
1.3. Information Displays.......................................................................................................................................................................................... 1
2. FUNCTIONAL DESCRIPTION 6000 SERIES CONTROL SYSTEMS......................................................................................................................... 3
2.1 System Overview.............................................................................................................................................................................................. 3
2.2 Generating set Parameter Displays................................................................................................................................................................... 3
2.3 Control Features............................................................................................................................................................................................... 3
2.4 Control Functions.............................................................................................................................................................................................. 4
2.5. Protective Features........................................................................................................................................................................................... 5
2.6 Standard Auxilliary Equipment.......................................................................................................................................................................... 5
2.7 Standard Options.............................................................................................................................................................................................. 5
2.8. Communications Options.................................................................................................................................................................................. 6
2.9 Hardware.......................................................................................................................................................................................................... 6
3. CONFIGURATION - OUTLINE OF SETPOINTS......................................................................................................................................................... 9
3.1 Configuration Menu........................................................................................................................................................................................... 9
3.2 Shutdowns, Alarms......................................................................................................................................................................................... 10
3.3 Engine Control................................................................................................................................................................................................ 13
3.4 Synchroscope................................................................................................................................................................................................. 13
3.5 Real Load Control........................................................................................................................................................................................... 14
3.6 Reactive Load Control..................................................................................................................................................................................... 15
3.7 Process Control.............................................................................................................................................................................................. 16
3.8 Calibration....................................................................................................................................................................................................... 16
3.9 NetComm Dropouts........................................................................................................................................................................................ 18
3.10 6100 - Single Generating set, Automatic Mains Failure................................................................................................................................... 18
4. RUN / GENERATING SET MANUAL RUN............................................................................................................................................................... 19
4.1 Functional Description.................................................................................................................................................................................... 19
4.2. Prime Power Variant - Normal Switch Positions.............................................................................................................................................. 19
4.3. AMF Variant - Normal Switch Positions........................................................................................................................................................... 20
5. 6300 - AUTOMATIC SYNCHRONISING OF ONE GENERATING SET WITH MAINS................................................................................................ 21
5.1 Functional Description.................................................................................................................................................................................... 21
5.2. Base Load Operation....................................................................................................................................................................................... 21
5.3. Base Load Variant - Normal Switch Positions.................................................................................................................................................. 21
5.4. Peak Shaving Operation.................................................................................................................................................................................. 22
5.5. Peak Shaving Variant - Normal Switch Positions............................................................................................................................................. 22
5.6. Soft Transfer Variant - Normal operation:......................................................................................................................................................... 23
5.7. Soft Transfer Variant - Normal Switch Positions............................................................................................................................................... 23
6. AUTOMATIC SYNCHRONISING OF MULTIPLE GENERATING SETS WITH MAINS............................................................................................... 24
6.1. Functional Description.................................................................................................................................................................................... 24
6.2. Base Load Operation....................................................................................................................................................................................... 24
6.3. Base Load Variant - Normal Switch Positions.................................................................................................................................................. 25
6.4 Peak Shaving Operation.................................................................................................................................................................................. 25
6.5 Peak Shaving Variant - Normal Switch Positions............................................................................................................................................. 25
6.6 Soft Transfer Variant - Normal operation:......................................................................................................................................................... 26
6.7 Soft Transfer Variant - Normal Switch Positions............................................................................................................................................... 26
7. ALARM / EVENT INDICATION AND LOGGING........................................................................................................................................................ 27
8. REMOTE CONTROL AND MONITORING VIA A PC:................................................................................................................................................. 27
8.1 System Outline................................................................................................................................................................................................ 28
8.2 Functional Description...................................................................................................................................................................................... 28
8.3 Hardware Specifications................................................................................................................................................................................... 28
8.4 Equipment Supplied With Each Option:........................................................................................................................................................... 29
9. INITIAL STARTUP AND COMMISSIONING............................................................................................................................................................... 29
9.1 Test Procedure for Single Generating set Systems........................................................................................................................................... 29
10. TROUBLESHOOTING............................................................................................................................................................................................... 32
10.1 Control Hardware and I/O................................................................................................................................................................................. 32
10.2 Engine Control / Sensing Parameters............................................................................................................................................................... 32
10.3 Synchronisation................................................................................................................................................................................................ 33
10.4 Breaker Close / Open Control........................................................................................................................................................................... 33
10.5 Real Load Control............................................................................................................................................................................................. 34
10.6 Reactive Load Control...................................................................................................................................................................................... 34
10.7 Sequencing...................................................................................................................................................................................................... 35
10.8 Mains / Bus Sensing........................................................................................................................................................................................ 35
10.9 Communications.............................................................................................................................................................................................. 35
11. DEFINITION OF TERMS........................................................................................................................................................................................... 36

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1. System Overview This document is intended for use by any suitably qualified
person wishing to obtain technical information regarding the
1.1. Scope of this Document configuration and setup of any of FG Wilson’s range of 6000
series control systems. It may also be used reference document

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for those in the Sales, Engineering and Product Support
departments within FG Wilson. The information contained herein
is sufficiently detailed as to give the reader insight into the
operating modes of the 6000 Series Control System and is
designed to replace the Woodward GCP-1 manual for any of the
FG Wilson range.
1.2. General Description
The 6000 Series Control System employs the 6000 Controller as
its core in addition to some ancillary components to realise the
range of 6000 Series Control Panels offered. Depending on the
requirements of the installation, the 6000 Series Control System
may be configured to operate in one of several modes: 6100,
6200 or 6300. It may also be configured to operate in the 6400
mode in conjunction with an external master control section.
The control panel provides a means of starting and stopping the
generating set, monitoring its operation and output, and
automatically shutting down the set in the event of a critical
condition arising such as low oil pressure or high engine coolant
temperature.
Figure 1 shows typical diagrams of the 6000 Series Control
Panel. Addition of optional equipment will add items to the panel
so the panel fitted on the generating set may be slightly different
from the one shown. The following descriptions explain the
function of each item on both the panel and controller and each
display screen menu on the panels:
1. ALARM LAMP: Figure 1: Diagram of Typical Control Panels
Fault lamp that illuminates to indicate that the protective 10. “STATUS PAD”:
circuitry has sensed a fault condition. The lamp flashes on A pad to move cursor into the status screen.
an ALARM condition and lights continuously on a
SHUTDOWN condition. The specific nature of the fault is 11. VOLTS RAISE / LOWER SWITCH:
detailed in the ALARM / EVENT LOG menu on the A switch to manually control the generator voltage (optional
STATUS screen. in 6100 Mode).
2. ALARM RESET: 12. SPEED RAISE / LOWER SWITCH:
By pressing this pad the audible alarm is reset. Specific This switch manually controls the engine speed (optional in
faults are reset by pressing the ALARM RESET pad when 6100 Mode).
in the ALARM / EVENT LOG menu on the STATUS 13. EMERGENCY STOP PUSHBUTTON:
screen.
A red lock-down pushbutton that immediately shuts down
3. ESC: Press this pad to exit from any menu. the generating set and will inhibit start until the pushbutton
4. COMMIT: has been released by turning it clockwise.
Use this pad to enter any menu or amended settings 14. CONTROL SWITCH:
(subject to security clearance). A four position switch that provides a means of controlling
5. “UP PAD”: the generating set mode and function.
A pad to step upwards through the menu items or to Position "1" - Off
increase numerical values of parameters (subject to Generating set is stopped and automatic starting is
security clearance). disabled.
6. “DOWN PAD”: Position "2" - Auto
A pad to step downwards through the menu items or to This is the normal position for automatic start up.
decrease numerical values of parameters (subject to Position “3” - Test
security clearance). Depending on exact configuration the generating set starts
7. “LEFT PAD”: and runs off load.
A pad to move cursor to the left on numerical parameters Position “4” - Run
(subject to security clearance). Depending on exact configuration the generating set starts
and runs on load.
8. “RIGHT PAD”:
15. AUDIBLE ALARM:
A pad to move cursor to the right on numerical parameters
(subject to security clearance). Buzzer that sounds on sensing of a fault condition
depending on fault handling description.
9. “TUNEABLE PAD”:
16. BREAKER / CONTACTOR CLOSED:
A pad to move cursor into the tuneable screen.
Light to indicate generator breaker / contactor closed.
1.3. Information Displays
The 6000 Series Control Panel has two 4 line alphanumeric LCD
displays. The lines of information displayed on these screens is
split into two sections. All four lines of the upper display and the
top two lines of the lower display make up the first section,
outlined on the front panel in blue. The bottom two lines of the
lower display make up the second section, outlined on the front
panel in white. The white section is the tunables section where
all tuning of setpoints is carried out. The blue section is used to
display all status information.
All information on the status of the generating set is subgrouped
into the various display screens listed below:
• Control Overview

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• Engine Overview #1 A B C
• Generator Overview V 221 220 220
A 250 248 251
• Generator Phases KW 58.2 58.2 58.2
• Synchroscope
Kvar 20.0 19.0 22.0
• Alarm/Event Log Kva 60.6 60.6 60.6
• I/O Status - Slip Frequency
• Sequencing - Phase Angle Difference
Control Overview Screen Layout - Voltage Differential
- Unit Number - Mains/Bus PT Selection
- Engine Status - Dead Bus (Yes/No)
- Mains/Bus Volts Status - Synchroniser Status
- Generator Output Status - Generator Voltage (A: )
- Mode of Operation - Mains/Bus Voltage (U: )
- Control Status SLIP PHASE VOLTS
**** **** ****
- List of All Available Units MAINS/BUS: MAINS
- Network Priorities of All Units on the Network DEAD BUS: NO

UNIT 1 ALARMS 0 (Synchroniser status) IN SYNC

ENGINE: OFF A: 381 U: 380
MAINS ~ GEN -
AUTO OFF Alarm/Event Log Screen Layout
- Number of Unacknowledged Faults
UNIT NO: 1 2 3
PRTY: 1 2 3 - Listing of up to Eight Most Recent Faults
Engine Overview Screen Layout UNACK FAULTS : 0
Faults Listing:
- Engine Coolant Temperature OVERSPEED
- Engine Oil Pressure 26-9 13:01

- Battery Voltage LOW OIL PRESSURE

28-9 11:59 1.5
- Time
- Date I/O Status Screen Layout
- Engine RPM - Status of Discrete Inputs 1-12 (‘*’ Denotes Active I/P)
- Generating set kW-Hrs - Status of Discrete Output 1-12 (‘*’ Denotes Active O/P)
- Generating set Run Time - Volts Bias Output
H2O OIL BATT - Speed Bias Output
67C 4.0B 27.9V
TIME DATE RPM DI: 1 2 3 4 5 6 7 8 9 0 1 2
12:00 26 09 1500 * * *
DO: 1 2 3 4 5 6 7 8 9 0 1 2
KW-HRS RUN TIME * * *
831 25
Volts Bias : 0
Generator Overview Screen Layout Speed Bias : 0
- 3 x Phase/Phase Volts
Sequencing Screen Layout
- 3 x Phase Currents
- List of All Available Units
- Generator Power Factor
- List of All Running Units
- Generator kW
- Network Priorities of All Units on the Network
- Load Status
- Unit Number of the Designated Master
#1 A B C
V 381 379 380 - Address of Next Unit to be Sequenced On
A 250 248 251
- Address of Next Unit to be Sequenced Off
Hz 50.0 kW 174.6
UNIT 1 2 3
PF 1.00 LAGGING
Generator Phases Screen Layout OPER X X
0.96 (Load Control status) PRTY 1 2 3
- 3 x Phase/Neutral Volts MASTER UNIT 1
- 3 x Phase Currents
NEXT ON: 3
- 3 x Phase kW
NEXT OFF: 2
- 3 x Phase kVar
- 3 x Phase kVA

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2. Functional Description 6000 Series Control Systems Import/Export Control (6300 Mode only)

2.1 System Overview
The 6000 Series control system incorporates a microprocessor
based complete load control and engine management system
and carries out all the functions necessary for engine control,
synchronising, real (kW) control, reactive (kVAR) control and
automatic generator sequencing. Protection is provided by the
control system against various fault conditions.
To simplify the variations in control capability the most common
operating modes have been designated as follows:-
6100 - Automatic mains failure (no paralleling).
6200 - Automatic synchronising of multiple generating sets (up to
8 sets).
6300 - Automatic synchronising of one generating set with mains
(baseload, peak lopping and soft transfer).
6400 - Automatic synchronising of multiple generating sets (up to
eight) with the mains (baseload and peak lopping).
Automatic Proportional Real and Reactive Load Sharing (6200
and 6400 Modes)
Automatic Soft Load Ramping Facility (6200, 6300 and 6400
Modes)
VAR or Power Factor Load Control in Mains Parallel Operation
(6300 and 6400 Modes)
Externally Adjustable VAR/PF Reference
Externally Adjustable Baseload/Process reference
Soft Load Ramping
Soft load Transfer and Re-transfer Control (6300 and 6400
Modes)
Manual Voltage Control Facility (depends on configuration)
Manual Frequency Control Capability (depends on configuration)
Synchronising

2.2 Generating Set Parameter Displays Automatic Phase Match Synchronisation

AC Voltage Phase/Phase and Phase/Neutral 3-Mode operation (Run, Permissive and Check)

AC Phase Current Automatic Voltage Matching

Output Frequency Dead Bus Closing

Power Factor (Cos Phi) Synch Timer

Total and Per Phase kW Reclose Attempt Timer

Per Phase kVAr Manual Synchronisation Capability (depends on configuration)

Total and Per Phase kVA Mains Sensing

Total kWh to Date Over / Under Voltage

% Voltage Difference between Bus and Generator (Single Over / Under Frequency
Phase/Neutral)
Load Surge Detection
Bus/Generator Phase Angle Difference
Programmable Loss of Mains Detection
Bus/Generator Frequency Slip
Loss of Mains Action Delay Timer
Generator Run Time
Programmable Mains Stable Delay
Engine Coolant Temperature
Sequencing (6200 and 6400 Modes)
Engine Lube Oil Pressure
Each unit in the system has an assigned priority
DC Voltage
Master (Highest Priority Unit) sequences units on / off line as
Single Phase/Neutral AC Bus Voltage required
Generator AC Voltage within limits indication Higher priority units are sequenced on in order of priority;
sequenced off in reverse of priority
Bus AC Voltage within limits indication
‘Max System Load’ and ‘Min System Load’ setpoints determine
2.3 Control Features percentage system load at which units are sequenced on or off
Engine Control line

OFF/AUTO/TEST/RUN Control Switch Programmable sequence on and off delays

Separate programmable time delay for overload (> 100%) system
Emergency Stop Pushbutton (Latching)
load levels
Multiple Attempt Crank Timer
Multiple Crank Repeat Setpoint
Crank Repeat Timer
Crank Fail Alarm/Shutdown
2.4 Control Functions
Crank Cutout (RPM based)
Engine Cranking
Programmable Pre-Glow Timer The GCP-1 Control is designed to automatically control the
Automatic Cooldown Timer cranking functions of the engine generator set. In order to safely
control engine cranking the GCP-1 uses the following setpoints,
Remote Starting capability (method employed depends on as found in the Engine Control tuning menu of the software:
application)
 Preglow Time
Automatic Mains Failure Control (handled externally in 6100 and
6200 Modes)  Crank Time
Alternator Output / Load Control  Crank Cutout

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 Crank Delay
 Crank Repeats
Starting Sequence:
Upon receiving a start command the following events occur:
1. The Preglow Output Energizes for the given preglow time
delay, and remains energized through the crank cycle.
2. After the preglow time expires, the Fuel Solenoid output
energizes.
3. 200 ms after the Fuel Solenoid output energizes, the
Crank output energizes.
At this point, the engine should be cranking at a certain RPM,
and receiving fuel. Typically a start would occur in these
conditions. To check if a start does occur, the GCP-1 monitors
the magnetic pickup from the engine. If the magnetic pickup input
indicates that the engine is operating above the Crank Cutout
speed, the GCP-1 will remove the Crank and Preglow outputs,
leaving the fuel solenoid energized. The engine state in the
control overview menu changes from “OFF” to “RUN”.
If for some reason the engine does not reach the crank cutout
RPM level, the GCP-1 will crank the engine for the Crank Time. If
the engine fails to rise above the crank cutout level in this time,
the GCP-1 will remove the Crank output signal, wait for the Crank
Delay, and if allowed by the number of Crank Repeats, will crank
the engine again. This sequence will continue until the number of
crank repeats is depleted, or until the engine speed rises above
the crank cutout RPM setting, whichever comes first. If the
number of crank repeats is depleted, the GCP-1 will activate the
Crank Fail Alarm Output based on this Alarm setpoint’s
configuration.
NOTE:
• The preglow output may stay energized between crank
attempts if the preglow time is greater than the sum of the
Crank Time and Crank Delay timers.
WARNING:
! Set Crank Repeats to zero when starting the engine for
the first time with the GCP-1. This will prevent starter
and ring gear damage to the engine if the MPU input to
the control should be faulty. Monitor Engine Overview
Status menu on the first start and confirm the RPM
readout during cranking. After a successful start is
made, the crank repeats may be set to the appropriate
value for the application.
Generator Voltage Control
The GCP-1 has the ability to control the voltage of the generator
set. This ability is used to control four separate operations which
require generator voltage adjustment :
1. Manual voltage adjustment
2. Voltage Matching during Synchronization across the
generator or mains breaker Reactive load sharing between
multiple units on an isolated bus
3. Reactive load control while in parallel with the mains.
The generator voltage, or reactive load (depending on the
operation) is adjusted by injecting a voltage bias signal to the
Automatic Voltage Regulator. The GCP-1 can be set for +/- 1
VDC, +/- 3 VDC, and +/- 9VDC outputs. The span of the output
is selected by a dip switch located on the back of the GCP-1, as
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SW-2, which is near the J5 connector. Here is a table showing
the dip switch settings, and resulting voltage bias output ranges
for those settings:
Dip Switches Voltage Bias Output Range
ON
SW2-5 +/- 1 VDC
SW2-4, SW2-1 +/- 3 VDC
SW2-4, SW2-3 , +/- 9 VDC
SW2-2
Select the proper voltage range input as recommended by the
AVR manufacturer.
Generator Voltage can be manually controlled from the Voltage
Raise and Voltage Lower Discrete inputs to the GCP-1. The rate
of change for manual voltage adjustment is set in the Reactive
Load Control tuning menu, at the Voltage Ramp Time setpoint.
The voltage ramp time is the amount of time it will take for the
GCP-1 to send a 0 to 100%, or 0 to -100% voltage bias signal to
the AVR.
When operating in the TEST mode, manual voltage
adjustment is only allowed through the voltage raise and
lower inputs. This allows testing of the Voltage Bias output,
and generator voltage levels prior to operation with load on
the generator.
When operating in Isoch mode, the GCP-1 does not allow
manual adjustment of the voltage, unless the Load Control
setpoint in the Configuration tuning menu is set for
“Droop”, or the VAR/PF Control Setpoint in the Reactive
Load Control tuning menu is set to “Disabled”. Using either
of these settings implies that a manual voltage control will
be used, and no automatic reactive load control functions
are active.
NOTE:
• It is highly recommended that the automatic reactive load
control in the GCP-1 be used for proper power conditioning
throughout the generator(s) load range. This is achieved by
setting the Load Control setpoint in the Configuration tuning
menu to Normal, or Soft Transfer (depending on the
application), and the VAR/PF Control setpoint in the Reactive
Load Control tuning menu to VAR or PF control (depending
on the application). For more details on these functions see
the Real Load Control and Reactive Load Control sections of
this manual.
The percent level of the voltage bias output can be monitored in
the I/O Display status screen of the GCP-1. This is a useful point
to monitor during initial start of the unit. By issuing Voltage Raise
and Lower inputs to the control while operating in the Test Mode,
confirmation of proper generator voltage levels at various voltage
bias points can easily be made. Typically the generator voltage
should change no more than +/- 10% for a +/- 100% voltage bias
output from the GCP-1.
All other modes of generator set operation rely upon the Reactive
Load Control functions of the GCP-1. See the information in the
“Reactive Load Control” section of the manual for more details on
voltage and reactive load control.
Generator Real Load Control
The GCP-1 Control has four core modes of generator load
control operation. These four modes are:
 Droop
 Isochronous Load Sharing
 Base Load
 Process Control
The specific mode of generator control that the unit is in at any
given time can be monitored on the Control Overview Menu.
A detailed description of each of these load control modes, and
the various operating states that will put the GCP-1 into each
respective load control operation can be found in section 3.5 of
this manual.
Mains Bus Overfrequency Alarm (Single Phase/Neutral)
Mains Bus Underfrequency Alarm (Single Phase/Neutral)
Up to 3 Spare Fault Channels
2.6 Standard Auxilliary Equipment
PBC5: 5A Battery Charger (fitted to all 6000 series systems)
2.7 Standard Options

Generator Reactive Load Control PBC5: 5A Battery Charger (Standard on all Systems)

When a small generator is paralleled with a Mains, the PSB3: 5A Battery Charger With Boost
synchronizer voltage matching function adjusts the generator PBL5: 5A Battery Charger Low Voltage (Standard on all low
voltage to match that of the Mains. Voltage variations that may voltage Systems)
occur in the Mains system after paralleling can cause large
WH: Water Heater Contactor
changes in reactive current in the generator. The VAR/Power
Factor Control provides closed loop control of either VARs or WHL: Water Heater Contactor Low Voltage
power factor when operating in parallel with another power
FP2: DC Fuel Pump Controls
system when that system can accept the reactive load.
FP3: AC Fuel Pump Controls
Voltage adjustment, however, can only affect reactive power when
another system is available to accept the reactive load. So the PML1: Oil Temperature Gauge
VAR/Power Factor control functions are automatically switched to PPE1: Earth Leakage (not available on 6200)
Power Factor sharing when either single or multiple units are
PPE2: Earth Fault
operating in isochronous load sharing mode on an isolated bus.
WS1: Low Coolant Level (Standard on CV12 / Dorman)
The 6000 series controller is capable of operating in 3 modes of
reactive load control:- FS1: Low Fuel Level Shutdown
FS2: Low Fuel Level Alarm
 VAr Control
 Power Factor Control LS1: High Lube Oil Temp
 VAr Sharing Crank Attempt Counter
The Reactive Load Control function may also be disabled if PSB: Emergency Stop Button With Security Key
desired. This mode is used as standard in 6100 and 6200
systems. PAT1: Terminals For Customer Supplied Remote Emergency
Stop
A more detailed description of each of the above operating modes PAC1: Set of Volt Free Contacts For Common Alarm
can be found in section 3.5 of this manual.
PRM1: Electronic Mains Sensing Unit (Phase Failure Unit)
2.5. Protective Features
PSB2: Canopy Mounted Emergency Stop
Engine Protection
AH1: Anti-Condensation Heater With Control Panel Mounted
High Coolant Temperature Pre-Alarm Auto control System and Contactor
High Coolant Temperature Shutdown FV1: DC Tank Base Mounted Solenoid Valve (For Use With FS3
or FS4)
Low Oil Pressure Pre-Alarm
FS3: 2 x Tank Mounted Fuel Level Switches (High and Low)
Low Oil Pressure Shutdown
FS4: 4 x Tank Mounted Fuel Level Switches (High, Extra High,
Overspeed Shutdown Low, Extra Low)
Fail to Start Shutdown E1: Electronic Governor (Standard on 6200 and 6300 Systems)
Emergency Stop Operated WC1: Low Coolant Temperature Switch
Battery Overvoltage Alarm 2.8. Communications Options
Battery Undervoltage Alarm PC1: Remote Monitoring (Hardwired)
Alternator Protection PC2: Remote Monitoring and Control (Hardwired)
Reverse Power Shutdown TEL1: Remote Monitoring (Dial Up Link)
Per-Phase Overvoltage Shutdown TEL2: Remote Monitoring and Control (Dial Up Link)
Per-Phase Undervoltage Shutdown TEL3: Remote Monitoring and Control With Fault Alert Callback
Overfrequency Shutdown (Dial Up Link)

Underfrequency Shutdown/Alarm MOD1: Remote Monitoring and Control Utilising a ModBus

Communications Network
Alternator Loss of Excitation Alarm
2.9 Hardware
Load Surge Detection (while in Mains Parallel)
Discrete Inputs and Outputs
System Protection / Alarms
The discrete inputs and outputs of the GCP–1 control are used
Fail to Synchronise Alarm to interface external commands to specific control actions and
operations, and to control external devices.
Mains Bus Overvoltage Alarm (Single Phase/Neutral)
Mains Bus Undervoltage Alarm (Single Phase/Neutral)

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The Discrete inputs are designed to be tied back into a switch
Loc. Description Signal Burden
common on the GCP–1 when closed. Each switch input will sink
5 mA of current at 12 VDC when closed. J5-19 Generator PT phase A Line AC Voltage
Below is a list of the discrete inputs available to the GCP–1 J5-23 Generator PT phase A Neutral AC Voltage
control.
J5-18 Generator PT phase B Line AC Voltage
ID Description
Number J5-22 Generator PT phase B Neutral AC Voltage

1 Mode Control Input #1 (Auto) J5-17 Generator PT phase C Line AC Voltage

2 Mode Control Input #2 (Test) J5-21 Generator PT phase C Neutral AC Voltage

3 Mode Control Input #3 (Run with Load) J5-9 Generator CT phase A Current AC Current .067
ohms
4 Volts Bias Raise J5-5 Generator CT phase B Current AC Current .067
ohms
5 Volts Bias Lower
J5-1 Generator CT Phase C Current AC Current .067
6 Speed Bias Raise ohms
7 Speed Bias Lower J5-10 Generator CT Neutral AC Current

8 Generator Circuit Breaker / Contactor Auxiliary J5-20 Mains/Bus PT phase A Line AC Voltage

9 Mains Circuit Breaker / Contactor Auxiliary J5-24 Mains/Bus PT phase A Neutral AC Voltage

10 Mode Control Input #4 (Process) J1-2 +Magnetic Pickup AC Freq.

11 High Engine Temperature Shutdown Contact J1-1 -Magnetic Pickup AC Freq.
12 Low Oil Pressure Shutdown Contact DC Inputs and Outputs

Location Description Signal I/O

13 Emergency Stop Input
J5-12 + power supply 9-15 VDC (12V unit) Isolated
14 - 16 Spare Fault Channels 1 – 3
J5-8 - power supply 18-32 VDC (24V unit) Input
Below is a list of the discrete outputs available. All discrete J5-2 + process signal 4-20 mA or 1-5 VDC 6 Watt
outputs consist of double-pole relays rated at 10A at 120VAC, 8A
J5-6 - process signal typical
at 277VAC resistive.
J1-17 + speed bias +/- 3 VDC Isolated
J1-13 - speed bias Output
J5-3 + voltage bias +/- 1, 3, or 9 VDC Isolated
J5-7 - voltage bias Output

Communication Ports
2 x serial communications ports are provided on the 6000 series
ID Description controller (1 x RS-485 and 1 x RS-422). Details of connections and
Number uses are given below.

1 Mains Breaker / Contactor Close Location Description Signal

2 Generator Breaker / Contactor Close
J8-2 - RS-485 communication line Intercontrol comms
3 Engine Preglow
J8-1 + RS-485 communication line Intercontrol comms
4 Fuel Control Solenoid
J8-4 + 5VDC Isolated Supply
5 Engine Crank
J8-5 - 5VDC Isolated Supply
6 Visual Alarm Relay
J8-3 + RXD RS-422 communication line Remote communications
7 Local Bus PT Connect
J8-6 - RXD RS-422 communication line Remote communications
8 Mains Bus PT Disconnect
J8-8 + TXD RS-422 communication line Remote communications
9 Mains Breaker Trip
J8-9 - TXD RS-422 communication line Remote communications
10 Generator Breaker Trip
11 Audible Alarm Relay

The identification numbers associated with the discrete inputs

and outputs are used in the I/O status screen of the GCP–1.

AC Inputs

The GCP–1 receives AC inputs from the

generator, bus, mains and engine. They are as
follows:

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Switch # Description Normal
Status
SW1-1 Not used N/A
SW1-2 Not used N/A
SW1-3 Not used N/A
SW1-4 Not used N/A
SW1-5 Oil pressure shunt resistor (100 ohms when on) OFF
SW1-6 Oil pressure shunt resistor (100 ohms when on) OFF
SW1-7 Water temp shunt resistor (100 ohms when on) ON
SW1-8 Water temp shunt resistor (100 ohms when on) ON
SW2-1 Voltage bias output scaling (ON for +/- 3VDC, OFF
OFF for others)
SW2-2 Voltage bias output scaling (ON for +/- 9VDC, OFF
OFF for others)
SW2-3 Voltage bias output scaling (ON for +/- 9VDC, OFF
OFF for others)
SW2-4 Voltage bias output scaling (OFF for +/- 1VDC, OFF
ON for others)
SW2-5 Voltage bias output scaling (ON for +/- 1VDC, ON
OFF for others)
SW2-6 Not used N/A
SW2-7 Not used N/A
SW2-8 Process input type selection ON
ON = 4-20 mA input, OFF = 1-5 VDC input (4-20
mA)
SW3-1 RS-422 Termination RxD+ ON
(end of
line units)
SW3-2 RS-422 +5VDC pull-up ON
(end of
line units)
SW3-3 RS-422 Termination RxD- ON
(end of
line units)
SW3-4 RS-485 +5 VDC pull-up ON
(end of
line units)
SW3-5 Not used N/A
SW3-6 Not used N/A
SW3-7 RS-485 Termination - ON
(end of
line units)
SW3-8 RS-485 Termination + ON
(end of
line units)

iii
Explanation of Dip Switches

J1 J2 EXPLANATION OF
SWITCHES
SW-1
8 water temp shunt resistor (100 ohms) when ON
7 water temp shunt resistor (100 ohms) when ON
6 oil pressure shunt resistor (100 ohms) when ON
5 oil pressure shunt resistor (100 ohms) when ON
4 not used
3 not used
2 not used
1 not used
on off
8
7
CONTRAST
6 ADJ. SW-2
5
4
3
8 process I/E: ON = 4-20 mA @250 ohms; OFF = 1-5 VDC @ 30Kohms
7 not used.
2
1 J5 6 not used. +/- 1 +/- 3 +/- 9
SW-1 5 voltage bias output
4 voltage bias output VDC VDC VDC
scaling
3 voltage
scaling bias output SW2-5 SW2-4 ON SW2-4 ON
2 voltage
scaling bias output ON SW2-1 ON SW2-3 ON
1 voltage bias output scaling
scaling SW2-2 ON

8 RS-485 Termination +
7 RS-485 Termination -
on
8
off 6 not used.
7 5 not used.
6 4 RS-485 +5VDC pull up.
5 3 RS-422 Termination RxD -
4
3 2 RS-422+5VDC pull up.
2 1 RS-422 Termination RxD +
J8 on
8
off
1

7 SW-2
6
5
4
3
2
1

SW-3

Connector Wiring Diagram

W ir ni g D iag ram fo rGCP -1
C onnec to r C onne c to r C onne c to r
J5 J1 J2

+ 12 - + 17 9
Sp eed b ai s ou tpu t M a ni s b re ake rc ol s e (D O 1 ) n .o .
1 2 Vd c o r 2 4 V d c - 13 18
- 8 n .c .
- 1 27
Sh ei dl te mr ni a toi n 4 M PU speed ni pu t
+ 2 8
+ 20 n .o .
M a ni s B/ usA ph as e PT G en e ra to rB rea ke rC ol se (D O 2 )
+
- 24 5 17
C oo al n t tem p e ra tu re s en so r n .c .
- 6 26
+ 19
G en e ra to rA ph as e PT O ilp ressu re sen so r
- 23 + 9 7
Eng ni e P reg olw (DO 3 ) n .o .
A u to m/ anu a l (D 1I ) 16
+ 18 16
n .c .
G ene ra to rB pha se PT Tes t eng ni e (D 2I )
- 22 10 25
R unw ith ol ad (D 3I ) 34
+ 17 11
Vo ltag e ra si e (D 4I ) Fu e lSo el no di (DO 4 ) n .o .
G en e ra to rC ph as e PT 35
- 21 12
n .c .
Vo ltage olw e r (D 5I ) 36
G ene ra to rA ph ase C T + 9 24
Sp eed ra si e (D 6I )
G ene ra to rB ph ase C T + 5 19 6
Eng ni e C ran k (DO 5 ) n .o .
Spe ed olw e r (D 7I )
G ene ra to rC ph ase C T + 1 20 15
G ene ra to rC B au x (D 8I ) n .c .
C T N eu tra l - 10 15 24
M a ni s C B au x (D 9I ) 22 31
+ 2 n .o .
P ro ces s mi po rt e/ xpo r t P roc es s IE/ (D 1I 0 ) Vsi u a Al al mr (DO 6 )
(4 -2 0m A 1/ -5 Vdc ) - 6 18 32
n .c .
Fau lt 1 (D 1I1 ) 33
+ 3 14
Vo ltage b ai s ou tpu t Fau lt 2 (D 1I 2 )
7 23 5
- n .o .
Fau lt 1 (D 1I1 ) Loca Bl u s PT C onnec t (DO 7 )
8 13
N o C on n e c t 11 n .c .
Fau lt 2 (D 1I 2 )
7 23
N o C on n e c t 13
Fau lt 1 (D 1I1 ) 4
14 4
N o C on n e c t n .o .
Fau lt 2 (D 1I 2 )
3 14
N o C on n e c t 15 M a ni s PT D si connec t (DO 8 ) n .c .
21 22
N o C on n e c t 16
1
M a ni s B rea k e rTrpi (DO 9 ) n .o .
10
n .c .
C onne c to r 3
J8
+ 1 2
G ene ra to rB rea ke rTrpi (DO 10 ) n .o .
R S -4 85 N e wt o rk
- 2 11
C onn ec to r J5 si 2 4 -p ni m a el Trmi Troi type n .c .
m( a el connec to ron PC boa rd ) Sh ei dl te mr ni a toi n 7 12

+ 3 28
C onn ec to rJ 1 si 2 4 -p ni fem a el Trmi Troi typ e R S -42 2 R xD A ud bi el A al mr (DO 11 ) n .o .
( fem a el connec to ron PC boa rd ) - 6 29
n .c .
+ 8 30
C onn ec to rJ 2 si 3 6 -p ni fem a el Trmi Troi typ e R S -42 2 TxD
( fem a el connec to ron PC boa rd ) - 9 N o C on n e c t 19

N o C o nn e c t 4 N o C o nn e c t 20
C onne c to r J8 si 9 -p ni m a el Trmi T roi type
m( a el conn ec to ron PC bo a rd ) N o C o nn e c t 5 N o C on n e c t 21

1
3. Configuration - Outline of Setpoints CT Ratio (numeric : 5)

3.1 Configuration Menu Scales sensed CT input for Amperage as seen at generator

Security Code - 4 Levels of Access Used for Load Sensing Algorithm (KVA,KW,KVAR,PF)
• Operator: Access to Alarm Log and Network PT Ratio (numeric : 1)
Priority
Scales sensed PT input to Voltage Levels as measured at the
• Supervisor: Allows access to Network Address and Generator
Time Set in addition to above access.
Used in Load Sensing Algorithm (KVA, KW, KVAR, PF)
• Technician: Allows access to all setpoints except
engine run time and calibration Used for Voltage Matching
• Factory: Allows access to all setpoints Voltage Input (Wye L-N, Delta L-L)
Network Address (1 to 8) Set for sensing/transformer used between generator and Gen
Unique Address for Each Unit in the System Part 6000.

Maximum of 8 units on network Defines which calculations will be used for kW, KVA, KVAR, etc.

Network Priority Wye (Star) Generator or Transformer Connection

Unique Priority for Each Unit in the System 4 Wire - volts measured Line to Neutral
Delta Generator or Transformer Connection
Lowest Active Priority is considered Master
3 Wire - volts measured Line to Line
Maximum of 8 units on network
Voltage Reference (numeric)
Sequencing effective from lowest to highest priority
Operating Voltage of Generator per Generator Spec.
“Set All” Function Used for Var/PF Sharing as the Reference that multiple
generators share reactive load to. This maintains the voltage
When priority is reduced below 1, the value will change to “Set reference while in Power Factor Sharing or KVAR Control mode
All”. If the commit key is pressed when this value is on the on an isolated bus.
display, the display will change to represent all units in auto on
the network, and their priority. The network priority of any unit Load Control Mode
can be changed by using the left/right and up/down keys n the
control. Once changes are made, the changes are committed by Normal: Standard setting for load control and VAR/PF functions
pressing the commit key twice. Soft Transfer: Standard load control and VAR/PF functions, but
Number of Poles (numeric) unit will issue mains breaker open command while in process
control if process reference is reached, or while in base load and
Determines Speed/Frequency Relationship base load reference is reached.
Used for Speed/Frequency Mismatch Alarm/Shutdown Droop: Manual Load and Voltage Control used primarily for
commissioning
Number of Teeth (numeric)
Process Action (direct, indirect)
Determines RPM Scaling
Defines action of speed bias when unit is operating in process
Engine Speed Readouts/Alarms control in parallel with the mains.
System Frequency (50/60 Hz) Direct action = Unit increases speed bias (fuel) to increase
process 4- 20 ma input
Used as a basis for generator waveform analysis Indirect action = Unit decreases speed bias (fuel) to increase
process 4-20 ma input.
Defines typical operating frequency of generator
Circuit Breaker Control (Breaker, Contactor)
Rated Speed (numeric)
Defines action of Generator and Mains closure command
Synchronous Speed of Generator Set
Breaker issues momentary close signal, momentary open signal
Used in Speed Calculation to determine “sample” period for MPU independently.
input
Contactor issues continuous close signal. Removes this signal to
Rated kW (numeric) open contactor.
Rated kW of Generator
Breaker Close
Rated kVA (numeric)
Normally Open and de-
Used to determine Rated Current of Generator energised on mains and
Equation: I=KVA/Rated Voltage generator
Rated kVAr (numeric)
Breaker Open
Rated KVAR of Unit Normally Open and
Typically .6 x Rated KVA energised on generator

NOTE:- Normally Contactor

Closed and de-
energised on mains
• Rated KVA must be less than or equal to the Voltage
Close/Open

Reference x CT Ratio Primary. Normally Open and

Rated kW must be less than or equal to the Rated KVA de-energised on generator
Rated KVAR must be less than or equal to the Rated KVA
Normally Closed and
Any Values Falling out side of these ranges will appear on the de-energised on mains
screen with a pound sign (#) next to them. This indicates the
value is out of range, and the engine will not operate until the #
symbol is cleared by entering the correct values.

2
Check Mains Breaker (enabled, disabled)
Used to activate checking of mains c.b. aux. input when enabled
If disabled, unit relies on other units with this setpoint enabled to
broadcast state of mains c.b. aux. contact over network
Operating Mode
Mains Parallel or No Mains Parallel
Mains Parallel will allow the unit to synchronise to the mains, and
carry load while in parallel with the mains as well.
No Parallel will allow the unit to operate with load until the mains
breaker is sensed as being open
All units operating in a load sharing system must be set for the
same parameter, i.e. mains parallel, or no parallel.
Number of Units (single, multiple)
Defines whether unit is part of a multiple unit system or not.
If single unit, there is no auto starting, auto sequencing, load or
pf sharing with other units under any circumstances. Unit
displays “single unit no sequencing” on sequencing screen.
If multiple unit, auto starting, auto sequencing, load and var/pf
sharing are active between all units in multiple. Unit displays
system-sequencing information on sequencing screen.
Auto Sequencing (enabled, disabled)
Enables or Disables Auto Sequencing for that unit
Can be used to disable sequencing for a particular unit in a
sequencing system if needed
RS-422 Protocol (Modbus, Servlink, Upload Setpoints)
Used to select between different types of communication options
as outlined below:
 ModBus
Utilises the industry standard ModBus protocol.
More details on ModBus communications
With the 6000 series system can be found in section xxxx of
this manual.
The controller must be re-booted if this option is selected to
initialise ModBus communications
 Servlink
Utilises the Servlink protocol.
This option is used in conjunction with the PC1, PC2, TEL1,
TEL2 and TEL3 communications options.
The controller must be re-booted if this option is selected to
initialise Servlink communications.
 Upload Setpoints
Used for uploading the stored setpoints from the controller
to a storage file on a PC compatible computer.
This option should not be used by any personnel other than
FGW commissioning personnel who have undergone the
appropriate training.
Modbus ID (numeric)
Used to uniquely identify each controller on a ModBus network
Any changes will not take effect until the controller has been re-
booted
Modbus Timeout (seconds)
Maximum time delay allowed between successive polls of the
slave controller by the master.
This should be set to greater then the polling period of the
ModBus master.
If this time is exceeded a link failure error will be logged.
Modbus Reset (True, False)
Used to reset all static ModBus error messages
3.2 Shutdowns, Alarms
3
Shutdowns and Alarms menu is used to configure the various
safety functions of the Gen Part 6000.
Each alarm setpoint can be set for:
 Disabled: Disables alarm indication and logging.
 Warning: LED on Control Flashes.
 Visual Alarm: LED Flashes, and Visual Alarm relay
energises.
 Audible Alarm: LED Flashes, Visual and Audible Alarm
relays energise.
 Soft Shutdown: LED Turns On, Visual and Audible
Alarm relays energise, Fuel Solenoid relay de-energises.
Unit soft unloads and cycles through cool down timer
when applicable.
 Hard Shutdown: Same as above, but immediately opens
generator breaker and de-energises fuel solenoid.
The following alarms have ‘special’ functions:
 Mains Voltage High
 Mains Voltage Low
 Mains Frequency High
 Mains Frequency Low
 Load Surge
These alarms cannot be set to ‘Soft Shutdown’ or ‘Hard
Shutdown’ but may be set to the following two extra functions:
 Loss Of Mains
- Triggers an internal Loss of Mains condition
- No alarm indication triggered
 Loss Of Mains With Alarms
- Triggers an internal Loss of Mains condition
- Triggers an audible alarm
Load Surge (numeric %/sec)
Used only in Base Load or Process Control (Mains Parallel
Operations)
Set to trigger at a percent setpoint of total generator load shift per
second while operating in Mains Parallel
Instantaneous Trigger
Load Surge Alarm
Type of alarm triggered on Load Surge event
Can be set for Loss of Mains Detection
Mains Volts High Limit
Maximum mains bus voltage for mains to be considered stable
Mains Volts High Alarm
Type of alarm triggered on Mains Volts High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Volts Low Limit
Minimum mains bus voltage for mains to be considered stable
Mains Volts Low Alarm
Type of alarm triggered on Mains Volts Low event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency High Limit
Minimum mains bus frequency for mains to be considered stable
Mains Frequency High Alarm
Type of alarm triggered on Mains Frequency High event
Can be set to Loss Of Mains / Loss of Mains with Alarms
Mains Frequency Low Limit
Maximum mains bus frequency for mains to be considered stable
Mains Frequency Low Alarm Used to indicate loss of MPU, or Loss of Generator Field Voltage
Type of Alarm triggered on Mains Frequency Low event Overspeed
Can be set to Loss Of Mains / Loss of Mains with Alarms Set for overspeed limit of engine
Loss of Mains (LOM) Action Delay Typically set for Hard Shutdown for safety
Sets Time Delay for LOM Action to begin once Loss of Mains is Typically Set for 10% above Rated Speed of engine
detected.
Overspeed Alarm
Typically Delay time From LOM to engine start command
Type of alarm triggered on a overspeed event
Voltage Range Alarm
Overcurrent Level
Type of alarm triggered once voltage bias signal to AVR reaches
+/- 100% 3 Phase Sensing

Generator Volts High Limit Set for Per Phase Overcurrent

Sets maximum allowable generator voltage level Over Current Detection begins when current exceeds rated
current as determined by Voltage Reference and Rated KVA
Triggered of any individual phase values in Configuration menu: (KVA/Voltage Ref)/3.
If voltage is above High Limit, generator is not considered stable, Uses Inverse Time Function as basis for overcurrent detection.
and is unfit for breaker closure. This allows different levels of overcurrent based on time span.
The controller will not allow voltage biasing which will cause the Per Phase Overcurrent Inverse Time Function
generator voltage to go above this level even if the alarm is amps
disabled. Overcurrent Trip Zone
overcurrent level
Generator Volts High Alarm
Type of alarm triggered on a Generator Volts High event
100% rated current
Generator Volts Low Limit
overcurrent time
Sets minimum allowable generator voltage level
delay
Triggered of any individual phase
Over Current Level
If voltage is below Low Limit, generator is not considered stable,
and is unfit for breaker closure. High Current, Short Duration
The controller will not allow voltage biasing which will cause the
generator voltage to go below this level even if the alarm is amps
Overcurrent Trip Zone
disabled.
overcurrent level
Generator Volts Low Alarm
Type of alarm triggered on a Generator Volts Low event
Voltage Alarm Delay time
overcurrent
Delay between detecting a Generator Voltage High or Low delay
condition and activating the configured alarm
Overcurrent Level
Generator Frequency High Limit
Sets maximum allowable generator output frequency Notice area of over current is the same

If frequency is above High Limit, generator is not considered

stable, and is unfit for breaker closure.
The controller will not allow speed biasing which will cause the amps
generator output frequency to go above this level even if the Overcurrent Trip Zone
alarm is disabled. overcurrent level

Generator Frequency High Alarm

overcurrent time
Type of alarm triggered on a Generator Frequency High event
delay
Generator Frequency Low Limit
Overcurrent Delay
Sets minimum allowable generator output frequency
Setpoint used in conjunction with the Overcurrent Level setpoint
If frequency is below Low Limit, generator is not considered
stable, and is unfit for breaker closure. to determine tripping time on an overcurrent condition

The controller will not allow speed biasing which will cause the Overcurrent Alarm
generator output frequency to go below this level even if the alarm
Type of alarm triggered on an Overcurrent event
is disabled.
Generator Frequency Low Alarm Reverse Power

Type of alarm triggered on a Generator Frequency Low event
Speed / Frequency Mismatch
Compares generator frequency to engine RPM and alarms on
difference
Reverse Power Condition begins when sensed kW on generator
goes negative. Reverse Power
Trip levels depend upon amplitude and duration of reverse power
condition.

4
 Reverse Power Delay Active when generator is stable
Reverse Power also uses an inverse time function. Sensed in ºC
Reverse Power Approaching High H2O Temp Alarm
Minimum Reverse Power Type of alarm triggered on an Approaching High H2O Temp event
Minimum reverse power level which can trigger a reverse power
alarm. Reverse power levels below this setpoint will never cause Low H2O Temperature
a reverse power alarm condition, regardless of duration. See
diagram above. Sets the trigger point for the Low H2O Temp alarm

Reverse Power Alarm Uses Engine mounted temperature sensor

Type of alarm triggered on a reverse power event. Active when generator is stable
Loss of Excitation (LOE) Sensed in ºC
Set as a percentage of total KVAR load on the generator that can Low H2O Temperature Alarm
be applied as a block reactive load to the unit. If control senses
changes in KVAR loads instantly applied greater than this value Type of alarm triggered on an Approaching High H2O Temp event
the LOE alarm triggers. High Engine Temperature
Used to indicate loss of field excitation to the generator Sets the type of alarm activated upon the application of the
external High Engine Temperature volt-free signal.
Loss of Excitation (LOE) Alarm
Type of alarm triggered on an LOE event. Normally set to ‘Soft Shutdown’

Battery Voltage High Limit Set to ‘Hard Shutdown if combined with an external Low Coolant
Level sensor
Maximum permissible DC voltage supply to 6000 control
Only activated 15 seconds after the engine has reached the
Can be used to detect faulty charging circuit crank cut-out speed
Battery Voltage High Alarm High Engine Temperature Timer
Type of alarm triggered on a Battery Voltage High event Additional delay between the application of the external High
Battery Voltage Low Limit Engine Temperature volt-free signal and the activation of the
configured alarm type
Minimum permissible DC voltage supply to 6000 control
Not active when engine not running
Used to detect weak battery/failed charger
Low Oil Pressure
Automatically Disabled during engine cranking
Sets the type of alarm activated upon the application of the
Battery Voltage Low Alarm external Low Oil Pressure volt-free signal.
Type of alarm triggered on a Battery Voltage Low event Normally set to ‘Hard Shutdown’
High Oil Pressure Limit Only activated 15 seconds after the engine has reached the
Sets the trigger point for the High Oil Pressure Alarm crank cut-out speed

Uses Engine mounted pressure sensor Low Oil Pressure Timer

Active when generator is stable Additional delay between the application of the external High
Engine Temperature volt-free signal and the activation of the
Sensed in Bar configured alarm type
High Oil Pressure Alarm Not active when engine not running
Type of alarm triggered on a High Oil Pressure event Emergency Stop
Approaching Low Oil Pressure Sets the type of alarm activated upon the application of the
Sets the trigger point for the Approaching Low Oil Pressure pre- external Emergency Stop volt-free signal.
alarm Normally set to ‘Hard Shutdown’
Uses Engine mounted pressure sensor Emergency Stop Timer
Active when generator is stable Delay between the application of the external High Engine
Temperature volt-free signal and the activation of the configured
Sensed in Bar
alarm type
Approaching Low Oil Pressure Alarm
Always activated
Type of alarm triggered on an Approaching Low Oil Pressure
event Spare Fault #1
Sets the type of alarm activated upon the application of the
Approaching High H2O Temp
external Spare Fault #1 volt-free signal.
Sets the trigger point for the Approaching High H2O Temp pre-
alarm Normally set to ‘Disabled’

Uses Engine mounted temperature sensor Spare Fault #1 Timer

5
Delay between the application of the external volt-free signal and May be re-set or pre-programmed by anyone with level 3 security
the activation of the configured alarm type access

Always activated MW Hours

Spare Fault #2 MW hours supplied by the generating set

Sets the type of alarm activated upon the application of the increments in 0.1 MW hour steps
external Spare Fault #2 volt-free signal.
Retained in EE memory
Normally set to ‘Disabled’
May be re-set or pre-programmed by anyone with level 3 security
Spare Fault #2 Timer access
Delay between the application of the external volt-free signal and 3.4 Synchroscope
the activation of the configured alarm type
Synchroniser Mode
Always activated
 Permissive
Spare Fault #3
- Acts as a synch check device.
Sets the type of alarm activated upon the application of the - 6000 will not issue speed or voltage bias commands,
external Spare Fault #3 volt-free signal. but if synchronisation conditions are within spec (phase
and voltage), control will issue a breaker close
Normally set to ‘Disabled’ command.

Spare Fault #3 Timer  Check

Delay between the application of the external volt-free signal and - Used for checking synchroniser prior to commissioning
the activation of the configured alarm type - 6000 control actively synchronises generator by issuing
speed and voltage bias commands, but does not issue
Always activated breaker closure command
3.3 Engine Control  Run
Preglow Time - Normal operating mode
Time of preglow allowed prior to engine crank cycle - Actively synchronises and issues breaker closure
command
Maintained through engine cranking - Control MUST be in RUN to operate as a dead bus-
closing device.
Resets after every crank attempt - In multiple unit systems 6000 control MUST have
AUTO input active to enable dead bus closing
Crank Time
Synchroniser Gain
Maximum allowable time for engine cranking
Sets Gain of synchroniser speed bias output
Crank Cut-out
Synchroniser Stability
Engine RPM level where crank command is cancelled
Sets Stability of synchroniser speed bias output
Crank Delay
Both Gain and Stability are used to tune the synchroniser
Time between engine crank attempts
dynamic response.
Crank Repeats Voltage Matching
Number of times the 6000 control will attempt to re-start the Enables/Disables Voltage Matching feature of 6000 control
engine. The number of actual cranking attempts = Crank
Repeats +1 Enables Voltage Window Setpoint

Crank Fail Voltage Window

Type of alarm triggered once the generating set has completed Overall percentage of error allowed between generator and bus,
its full crank sequence and the engine has not yet started. or generator and mains

Cool down Time 6000 control will not issue a breaker closure if error is greater
than voltage window
Time allowed for cool down after coming off-line during a normal
stop sequence Maximum Phase Window
Only activated if the generating set load has exceeded the Cool Maximum allowable phase angle deviation from phase matched
down Limit condition.

Cool down Limit 6000 Control will not issue breaker closure if phase angle
between generator and bus, or generator and mains exceeds this
kVA setpoint at which, when exceeded will cause the engine will
window
execute a cool down during a stop sequence
Dwell Time
Engine Run Time
The period of time that the generator must be within the Max.
Hours of run time on the engine
Phase Window for before the 6000 control will issue a breaker
Increments in hours closure

Retained in EE memory - retains value after power loss Longer dwell times will give typically give better stability after the
breaker closes

6
Shorter dwell times reduce amount of time required to
synchronise unit
C.B. Hold Time
Time in Seconds that Breaker/Contactor Close output is held
after breaker close command is issued
Close Attempts
Number of Close Attempts allowed while synchronising
Close attempt incremented if breaker does not send back
continuous CB aux. signal to 6000.
Reclose Delay
Time in Seconds before 6000 control attempts re-synchronisation
after failed closure attempt
Synch Reclose Alarm
Alarm setpoint if number of close attempts is depleted
Synch Timeout
Sets time allowed for synchronisation in seconds
Begins timing when synchroniser activates
Active for all gen and mains breaker open and close commands
from 6000 control
A setting of zero (0) seconds disables synch. time-out - infinite
synch time allowed
Synch Timeout Alarm
Sets alarm mode if synch time-out is exceeded
Dead Bus Closure
Enables/Disables Dead Bus Closing Feature
Only active in multiple unit systems. Dead bus closing is always
active in single unit configuration.
Unit must be within voltage and frequency high/low limits to be
considered for dead bus closure.
Dead Bus Closure uses Token Passing Scheme to assure that
only one unit in a networked system will close onto the dead bus
at any given time.
Multiple unit systems must have Auto switch input to allow dead
bus closing between networked units
3.5 Real Load Control
Load Control Gain
Sets gain response of load control
Active in load ramping and base load operations
Load Share Gain
Sets gain response of proportional load sharing
Active in load sharing operations
Load Stability
Sets stability response of load control
Active in load ramping and baseload operations
Load Derivative
Sets derivative response of load control
Active in load ramping and baseload operations
Load Control Filter
7
Low pass filter used to attenuate higher frequency transients for
better stability
Active in proportional load sharing, load ramping and baseload
control modes
Baseload
Load Level Generator will automatically ramp to when operating in
Base Load
Unload Trip
Load Level where Generator Breaker/Contactor open command
will be issued when 6000 control is off loading generator set
Load Droop
Percentage of kW droop used when 6000 control is operating in
a droop mode
Load Time
Time in Seconds for generator to load from unload trip level to
base load level. This rate is applied during any automatic loading
function, including ramping to load sharing
Unload Time
Time in Seconds for generator to unload from base load level to
unload trip level. This ramp rate is applied during any automatic
unload functions, including ramping from load sharing
Raise Load Rate
Percent Load per Second ramp rate used when the raise load
contact input is used during base load operation.
Lower Load Rate
Percent per Second Ramp Rate used when the load lower input
is active in base load control operation
Fast Xfer Delay
Time required for a transition in switching from Mains to
Generator operations, and from Generator to Mains operations.
This includes transition times between bus and mains sensing.
Mains Stable Delay
Period of time required for the mains to be declared stable before
transition from generator(s) to mains.
Generator Stable Delay
Period of time generator must be declared stable before transition
from Mains to Generator, as well as dead bus closing
Load High Limit
Maximum allowed load while operating in Base load or Process
control modes
Prevents overload of unit
High Limit Alarm
Sets alarm mode when unit is at or above High Load Limit
Active during all load control operations
Load Low Limit
Minimum allowed load while operating in Base load or Process
control modes
Prevents reverse current of unit
Low Limit Alarm
Sets Alarm Mode when unit is at or below Low Load Limit
Active during all load control operations
Maximum Generator Load
% system load on all units with gen breakers closed, and on the
same network, in Auto,and in Load Sharing or Process control
modes, at which active master unit will begin timing to sequence
next unit on line.
Next Generating set Delay
Period of time that will pass before master auto sequences an
additional generator on line.
Delay is effective only in active master unit
Rated Load Delay
Delay when system load exceeds 100%, before master starts
next generating set in sequence
Maximum Start Time
Time allowed by master to see next unit to be sequenced on line
in an “active” condition, i.e. started and ready to load.
This is determined by a flag, which indicates the unit is ready to
load, is sent over the network by the unit being sequenced on by
the master.
If master does not detect this flag within the Max. Start Time
allowed, it will go to the next lower priority unit and try starting it,
or if no other units are available, it will retry the start command on
the same unit.
Minimum Generator Load
% of system load at which active master begins timing to
sequence units off line
Master may have to wait until system load is below this level if
unit next in line to be sequenced off will cause the system load to
increase above the Max Gen Load setpoint of the Master.
Reduced Load Delay
Time in seconds which the active master waits before
sequencing units off line.
Delay is effective only on active master unit
Lowest priority units are sequenced off line first
Maximum Stop Time
Time in seconds allowed by master for slave to sequence off line
Master begins sequencing next lowest priority unit off line if
system load is still above Min. Gen. Load setpoint at the end of
the Max Stop Time Limit.
3.6 Reactive Load Control
VAr / PF Mode
Can be set to one of three modes
 Disabled
- Unit does not PF share, or control PF under any
circumstances
- This setting should be used for all 6100 and 6200
systems
 VAR Control
- Unit PF shares in isolated bus load sharing mode
- Unit controls KVAR in Base Load and Process Control
Modes
 PF Control
- Unit PF shares in isolated bus load sharing mode
- Unit controls PF in Base Load and Process Control
Modes
8
VAr / PF Gain
Controls Gain Response of unit in Var/PF control mode
NOT active in PF sharing mode
Voltage Ramp Time
Ramp time from 0 to +/-100% voltage bias output
Controls response of units in PF sharing modes
Controls ramp time of voltage during synchronisation
Controls ramp time of voltage during manual voltage adjust
VAr / PF Share Gain
Not Active in any modes (reserved for future use)
VAr / PF Stability
Controls Stability Response of unit in Var/PF control mode
NOT active in PF sharing mode
kVAr Reference
When KVAR control mode is selected, this references the
amount of KVAR the generator will produce while in Base Load or
Process control modes
Can be set for generate or absorb levels of KVAR
KVAR levels limited by Rated KVAR of unit
PF Reference
PF level that will be maintained by the generator while in Base
Load or Process control modes.
Can be set for leading or lagging power factor
Scaled from 0 (unity) to - .5 (.5 leading) to +.5 (.5 lagging)
PF Deadband
+/- deadband around PF reference point
set in PF
Active in PF and PF sharing modes
Can be used to stabilise units at low loads if needed
3.7 Process Control
Process Master Uses Process PID to control
Gain, Stability, Derivative, Filter, Droop
Slaves to the Process Master use Load Control PID Values to
track master system load reference
Load Gain, Stability, Derivative, and Filter
Process Gain
Sets system gain response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Stability
Sets system stability response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Derivative
Sets system derivative response while in process control
Effective at active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference
Should be set with maximum number of units operating in
process control mode
Process Deadband
+/- deadband around process reference point
Set in mA
Process Droop
Introduces negative feedback on the process reference as the
process input increases
Used to add stability to marginally stable processes
Process Filter
Low Pass Filter attenuates higher frequency transients on
process 4-20 mA input signal
The higher the filter is set, the more active the process control
will be to higher frequency process transients
The lower the filter is set, the less active, and more stable the
process control will be to higher frequency process transients
Process Reference
The reference point, in mA, at which the master will control the
process input.
Also used in Soft Transfer modes to set the level of process at
which the transfer from mains to generator will occur
Raise Rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a raise load contact input while
operating in process control mode
Lower rate
Rate, in mA/Sec., at which the process reference will change
when the 6000 control receives a lower load contact input while
operating in process control mode
Process High Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process High Limit Alarm
Sets alarm mode when process High Limit is reached
Process Low Limit
Maximum allowable process reference level. Set in mA
Effective on active master unit only
Process Low Limit Alarm
Sets alarm mode when process reference reaches the Low Limit
Process Low Limit Alarm
Sets alarm mode when Process Low Limit is reached
3.8 Calibration
While each unit will be factory calibrated at Woodward prior to
shipment, there are bound to be some inputs/outputs affected by
9
external wiring and/or interfaces (relays, transformers, etc.) that
will require calibration at the site during commissioning.
The Calibration Menu allows calibration of all the analogue inputs
to the 6000 control, as well as the speed bias and voltage bias
outputs.
All calibration points in the 6000 control are used to make the
actual value of an input such as generator voltage, read out on
the respective display screen of the 6000 control, the proper
value of the signal being monitored.
Example:
380VAC measured line to line on the generator should read
380VAC in the line to line voltage measurement area of the 6000
control “generator overview” menu.
Any differences between the measured and actual values can be
corrected using the generator PT calibration points in the
calibration menu.
Process In Scale
Actual Input - 4-20 mA, or 1- 5VDC process signal from external
transducer.
Monitor the Pin (process in) reading in the Load Control Monitor
menu
Calibrate Process input scale until Pin reads accurately what
measured process signal is.
Engine must be in a test or run mode and operating to observe
the Pin value in the Load Control Monitor menu
Speed Bias Offset
Factory calibrated for 0VDC offset on +/- 3 VDC range.
All Woodward Speed controls operate with this bias output, so no
calibration should be required to operate with these controls
Calibration may be required for other manufacturer’s speed
controls.
Voltage Bias Offset
Factory set for zero Volts DC.
Dip Switch selectable +/- 1VDC, +/- 3 VDC, +/- 9 VDC range.
Some regulators require a positive voltage bias offset because
they cannot receive a negative voltage bias command.
6000 control will always reset to the voltage bias offset when off
line.
PT Phase A Scale
Calibrates PT phase A voltage input
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
and adjust PT Phase A scale until these values match measured
generator voltage on A phase
PT Phase B Scale
Calibrates PT phase B voltage input
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
and adjust PT Phase B scale until these values match measured
generator voltage on A phase
PT Phase C Scale
Calibrates PT phase C voltage input
Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N)
and adjust PT Phase C scale until these values match measured
generator voltage on A phase
 Analog inputs to VCOs (Voltage Controlled Osc.)

CT Phase A Scale
Calibrates CT Phase A sensing of 6000 control Freq.
(Hz)
Load generator and monitor gen. currents in phase overview
menu.

Measure actual gen. currents with clamp on ammeter, or panel

ammeter.
Analog Input
Calibrate phase A CT reading in phase overview.

CT Phase B Scale Used for Batt Volts, Water Temp (Ain2) and Oil Pressure (Ain1)
Calibrates CT Phase B sensing of 6000 control Voltage Controlled Oscillators
Load generator and monitor gen. currents in phase overview
menu.
Increasing offset
Measure actual gen. currents with clamp on ammeter, or panel
ammeter. Freq.
Calibrate phase B CT reading in phase overview.
Decreasing offset
CT Phase C Scale
Calibrates CT Phase C sensing of 6000 control
Analog Input
Load generator and monitor gen. currents in phase overview
menu.

Measure actual gen. currents with clamp on ammeter, or panel

ammeter.

Calibrate phase C CT reading in phase overview. Increasing gain

If CT polarity is reversed, that phase will read negative kW when
loaded in the Phase overview menu.

If CTs are on the incorrect phases, then KVAR readings in phase Decreasing gain
overview will be off.

Bus PT Scale
Battery VCO Offset
Similar to Gen PT scaling, but this scale is for single phase bus
PT input to the 6000 control. Sets level, or offset of Battery VCO over operating range

Put 6000 control synchroniser in “check” mode in synchroniser Battery Voltage is a linear increasing type VCO function
setup menu. Ain1 VCO Gain
Start engine in run/load mode to a live bus (either paralleling to Oil Pressure sensor input
another generating set, or the Mains).
0-200 ohm sensor on engine is a direct, mostly linear VCO
Monitor Synchroscope status menu. Observe and calibrate U: function
volts reading until measured matches monitored.
Sets slope of oil pressure input to VCO frequency
Synchroscope Offset
Ain1 VCO Offset
Calibrates phase angle error detection of 6000 control.
Sets level, or offset of oil pressure input to VCO frequency
Factory calibrated for zero phase angle error between bus and A
Ain2 VCO Gain
phase generator inputs
Sets slope of water temp. input to VCO frequency
With synchroniser in “check” mode, and a live bus, monitor the
synchroscope menu of the 6000 control for “phase angle”. Ain2 VCO Offset

Monitor Voltage across open gen contactor/breaker or panel Sets level, or offset of VCO frequency to water temperature slope
synchroscope for phase angle error between generator and bus. Water Temp VCO Sensor without shunt
Adjust synchroscope calibration for lowest voltage across gen
breaker, or 12 o’clock reading on panel mounted synchroscope. Sensor with shunt

Battery VCO Gain

VCO
Sets slope of battery VCO over operating range Freq.

Water Temperature

Shunt Resistor Switches 7 and 8 closed on SW-1 of 6000 control

10
3.9 NetComm Dropouts
The number of lost or corrupted network communications
tolerated by the receiving unit.
Excess numbers of NetComm Dropouts on network due to faulty
wiring, improper shielding, or improper setup will result in the unit
experiencing the dropouts to flash intermittently in the
Sequencing Menu of the 6000 control. Typically set at 5 to 10
dropouts.
Calibrated Unit
When set for true, indicates unit has been factory calibrated.
Requires level 4 security code to change.
3.10 6100 - Single Generating set, Automatic Mains Failure
Functional Description
In this mode of operation an external changeover system must be
used in conjunction with the 6000 Control System to handle all
mains sensing and load transfer functions providing a volt free
start signal.
Normal Switch Positions
OFF / Generating Set off
 If selected while engine is running the generating set will
stop immediately.
NOTE:
• The 6100 control system has no control over the load
transfer, therefore the load should be removed from the
generating set before shutting down.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into
the changeover system. The 6100 control system can be
programmed to perform the cooldown function itself if
required but must be requested prior to build.
 If selected while the engine is stopped will disable engine
starting.
WARNING:
! If maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery.
AUTO / Auto Start Position
 Generating set awaits an external (Volt Free) start signal
indicating a mains failure from the changeover system.
Upon receiving this signal the generating set will start and
assume any load on the local bus.
 The generating set will continue supplying the load until the
start signal is removed.
 Upon removal of this start signal the generating set will stop
immediately.
NOTE:
• All load transfer functions and mains failure detection are
handled by an external changeover system.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into the
changeover system. The 6100 control system can be
programmed to perform the cooldown function itself if required
but must be requested prior to build.
TEST / Generating Set Test Position
 If selected the generating set will start and assume any load
on the local bus.
NOTE:
• The 6100 control panel has no control over the load transfer
and so the generating set can carry out a test without load
11
by using this switch position only if the changeover system
used will not cause a load transfer under these conditions.
 If the mains fails while the generating set is running and a
load transfer is initiated by the changeover system the
generating set will assume the load and run isochronously.
4. RUN / Generating Set Manual Run
 Same as for ‘TEST’ position in this mode since the
generating set has no control over the load transfer.
6200 - Multiple Generating set, No Mains Parallel
4.1 Functional Description
In this mode of operation an external changeover system must be
used in conjunction with the 6000 Control System to handle all
mains sensing and load transfer functions providing a volt free
start signal. In this mode the generators only parallel with other
similarly equipped generating sets (up to a total of 8 sets).
Where there is a group of generating sets each set is given its
own unique identifying number (1-8). There are two main
operational variants within the 6200 operating mode, i.e. Prime
Power and Automatic Mains Failure (AMF). Depending on the
configuration set-up the generating sets may be started manually,
start automatically if a machine in the running group fails, start
automatically according to load demand (load dependant
sequencing) and, in the case of the AMF variant, start
automatically on a failure of the mains supply.
4.2. Prime Power Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running the generating set will
ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on the
local bus the next available generating set in the network
may be sequenced on before the generating set will initiate a
stop sequence.
The 6200 control system has no control over the load transfer
to/from the mains and so this should not be used to initiate
a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into the
changeover system. The 6200 control system can be
programmed to perform the cooldown function itself if
required but must be requested prior to build.
 If selected while the engine is stopped will disable engine
starting.
WARNING
! if maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and no generating sets
are online the generating set will start and assume the load.
 If selected while the engine is stopped with other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
generating set will now assume master status and sequence
the lowest priority generating set offline if the system load is
less than the ‘Min Gen Load’ setpoint. The generating set
will continue running online until a shutdown fault occurs or
the control switch is turned out of ‘AUTO’.
 If selected with at least one generating set of a lower priority
online the generating set will start, synchronise and close to
the local bus, soft load ramp then load share with the other
 generating sets online. The lowest priority generating set
may now sequence offline automatically if the system load is
less than the ‘Min Gen Load’ setpoint on the active master
generating set. The generating set will now revert to normal
load dependant automatic sequencing and will be brought
on and offline by the active master generating set as
required.
 If selected with other generating sets of only higher priorities
online the generating set will go directly into auto
sequencing and will not start unless the system load is
greater than the ‘Max Gen Load’ setpoint on the active
master generating set. If this is the case the generating set
will start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required.
TEST / Generating Set Test Position
 If selected while the engine is stopped the generating set
will start and run off load. The generating set will continue to
run off load until the control switch is turned out of ‘TEST’.
NOTE:
• During this time the generating set will be unavailable for
automatic sequencing and will never close onto the load.
RUN / Generating Set Manual Run
 If selected while the system is dead and no generating sets
are online the generating set will start and assume the load.
 If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
generating set will now assume master status and sequence
the lowest priority generating set offline if the system load is
less than the ‘Min Gen Load’ setpoint. The generating set
will continue running online until a shutdown fault occurs or
the control switch is turned out of ‘RUN’.
 If selected with at least one generating set of a lower priority
online the generating set will start, synchronise and close to
the local bus, soft load ramp and then load share with the
other generating sets online. The lowest priority generating
set may now sequence offline automatically if the system
load is less than the ‘Min Gen Load’ setpoint on the active
master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline. Switching
the control switch to the ‘AUTO’ position will enable the
automatic load dependant sequencing on this generating
set.
 If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
next lowest priority generating set online may be sequenced
offline if the system load is less than the ‘Min Gen Load’
setpoint on the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline. Switching
the control switch to the ‘AUTO’ position will enable the
automatic load dependant sequencing on this generating
set.
Prime Power Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’ position
on the control switch on startup. This will bring all generating
sets on line supplying the load and will allow the 6000 Control
System to initialise all load dependant sequencing correctly. After
12
approximately 2 mins of running all generating sets can be
placed in the ‘AUTO’ position for normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run. As
the load increases then the number of sets increase and vice
versa. The generating sets have a pre-set starting priority as the
load increases. As the load decreases they stop in reverse order.
The starting and stopping order sequence can be changed by the
operator at any time. Another feature in the automatic mode is
that if a generating set stops because of a fault then the next
generating set in the sequence starts up and synchronises
automatically to the load. When the faulty generating set is
repaired it will automatically take its place back in the running
sequence (see section on ‘AUTO’ switch position). The 6200
mode requires that there must be a minimum of one generating
set running.
4.3. AMF Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running the generating set will
ramp off load and stop.
NOTE:
• If all generating sets are not running and there is load on the
local bus the next available generating set in the network
may be sequenced on before the generating set will initiate a
stop sequence.
The 6200 control system has no control over the load
transfer to/from the mains and so this should not be used to
initiate a manual load transfer.
Any ‘Run-On’ or ‘Cooldown’ timers should be integrated into
the changeover system. The 6200 control system can be
programmed to perform the cooldown function itself if
required but must be requested prior to build.
If selected while the engine is stopped will disable engine
starting.
WARNING
! If maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and no generating sets
are online the generating set awaits an external (Volt Free)
start signal indicating a mains failure from the changeover
system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will continue to run online for at least 5
minutes then revert to normal load dependant automatic
sequencing.
 If selected while the engine is stopped with other generating
sets of only lower priorities online the generating set awaits
an external (Volt Free) start signal indicating a mains failure
from the changeover system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will now assume master status and sequence
the lowest priority generating set offline if the system load is
less than the ‘Min Gen Load’ setpoint. The generating set
will continue running online until a shutdown fault occurs or
the control switch is turned out of ‘AUTO’.
 If selected with at least one generating set of a lower priority
online the generating set awaits an external (Volt Free) start
signal indicating a mains failure from the changeover
system.
Upon receiving this signal the generating set will start,
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The lowest
 priority generating set may now sequence offline
automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required.
 If selected with other generating sets of only higher priorities
online the generating set awaits an external (Volt Free) start
signal indicating a mains failure from the changeover
system.
Upon receiving this signal the generating set will go directly
into auto sequencing and will not start unless the system
load is greater than the ‘Max Gen Load’ setpoint on the
active master generating set. If this is the case the
generating set will start, synchronise and close to the local
bus, soft load ramp then load share with the other
generating sets online. The generating set will now revert to
normal load dependant automatic sequencing and will be
brought on and offline by the active master generating set as
required.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the external start
signal is not active the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the generating
set receives the external start signal.
Upon receiving this signal the generating set will
synchronise and close to the local bus, soft load ramp then
load share with the other generating sets online. The
generating set will continue to run online for at least 5
minutes then revert to normal load dependant automatic
sequencing.
 If selected while the engine is stopped with other generating
sets of only lower priorities online and the external start
signal active the generating set will start, synchronise and
close to the local bus, soft load ramp then load share with
the other generating sets online. The generating set will
now assume master status and sequence the lowest priority
generating set offline if the system load is less than the ‘Min
Gen Load’ setpoint. The engine will continue to run until the
control switch is turned out of ‘TEST’ and will remain online
until the external start signal is deactivated.
 If selected with at least one generating set of a lower priority
online and the external start signal active the generating set
will start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The lowest priority generating set may now sequence offline
automatically if the system load is less than the ‘Min Gen
Load’ setpoint on the active master generating set. The
generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required. The engine will
continue to run until the control switch is turned out of
‘TEST’ and will be sequenced on and offline by the active
master generating set as required.
 If selected with other generating sets of only higher priorities
online, the engine is stopped, with the external start signal
active and the system load less than the ‘Min Gen Load’
setpoint the generating set will start and run off load. The
generating set will continue to run off load until the control
switch is turned out of ‘TEST’ or the system load becomes
greater than the ‘Max Gen Load’ setpoint on the active
master generating set. If this is the case the generating set
will start, synchronise and close to the local bus, soft load
ramp then load share with the other generating sets online.
The generating set will now revert to normal load dependant
automatic sequencing and will be brought on and offline by
the active master generating set as required. The engine will
continue to run until the control switch is turned out of
‘TEST’ and will be sequenced on and offline by the active
master generating set as required.
 If selected with other generating sets of only higher priorities
online, the engine is stopped, the external start signal active
and the system load greater than the ‘Max Gen Load’
setpoint the generating set will start, synchronise and close
to the local bus, soft load ramp then load share with the
13
other generating sets online. The generating set will now
revert to normal load dependant automatic sequencing and
will be brought on and offline by the active master generating
set as required. The engine will continue to run until the
control switch is turned out of ‘TEST’ and will be sequenced
on and offline by the active master generating set as
required.
NOTE:
• If it is required to disable the generating set from going
online the local alternator output circuit breaker should be
placed in the open position.
RUN / Generating Set Manual Run
 If selected while the system is dead and no generating sets
are online the generating set will start and assume any load
on the local bus.
 If selected with the engine stopped and other generating
sets of only lower priorities online the generating set will
start, synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
generating set will now assume master status and sequence
the lowest priority generating set offline if the system load is
less than the ‘Min Gen Load’ setpoint. The generating set
will continue running online until a shutdown fault occurs or
the control switch is turned out of ‘RUN’.
 If selected with at least one generating set of a lower priority
online the generating set will start, synchronise and close to
the local bus, soft load ramp and then load share with the
other generating sets online. The lowest priority generating
set may now sequence offline automatically if the system
load is less than the ‘Min Gen Load’ setpoint on the active
master generating set.
 If selected with the engine stopped and other generating
sets of only higher priorities online the generating set will
start, synchronise and close to the local bus, soft load ramp
then load share with the other generating sets online. The
next lowest priority generating set online may be sequenced
offline if the system load is less than the ‘Min Gen Load’
setpoint on the active master generating set.
NOTE:
• Leaving the control switch in the ‘RUN’ position will prevent
this generating set from being sequenced offline. Switching
the control switch to the ‘AUTO’ position will enable the
automatic load dependant sequencing on this generating
set.
AMF Variant - Additional Information
In a Prime Power system with load dependant sequencing
enabled all generating sets must be turned to the ‘RUN’ position
on the control switch on startup. This will bring all generating
sets on line supplying the load and will allow the 6000 Control
System to initialise all load dependant sequencing correctly. After
approximately 2 mins of running all generating sets can be
placed in the ‘AUTO’ position for normal running.
While the generating sets are in load dependant sequencing
mode where the load dictates how many generating sets run. As
the load increases then the number of sets increase and vice
versa. The generating sets have a pre-set starting priority as the
load increases. As the load decreases they stop in reverse order.
The starting and stopping order sequence can be changed by the
operator at any time. Another feature in the automatic mode is
that if a generating set stops because of a fault then the next
generating set in the sequence starts up and synchronises
automatically to the load. When the faulty generating set is
repaired it will automatically take its place back in the running
sequence (see section on ‘AUTO’ switch position). The 6200
mode requires that there must be a minimum of one generating
set running.
5. 6300 - Automatic Synchronising of One Generating Set with
Mains
5.1 Functional Description
In addition to the automatic mains failure function (with soft load
retransfer), this variant can operate in base load mode, peak
lopping mode or soft load transfer mode. The operating mode is
pre-programmed at the factory and must be specified when
ordering.
In all variants the 6300 Control System must have full control of
both the generator and mains breakers with state feedback
provided for each by means of an auxiliary contact.
5.2. Base Load Operation
In this mode the generating set may be manually started. It will
automatically synchronise to the mains grid and take up load to a
pre-set value (usually the full output of the generating set). If
there is insufficient local load for the generating set then it will
export its excess power to the mains.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in the
event of a mains failure. The generating set will perform a soft
load retransfer (closed retransfer) of the load back to the mains
supply on return of the mains.
5.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
supplying the site load until the mains returns or a shutdown
fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control is
disabled. If the mains fails during this time and the mains
breaker subsequently opens the control system will not
attempt to close the breaker until the control switch is turned
to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is to
be taken out of service for prolonged periods of time that the
maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close the
mains breaker on a short term mains failure.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains is
supplying the load, the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
14
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving the
control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a preset ‘Baseload’ level against the mains supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
5.4. Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set so that a minimum load is kept on the mains and
the rest is supplied by the generating set. This continues until
the generating set is at its maximum load then any further loading
is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the mains
until the control switch is returned to the OFF position or to the
AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in the
event of a mains failure. The generating set will perform a soft
load retransfer (closed retransfer) of the load back to the mains
supply on return of the mains.
5.5. Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
  If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
NOTE:
functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
supplying the site load until the mains returns or a shutdown
fault occurs.
 When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control is
disabled. If the mains fails during this time and the mains
breaker subsequently opens the control system will not
attempt to close the breaker until the control switch is turned
to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is to be
taken out of service for prolonged periods of time that the
maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close
the mains breaker on a short term mains failure.
WARNING:
! If maintenance is to be carried out on the generating set
then the battery negative should be disconnected at the
battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving the
control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
15
the mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating Set Manual Run
If selected while the engine is stopped with the mains supplying
the load the generating set will start, synchronise with the mains,
close the generator breaker and soft load ramp to a pre-set
import power level from the mains supply. The generating set
will maintain this import power level as the site load varies.
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
5.6. Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock and run in parallel with the mains
supply. After synchronising with the mains an external watt
transducer on the mains provides a signal of the load on the
mains. The 6300 uses this signal to adjust the load on the
generating set to the point where zero load is being supplied by
the mains then opens the mains breaker so assuming the full site
load. On removal of the time clock start signal the generating set
will resynch with the mains supply and perform a soft load
retransfer (closed retransfer) of the site load back to the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or to
the AUTO position with the time clock start signal off.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in the
event of a mains failure. The generating set will perform a soft
load retransfer (closed retransfer) of the load back to the mains
supply on return of the mains.
5.7. Soft Transfer Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
supplying the site load until the mains returns or a shutdown
fault occurs.
 When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable disable
engine starting.
NOTE:
• While in the ‘OFF’ position all active mains breaker control is
disabled. If the mains fails during this time and the mains
breaker subsequently opens the control system will not
attempt to close the breaker until the control switch is turned
to the ‘AUTO’ position.
It is therefore strongly advised that if the generating set is to
be taken out of service for prolonged periods of time that
the maintenance switch inside the control panel should be
switched to the ‘Maintenance’ position. This will re-close
the mains breaker on a short term mains failure.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the system is dead and the mains
supplying the load the generating set is operating in AMF
mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an exercise timer is fitted to the generating set leaving the
control system in the ‘AUTO’ position will enable the
generating set paralleling via the timer.
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to the point where there is no load being imported from
the mains at which point the control system will open the
mains breaker and assume the full site load.
16
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6. Automatic Synchronising of Multiple Generating sets with
Mains
6.1. Functional Description
In addition to the automatic mains failure function (with soft load
retransfer), this variant can operate in base load mode, peak
lopping mode or soft load transfer mode. The operating mode is
pre-programmed at the factory and must be specified when
ordering.
This section describes the functionality of the ‘standard’ system
which consists of up to 4 generating sets paralleling with each
other onto a local generator bus and with a single mains supply.
This system is fitted with a mains breaker, feeder breaker and a
separate generator breaker for each generating set. For a
detailed outline of the system wiring consult the relevant drawings
and / or a member of the Electrical Drawing Office. The
Electrical Drawing Office should also be consulted if the
requirements of the proposed installation dictate changes in the
basic configuration of the system as this may require significant
modification to the control system philosophy.
6.2. Base Load Operation
In this mode the generating sets may be manually started either
by an external start signal starting all generating sets which are in
‘AUTO’ or individually by selecting ‘RUN’ on the control switch.
Any generating sets told to run in baseload will automatically
synchronise to the mains grid and take up load to a pre-set value
(usually the full output of the generating set). If there is
insufficient local load for the generating sets then surplus power
over and above the site load will be exported to the mains.
With the generating sets in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in the
event of a mains failure. In his case the system will open the
feeder breaker and attempt to start all generating sets
simultaneously. After all available generating sets have come on-
line and have closed to the local bus the feeder breaker will close.
The number of generating sets required to be on-line before the
feeder breaker will close can be customised for each individual
application. The generating set will perform a soft load retransfer
(closed retransfer) of the load back to the mains supply on return
of the mains.
6.3. Base Load Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in Baseload the generating set will ramp off load,
disconnect from the local bus, cooldown (if required) and
stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF and
externally triggered starting functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
 supplying the site load until the mains returns or a shutdown
fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable engine
starting.
WARNING:
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.3.4).
TEST / Generating Set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’, the mains supply
goes outside specification or the external start signal is
received.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs. When the mains returns
the generating set will wait for the duration of the mains
stable delay timer then synchronise to the mains, close the
mains breaker, soft unload ramp, open the generator
breaker and continue running offline.
 If an external start signal is received the generating set will
parallel to the mains supply and go into RUN mode (see
section 6.3.)
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating Set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a pre-set ‘Baseload’ level against the mains supply.
NOTE:
• If the site load is less than this Baseload level then the
excess power will be exported to the mains utility.
17
 If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6.4 Peak Shaving Operation
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a pre-set time clock or externally applied run signal and run
in parallel with the mains supply. After synchronising with the
mains an external watt transducer provides a signal which is
representative of the loading applied to the mains supply. The
6400 uses this signal to adjust the load on the generating set so
that a minimum load is kept on the mains. This continues until
the generating set is at its maximum load after which any further
loading is put on the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will run in parallel with the mains
until the control switch is returned to the OFF position or to the
AUTO position with the external start signal removed.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load in the
event of a mains failure. The generating set will perform a soft
load retransfer (closed retransfer) of the load back to the mains
supply on return of the mains.
6.5 Peak Shaving Variant - Normal Switch Positions
OFF / Generating Set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set from the local bus, cooldown
(if required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
supplying the site load until the mains returns or a shutdown
fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable engine
starting.
WARNING:
! if maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains is supplying the load, the generating set will enter
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
 the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.5.).
TEST / Generating set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
NOTE:
• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to a preset import / export power level from the mains
supply. The generating set will maintain this import / export
power level as the site load varies.
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6400 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
6.6 Soft Transfer Variant - Normal operation:
With the control switch in the AUTO position and the Process
switch in the ON position generating set will start on a signal
from a preset time clock or externally applied start signal and run
in parallel with the mains supply. After synchronising with the
mains an external watt transducer on the mains provides a signal
of the load on the mains. The 6400 uses this signal to adjust the
load on the generating set to the point where zero load is being
supplied by the mains then opens the mains breaker so
assuming the full site load. On removal of the time clock start
signal the generating set will resynch with the mains supply and
perform a soft load retransfer (closed retransfer) of the site load
back to the mains.
Turning the control switch to the RUN position at any time will
manually start the generating set and carry out the above
operation. The generating set will continue supplying the site
load until the control switch is returned to the OFF position or to
the AUTO position with the external start signal removed.
NOTE:
• If only one generating set is turned into the RUN position the
site load may exceed the maximum generating set load in
18
which case the generating set will never reach the zero load
transfer point and will not disconnect the mains supply.
With the generating set in the AUTO position the system will
operate in AMF Mode and will start and supply the site load
in the event of a mains failure. The generating set will
perform a soft load retransfer (closed retransfer) of the load
back to the mains supply on return of the mains.
6.7 Soft Transfer Variant - Normal Switch Positions
OFF / Generating set Off
 If selected while the engine is running and the generating
set is in main parallel the generating set will ramp off load,
disconnect the generating set from the local bus, cooldown
(if required) and stop.
NOTE:
• While the generating set is in the ‘OFF’ position all AMF
functions are disabled.
 If selected while the generating set is supplying the site load
and the mains is dead the generating set will continue
supplying the site load until the mains returns or a shutdown
fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If selected while the generating set is supplying the site load
and the mains has returned after a mains failure but the
mains stable delay timer has not timed out the generating
set will synchronise to the mains, close the mains breaker,
soft unload ramp, open the generator breaker, cooldown and
stop.
 If selected while the engine is stopped will disable disable
engine starting.
WARNING
! If maintenance is to be carried out on the generating
set then the battery negative should be disconnected
at the battery itself.
AUTO / Auto Start Position
 If selected while the generating sets are stopped and the
mains supplying the load the generating set will enter in
AMF mode and will not start.
 If the mains supply goes outside spec the generating set
will start, open the mains breaker and assume the site load.
The generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker, cooldown and stop.
 If an external start signal is applied via the PLC panel the
generating set will start and enter RUN mode (see section
6.7.).
TEST / Generating set Test Position
 If selected while the engine is stopped and the mains
supplying the load the generating set will start and run off
load. The generating set will continue to run off load until
the control switch is turned out of ‘TEST’ or the mains
supply goes outside specification.
 If the mains supply goes outside spec the generating set
will open the mains breaker and assume the site load. The
generating set will continue to run online until the mains
returns or a shutdown fault occurs.
When the mains returns the generating set will wait for the
duration of the mains stable delay timer then synchronise to
the mains, close the mains breaker, soft unload ramp, open
the generator breaker and continue running offline.
NOTE:

• If it is required to disable the generating set from going
online in the event of a mains failure the local alternator
output circuit breaker should be placed in the open position.
RUN / Generating set Manual Run
 If selected while the engine is stopped with the mains
supplying the load the generating set will start, synchronise
with the mains, close the generator breaker and soft load
ramp to the point where there is no load being imported from
the mains at which point the control system will open the
mains breaker and assume the full site load.
NOTE:
• It may be necessary to fit external protection to prevent the
generating set from exporting power to the mains utility.
Consult the local mains provider for exact requirements.
 If the mains fails while the generating set is running in
parallel with the mains utility the 6300 control system will
disconnect the mains supply and assume the full site load.
NOTE:
• It may be necessary to use an external means of mains
failure detection. Consult the local mains provider for exact
requirements.
7. Alarm / Event Indication and Logging
Fault conditions on the 6000 Series Control Panel are set as
warnings, alarms, soft shutdowns and hard shutdowns.
Warnings flash the ALARM light only, alarms energise the
audible alarm and flash the ALARM lamp, soft shutdowns unload
the generator, open the breaker and perform a cooldown cycle if
required. Hard shutdowns immediately open the breaker and shut
the generating set down. All alarms are logged with a timestamp
in the ALARM / EVENT LOG. These settings are intrinsic to the
setup parameters in the software and can only be changed with
suitable security clearance. When a hard shutdown fault is
sensed, the alarm lamp illuminates, the audible alarm is
energised and the generating set is automatically shut down
immediately. The audible alarm will remain energised until the
ALARM RESET pushbutton is pressed. The engine remains
locked out until the fault has been acknowledged. The alarm
lamp will flash until the enter ( ) pushbutton is pressed while in
the ALARM / EVENT LOG. This will acknowledge the alarm and
allow the generator to start but will not clear it from the log. The
alarm may be cleared from the log by pressing the ALARM
RESET pushbutton while in the ALARM/EVENT LOG subject to
technician level or higher security clearance. The possible fault
conditions available for sensing are dependant on the particular
operating mode of the generating set. See earlier section for a
list of all available alarms/shutdowns.
8. Remote Control and Monitoring Via a PC:
8.1 System Outline
The PC-Tools package is available in two main forms, which are
subdivided into 5 variants in total. A brief description of each is
given below:
 PC options:
PC1: This option offers monitoring of the 6000 series
system only via a direct hardwired connection to the control
system.
PC2: This option offers monitoring and control of the 6000
series system via a direct hardwired connection to the
control system.
 TEL options:
TEL1: This option offers monitoring of the 6000 series
system only via a standard telephone line.
TEL2: This option offers monitoring and control of the 6000
series system via a standard telephone line.
19
TEL3: This option offers monitoring and control of the 6000
series system via a standard telephone line with fault alert
callback.
The PC1 and PC2 options use a separate control box per control
system to interface between the RS-232 serial communications
port of the monitoring PC and the RS-422 communications
network used by the 6000 series control panels. The GP 6000
software in conjunction with the Servlink software then utilises
the information transmitted by this communication path to allow
users to monitor or control various aspects of the 6000 series
control panel from the computer.
The TEL1, TEL2 and TEL3 options also use a separate but
different control box per system to interface between the RS-422
network used by the 6000 series control panels and the
telephone line.
Each 6000 series control system should have its own dedicated
communications path, e.g. one hard wired connection with one
PC1 interface panel per 6100 or 6300 panel with PC1option, and
one telephone line with one PC1 interface panel per 6200 or
6400 system with PC1 option.
Each control box requires a mains supply but does contain
battery backup to enable uninterrupted remote communications
even in the event of a mains and/or generator system failure.
The control box used with the TEL3 option differs from that used
with the TEL1 and TEL2 options in that it also incorporates the
fault callback unit. This control box will require two dedicated
telephone lines, one for data transfer and one for the recorded
message callback facility.
8.2 Functional Description
The GP 6000 software duplicates the front panel of the 6000
series hardware platform. All the monitoring information which
can be obtained from the hardware can also be accessed by the
GP 6000 software in a format which is identical to that of the
hardware. This makes the software
very familiar to those accustomed to the 6000 controller keypad
functions and LCD readout displays.
There are two main information display sections within the GP
6000 software. These are the ‘Master Situation Monitor’ and the
‘Front Panel Display’. The ‘Master Situation Monitor’ displays the
essential information from up to eight of the individual control
panels in the system. The parameters displayed are:
 Network Address
 Network Priority
 Present kW loading of the generating set
 Alarm Status (ALARM or OK)
An example of a typical 3 generating set 6200 system display is
shown below:
In this example the Master Situation Monitor is showing an alarm
condition on generating set number 3. Highlighting generating set
number 3, and then clicking on the front panel display icon in the
lower right corner of the Master Situation Monitor brings up the
front panel display for generating set number 3:
The operator can now carry out any of the functions accessible
by using the membrane keypad on the hardware control itself.
This is done by simply clicking on the appropriate button on the
front panel display, which will cause the 6000 series control to
react in exactly the same manner as if the button was pressed
locally.
In addition to the Monitoring version of the GP6000 software
there is also a version which gives the remote operator the
capability to simulate the operation of the control switch, panel
mounted emergency stop button, and the speed/volts raise/lower
buttons. This version is used with the PC2, TEL2 and TEL3
options. An example of the front panel display for this version is
shown below:
As it can be seen, this version is identical to the monitoring only
version with the exception of the added control buttons on the
right side of the display.
These control buttons not only allow the remote operator to
perform all the basic control functions but also indicate the
current state of these control inputs, i.e. if the panel mounted
emergency stop is locked on or has been released etc.
The control system works by acknowledging a change of state of
any of these switch inputs, whether triggered locally or remotely,
as the last valid control input. This means that there is no
overriding priority put on either the local or remote inputs, and so
it is quite conceivable that the local control switch could be in the
AUTO position but due to the remote operator pressing the RUN
20
button, the generating set will be operating in the RUN mode. It
should be noted however that the status as indicated on
the remote display will always match the current operating
mode of the controller.
The Emergency Stop control operates in a slightly different
manner however due to safety constraints. In this case the local
panel mounted emergency stop always has priority while
pressed. This prevents the remote operator from starting the
generating set if the local emergency stop button is still locked on
due to the occurrence of a dangerous or potentially dangerous
situation. Once the local emergency stop button has been
released the alarm can be reset and the generating set started
either locally or remotely.
It should also be noted that in the case of a 6100, or 6200 system
that as all mains failure and load transfer functions are performed
by an external changeover system the PC2, TEL2 and TEL3.
Options cannot be used to initiate a manual load transfer/ re-
transfer of the load to/from the mains supply.
8.3 Hardware Specifications
Communications:
RS-422 protocol
9600 Baud (fixed maximum)
No Parity
1 Stop Bit
Computer Requirements:
Minimum:
PC compatible running Windows 95 or Windows NT 4.0 and
above, 3 MB hard drive space.
Recommended:
100 MHz Pentium PC, 16 MB RAM, 3 MB hard drive space,
running Windows 95 or Windows NT 4.0 and above.
Modem Requirements (for TEL1, TEL2 and TEL3 options
only):
Remote PC end:
9600 Baud Capability (minimum)
8 Data Bits
No Parity
1 Stop Bit
Recommended:
Multitech MT1932ZDX-K, MT2834ZDX-K, MT2834ZPX-Internal
US-Robotics Sportster 14.4 Vi Fax/Modem, Sportster 14.4
Fax/Modem, Sportster Voice 33.6 Fax/Modem, Courier Dual Std,
Courier HST.
Miracom Courier HST
Megahertz CC3144/CC4144 PCMCIA
Xircom PS-CEM28 range
NEC (AT&T) 14.4 Kbps Data/Fax Modem
Tornado FM144E
PC1 and PC2 communications path.
Standard RS-422 protocol communications.
Recommended cable: 6-core (3 x twisted pair), overall screened,
min core diameter of 0.5mm2.
Maximum length: 1km (special attention must be paid to cable
routing to minimise interference).
Connection Method: daisy chain (parallel looped) with PC
interface box at one end of the line - screen earthed at one place
only but interconnected.
TEL1, TEL2, and TEL3 communications path.
Hardwired RS-422 connection as in PC1, PC2 option.
 Each TEL1 and TEL2 option requires one dedicated, analogue
telephone line.
Each TEL3 option requires two dedicated, analogue telephone
lines.
NOTE:
• Connection of the TEL1, TEL2 and TEL3 option interface
boxes to a digital telephone line, such as used on some PBX
switchboard systems, may result in permanent damage to
the interface system.
8.4 Equipment Supplied With Each Option:
PC1 Option
1 x PC interface box.
1 x 9-pin serial cable.
1 x GP6000 Monitoring Software package.
PC2 Option
1 x PC Interface box.
1 x 9-pin serial cable.
1 x GP6000 Monitoring and Control Software package.
TEL1 Option
1 x TEL1 interface box.
1 x GP6000 Monitoring Software package.
1 x Telephone cable (cable connectors fitted will depend on
country).
TEL2 Option
1 x TEL2 interface box.
1 x GP6000 Monitoring and Control Software package.
1 x Telephone cable (cable connectors fitted will depend on
country).
TEL3 Option
1 x TEL3 interface box with integral fault alert callback.
1 x GP6000 Monitoring and Control Software package.
2 x Telephone cables (cable connectors fitted will depend on
country).
9. Initial Startup and Commissioning
9.1 Test Procedure for Single Generating set Systems.
Pre-Startup Instructions
 Check all electrical connections.
 Check engine oil and coolant level.
 Ensure that the control switch is in the OFF position.
 Power up the 6000 series control panel.
 The unit will carry out a RAM check after which it will
display the application code version installed in the unit.
Verify that this is the latest version. If not, download the
latest version. The unit should now display the ‘Control
Overview’ screen.
 Enter security code.
 Check all program setpoints.
 Set synchroniser to ‘Run’.
 Set ‘Load Control Mode’ to ‘Droop’.
 For multiple unit systems set ‘Number of Units’ to ‘Single’.
Ensure that the generating set is connected to a isolated bus or
load bank.
Start engine using the ‘RUN’ position on the control switch.
Check operation of Emergency stop button.
Re-start generating set by clearing Emergency stop fault while
control switch still in ‘RUN’.
21
Check the RPM reading on the ‘Engine Overview’ screen.
Set up electronic governor (if fitted).
Ensure that generator breaker closes.
Ensure that generating set is running in ‘Droop’ mode by looking
at the ‘Synchroscope’ screen.
Check that the Volts and Speed Bias outputs on the ‘I/O Status’
screen are both zero.
Check the generator output voltage on the load bank.
Calibrate the Line-Neutral voltages as seen on the ‘Gen Phases’
screen.
Adjust output voltage at AVR to specified voltage.
Verify operation of the Volts raise/lower switches (if applicable).
 Verify that ‘Volts Bias’ reading in ‘I/O Status’ screen
changes when raise/lower switches are pressed.
 Set ‘Voltage Ramp Time’ if necessary.
Verify operation of the Speed raise/lower switches (if applicable).
 Verify that ‘Speed Bias’ reading in ‘I/O Status’ screen
changes when raise/lower switches are pressed.
 Set ‘Load Raise Rate’ and ‘Load Lower Rate’ if necessary.
If the 6000 series control panel is controlling the generating
set volts:
 Set AVR ‘Droop’ potentiometer to halfway.
 Set AVR ‘Trim’ pot to give +/- 10% output voltage swing for
+/- 100% voltage bias output (by using the Volts raise/lower
switches).
If Mains PT connected:
 Check mains voltage readout (U:) in ‘Synchroscope’ screen.
Calibrate if necessary.
Apply a small load to the generating set.
Check CT polarity by observing current readouts in the ‘Gen
Phases’ screen.
Load generating set to full load.
Check current readouts on ‘Gen Phases’ screen.
Calibrate current readouts if necessary.
Remove load.
Turn control switch to ‘OFF’.
Verify that generating set shuts down correctly.
Set ‘Load Control Mode’ to ‘Normal’.
Start generating set by turning the control switch to ‘RUN’.
Check operation of all shutdowns and alarms.
Load up generating set to full load and complete full load test.
Remove load and shut down generating set.
Test Procedure for Multiple Generating set Systems.
Test each individual unit in single generating set mode as
outlined above.
Connect all generating sets to common local bus.
Set up RS-485 communication lines.
 Connect proper RS-485 twisted pair, overall screened cable
of characteristic impedance of 120 ohms between all
generating sets in system.
 If RS-485, 120 ohm cable is not available standard twisted
pair, overall screened cable should suffice.
 Connect screen to panel earth at one end only ensuring that
the screen connection is carried right through to the
opposite end of the system.
 Ensure proper RS-485 termination by setting DIP switches  Ensure that first unit is running and closed onto the bus.
4, 7, and 8 on switch bank SW-3 (located beside J-8) are in
the ‘ON’ position on both units at the end of the  Apply a load of approx. 1/2 full load capacity of first
communication path. generating set.

 Ensure DIP switches 4-8 on switch bank SW-3 are in the  Turn the control switch on the next generating set to ‘RUN’.
‘OFF’ position on all other units.
 Confirm phase/voltage matching and synchroniser
Ensure all control switches is in the ‘OFF’ position. operation.

Power up all 6000 series panels.  Verify generating set breaker closure.
Enter security code. Check ‘Load Control’:
Set up all controllers as follows:  Verify load ramping operation.
 Set synchroniser to ‘Check’ on all but first machine.  Verify that ramp rate is reasonable.
 Set synchroniser to ‘Run’ on fist machine only.  Reduce ‘Load Control Gain’ setting if unstable during
ramping.
 Set ‘Number of units’ setpoint to ‘Multiple’.
 Verify that operating mode changes to ‘ISOCH’ when
 Set ‘Load Control Mode’ to ‘Normal’. ramping complete.
 Disable any Loss of Mains detection.  Increase bus load to approximately 1/2 full load capacity of
all generating sets currently on-line.
 Set up network addresses and priorities ensuring that
network addresses are all unique.  Verify real load sharing operation.
 Disable closure of all generating set breakers, except first  Reduce ‘Load Share Gain’ if unstable during load sharing.
unit, by disconnecting the close signal from the control
panel.  Verify Var/PF sharing (if applicable).
Turn all control switches to Auto and verify network  Reduce ‘VAR/PF Gain’ if unstable during Var/PF sharing.
communications:
Repeat Synchroniser and Load Control operational checks for all
 All generating sets in ‘AUTO’ should be shown in the remaining generating sets.
‘Control Overview’ screen after the ‘UNIT:’ prompt.
Once all sets are on line and correctly set up, increase load on
 If any controllers are missing from the display, check that bus to full system load capacity.
there is no duplication of network priorities, check all RS-
485 cable connections and that the end of line termination Run on full load for 5-10 mins to verify long term stability.
resistors are set correctly (see above). Take units off line one at a time ensuring that bus load does not
exceed full load capacity of remaining units.
 If all of the above are correct, but any controllers are still
missing from the display, increase the ‘NetComm Dropouts’  Verify unload ramping.
setpoint to 10.
 Verify unload trip.
 If communications still not correct, replace faulty controller
and repeat all previous setup procedures.  Verify cooldown operation.
Turn all control switches back to ‘OFF’. Carry any further application specific operational tests required.
Turn control switch on first unit to ‘RUN’.
Verify that first unit starts and closes onto the bus.
Calibrate Synchroniser on all remaining units.
 Turn control switch on next unit to ‘RUN’.
 Change to the ‘Synchroscope’ screen.
 Verify that the ‘Mains/Bus’ sensing changes to ‘BUS’.
 Verify that the ‘Dead Bus’ display changes to ‘NO’.
 Verify the Bus Volts readout, ‘U:’ on screen, is correct and
calibrate if necessary.
 Verify synching by measuring volts across generating set
breaker.
 When satisfied that synchroniser is correct, shut down
generating set and repeat steps 1-7 for next unit.
Check synchroniser operation on next unit:

22
10. Troubleshooting

10.1 Control Hardware and I/O

Problem Probable Cause Corrective Action

Unit does not power up No input power supply Check +12 Vdc or +24 Vdc power supply
Input power supply reversed Ensure proper polarity of power supply to
GCP-1
Discrete inputs don’t show active in I/O STATUS screen Faulty wiring of discrete input switches Verify wiring of discrete input switches
when switches are activated
Displayed generator voltages are very small Faulty wiring of generator Potential Verify wiring of generator Potential
Transformers(PT’s) Transformers(PT’s)
Generator PT inputs are improperly Calibrate the appropriate PT input
calibrated channel(s). See section 1.10 Calibration of
Control Inputs and Outputs
I/O STATUS shows relay(s) is energized, but action(i.e. Faulty wiring of relay output contacts Verify wiring of relay output contacts
alarm) does not occur
Generator voltage fluctuates or is unstable at no load on AVR dynamics are improperly set up Tune the AVR dynamics for stable
generator operation. See AVR manufacturer’s
instruction manual for more details

23
 Voltages or currents displayed by GCP-1 are different GCP-1 PT inputs are inaccurately Calibrate the appropriate PT input
than measured parameter calibrated channel(s). See section 1.10 Calibration of
Control Inputs and Outputs

10.2 Engine Control / Sensing Parameters

Problem Probable Cause Corrective Action

Start command(i.e. test or run with load) does not start
engine
Starter motor stays engaged after engine starts
Engine starts, but starter re-engages while engine is
running
Engine speed is unstable when unit is at no load
When crank command is issued, GCP-1 loses power
and conducts a reset and RAM test
Configuration menu has not been accepted
or entered properly
An active alarm condition exists
Relay output contacts are not properly
connected to engine starter, fuel solenoid
Crank cutout set point in Engine control
menu is to large
Inadequate MPU signal to GCP-1 input
Inadequate MPU signal to GCP-1 input
Speed control dynamics are improperly set
up
Battery is too weak for the current demand
of the starter motor
Faulty wiring of power supply to the GCP-1
control
Enter the configuration set points in the
Configuration menu such that all “*” and “#”
symbols are removed from the lower two
lines of the display. See section 1.3.4
Description of set points for more details.
Commit or reset alarm condition(s). See
section 1.3.2 Description of Screens
Verify wiring of relay output contacts
Set CRANK CUTOUT set point to
appropriate value. See section 1.3.4
Description of set points
Verify MPU wiring, and that adequate MPU
signal exists at input to GCP-1 control
Verify MPU wiring, and that adequate MPU
signal exists at input to GCP-1 control
Tune the speed control dynamics for stable
operation. See speed control
manufacturer’s instruction manual for more
details
Install a higher capacity battery or a more
efficient starter motor
Verify wiring of power supply to the GCP-1
control

10.3 Synchronisation
Problem Probable Cause Corrective Action

Unit never adequately matches phase
Synchronizer displays small phase difference, but
measured phase difference is large
Synchronizer matches phase, but never
breaker/contactor
Synchronizer displays matched phase, but measured
phase difference is ~180 degrees, or when breaker
Synchronizer Mode set point in
synchroscope menu set to PERMISSIVE
Synchronizer dynamics in synchroscope
menu are improperly set up
Generator A phase PT input is L-L and bus
A phase PT input is L-N or vice versa
Bus and/or generator PT inputs are not A
phase
Synchronizer improperly calibrated
closes Synchronizer Mode set point
synchroscope menu is set to CHECK
Dwell time set point in synchroscope menu
is too large
Generator or bus PT is reversed polarity
(faulty wiring)
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Tune synchronizer dynamics. See section
1.3.4 Description of Set points
Verify that Generator A phase PT input bus
A phase PT input are the same form (i.e. L-
N or L-L)
Verify that Bus and generator PT inputs are
A phase
Calibrate synchronizer. See section 1.10
Calibration of Control Inputs and Outputs
in Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points
Reduce Dwell Time set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify correct polarity of Generator and bus
PT inputs

24
 closes it crash parallels the set 180 degrees out of
phase
Unit won’t close to dead bus Multiple unit system with DEADBUS
CLOSING set point in configuration menu
set to DISABLED
Synchronizer set point is set to CHECK
ENABLE DEADBUS CLOSING set point in
configuration menu. See section 1.3.4
Description of Set points
Set synchronizer Mode to appropriate
setting. See section 1.3.4 Description of
Set points

Synchronizer won’t voltage match
Synchronizer does not voltage match within spec.
VOLTAGE MATCHING set point
synchroscope menu is DISABLED
Generator A phase PT and/or Bus A phase
PT input(s) are inadequately calibrated
Voltage matching tolerance set point in
synchroscope menu is too large
in ENABLE the VOLTAGE MATCHING set
point in synchroscope menu. See section
1.3.4 Description of Set points
Calibrate the Generator A phase PT and
Bus A phase PT inputs. See section 1.10
Calibration of Control Inputs and Outputs
Appropriately set the Voltage matching
tolerance set point in synchroscope menu.
See section 1.3.4 Description of Set points

10.4 Breaker Close / Open Control

Problem Probable Cause Corrective Action

When generator set is in synchronization, the Synchronizer set to CHECK Set synchronizer Mode to appropriate setting.
breaker never closes See section 1.3.4 Description of Set points

Faulty wiring causing the relay output to not make
connection to the breaker
Dwell time set point in the synchroscope menu is
too long
Contactor closes for a brief moment and then opens C B CONTROL set point in configuration menu is
set for BREAKER
C B HOLD TIME set point in synchroscope menu
is too short
Faulty wiring on C.B. aux contacts
Breaker close relay stays energized when a close C B CONTROL set point is set for CONTACTOR
command is given and never issues an open
command
Verify wiring of the relay output contacts.
Reduce Dwell time set point in the
synchroscope menu. See section 1.3.4
Description of Set points
Appropriately set the C B CONTROL set point
in configuration menu. See section 1.3.4
Description of Set points
Increase C B HOLD TIME set point in
synchroscope menu. See section 1.3.4
Description of Set points
Verify wiring of C.B. aux contacts to GCP-1
input
Appropriately set the C B CONTROL set point
in configuration menu. See section 1.3.4
Description of Set points

10.5 Real Load Control

Problem Probable Cause Corrective Action

kW for a phase(s) reads negative.
Unit carries improper proportion of real load during
isochronous load sharing
Real load control is unstable when paralleled with the
mains source
Process control operation causes overload or reverse
power
Loading and/or unloading is too fast/slow
Current transformer(CT) has reversed
polarity
Rated kW set point in configuration menu
set at incorrect value
A proportional dc speed error exists on the
speed control unit (no-load speed not set to
match bus frequency)
Real load control dynamics in real load
control menu are improperly set up
PROCESS ACTION set point in process
control menu set for incorrect action
Load and/or unload ramp rates in the real
load control menu are set incorrectly
Verify/reverse polarity of current transformer
for effected channel(s)
NOTE: engine generator set must be off
to safely open circuit a current
transformer
Appropriately set Rated kW set point in
configuration menu. See section 1.3.4
Description of Set points
Adjust speed setting of speed control to
match the bus frequency. If unit is carrying
too little load, the speed setting needs
increased. If unit is carrying too much load,
the speed setting needs decreased.
Tune Real load control dynamics in real load
control menu. See section 1.3.4 Description
of Set points
Appropriately set PROCESS ACTION set
point in process control menu. See section
1.3.4 Description of Set points
Appropriately increase/decrease the Load
and/or unload ramp rates in the real load
control menu. See section 1.3.4 Description

25
 of Set points
Engine speed/load has an instability that fluctuates very Speed control dynamics are improperly set Tune the speed control dynamics for stable
quickly. up operation. See speed control manufacturer’s
instruction manual for more details

10.6 Reactive Load Control

Problem Probable Cause Corrective Action

Phase power factors do not agree. Two of the three CT’s are connected to incorrect phase inputs Verify CT’s are connected to the appropriate
phases are extremely far out of range input terminals
NOTE: engine generator set must be off
to safely open circuit a current
transformer
Unit carries improper proportion of reactive load during Rated kVA set point in the configuration Appropriately set the Rated kVA set point in
isochronous load sharing menu is set at incorrect value the configuration menu. See section 1.3.4
Description of Set points
Generator A phase PT input(s) are Calibrate the Generator A phase PT input(s)
improperly calibrated of the generator set(s). See section 1.10
Calibration of Control Inputs and Outputs
Reactive load control is unstable when paralleled with the Reactive load control dynamics in the Tune the Reactive load control dynamics in
mains source reactive load control menu are improperly set the reactive load control menu. See section
up 1.3.4 Description of Set points
Unit maintains a constant VAR load rather than a constant VAR/PF set point in the reactive load control Appropriately set the VAR/PF set point in
power factor when paralleled with the mains source menu is set to VAR CONTROL the reactive load control menu. See section
1.3.4 Description of Set points
Unit maintains a constant power factor load rather than a VAR/PF set point is set to PF CONTROL Appropriately set the VAR/PF set point in
constant VAR when paralleled with the mains source the reactive load control menu. See section
1.3.4 Description of Set points
Multiple generator sets are unstable when VAR/PF VOLTS RAMP TIME set point in reactive Appropriately set the VOLTS RAMP TIME
sharing at light loads load control menu is not adjusted properly set point in reactive load control menu. See
section 1.3.4 Description of Set points
Droop Current Transformer not properly Verify the connection of the Droop Current
connected to AVR Transformer to the AVR. See AVR
manufacturer’s instruction manual for more
details

10.7 Sequencing
Problem Probable Cause Corrective Action

Unit number(s) does not show up in the sequencing
order in the sequencing screen/unit doesn’t auto
sequence
When system load is large enough to require additional
gen-sets, more than one set is sequenced on line
When system load is small enough to take additional
sets off line, more than one set is sequenced off line
switch in manual position
Automatic mode set point in the configuration
menu set to disabled
Unit has an active alarm
RS-485 Network not connected at unit(s)
RS-485 Network is inadequately terminated
NEXT GENERATING SET DELAY set point in
sequencing menu is too short
MAX START TIME set point in sequencing
menu is too short
REDUCED LOAD DELAY set point in
sequencing menu is too short
MAX STOP TIME set point in sequencing menu Increase MAX STOP TIME set point in
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
ENABLE the Automatic mode set point in
the configuration menu. See section 1.3.4
Description of Set points
Commit or reset alarm condition(s). See
section 1.3.2 Description of Screens
Verify that the RS-485 network is connected
to all GCP-1 controls in system.
Verify that the RS-485 Network is correctly
terminated. See section 1.9.6 Inter-Control
Communications (RS-485)
Increase NEXT GENERATING SET DELAY
set point in sequencing menu. See section
1.3.4 Description of Set points
Increase MAX START TIME set point in
sequencing menu. See section 1.3.4
Description of Set points
Increase REDUCED LOAD DELAY set
point in sequencing menu. See section 1.3.4
Description of Set points

26
 is too short sequencing menu. See section 1.3.4
Description of Set points

10.8 Mains / Bus Sensing

Problem Probable Cause Corrective Action

Unit(s) do not respond to loss of mains
Unit does not recognize when mains are in spec.
Shutdown/alarm set points for mains
sensing not set for LOSS OF MAINS
Unit(s) do not have an active auto switch
input
Set points for mains high/low frequency
and high/low voltage in shutdown/alarm
menu are set too tight for sensing when
mains are in spec
Appropriately set mains high/low frequency
and high/low voltage set points in
shutdown/alarm menu. See section 1.3.4
Description of set points
Switch unit(s) to the Auto switch active
position. See section 1.1.5 DC
inputs/outputs
Increase Mains high frequency and voltage
and decrease mains low frequency and
voltage set points in the shutdown/alarm
menu. See section 1.3.4 Description of Set
points

10.9 Communications
Problem Probable Cause Corrective Action

A unit number(s) does not show up in the sequencing
order in the sequencing screen
If a unit with the network termination is powered down,
communications become unreliable or completely cease
RS-485 Network is inadequately terminated
RS-485 Network not connected at unit(s)
RS-485 network is connected with reverse
polarity at one or more units
+5Vdc power supply is not linked between
units (inadequate wiring)
Verify that the RS-485 Network is correctly
terminated. See section 1.9.6 Inter-Control
Communications (RS-485)
Verify that the RS-485 Network is
connected to the GCP-1 RS-485 input at all
units
Verify the polarity of the RS-485 network on
all units
Verify that the +5Vdc power supply is linked
between all units

11. Definition of Terms

stable. The GCP–1 control has ATS functions.

AMF Automatic Mains Failure. The ability of a control to
detect, and take action on a mains failure condition.
The GCP–1, which has AMF capabilities, can be
programmed to sense a loss of mains condition
based on mains voltage, frequency, or a sudden
load surge on a generator operating in parallel with
the mains. The action taken by the GCP–1 when it
senses a mains failure can be programmed for
either an alarm action, or a standby power action
where all generators start and tie to the load after
the failed mains have been isolated from that load.
Automatic A control mode used by the GCP–1 to activate
Control several automatic functions within the control.
These functions, which are dependent upon
program setpoints and system configuration, are
Loss of Mains detection, Automatic Sequencing,
and Automatic dead bus closing, Automatic control
also effectively connects those GCP–1 units in
automatic to the Local Operating Network (LON).
Auto Switch A discrete input to the control which will initiate
automatic operation of the GCP–1.
Audible An alarm condition used by the GCP–1 for various
Alarm alarm settings which will cause the audible alarm
relay output to energize when reaching or
exceeding the alarm parameters.
Automatic The automatic addition, or subtraction of
Sequencing generators to/from the load based on
predetermined load levels being crossed for
specific periods of time. Automatic sequencing is a
function of a multiple generator system which is
operating in load sharing mode isolated from the
mains, or process control mode in parallel with the
mains.
AVR Automatic Voltage Regulator. A device which
controls the field excitation of an AC generator in
such a way as to maintain a specific voltage level
over the operating load range of the generator. The
GCP–1 control biases the voltage setting of the
AVR to voltage match during synchronization and
to control reactive load during load share and
mains parallel operation.

Base A term used to describe a generator loading

ATS Automatic Transfer Switch. A device which isolates Load condition in which the generator is paralleled to
the mains upon a sensed fault in the mains, or another source of power, typically the mains, and
through manual operation. The ATS selects a loaded to a fixed kW level. The generator maintains
secondary power source, such as a diesel this kW level regardless of load on the Mains.
generator to supply the load when the mains have
been isolated. The ATS will also re-connect the
load to the mains when they are re-established and

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Breaker A device used to connect one power source to a
load, or to another power source. Breakers can be
either manually or automatically operated, and will
usually contain overcurrent protection. The GCP–1
controls motorized breakers by issuing a
momentary breaker close output to energize the
breaker coil, and a separate breaker open output to
shunt trip the breaker to open it.
Contactor A device used to connect one power source to a
load, or to another power source. Contactors are
typically automatic in operation, and are energized
for closure from an external source. The GCP–1
controls contactors by issuing a contactor close
output to close the contactor, and removing this
output to open the contactor.
Dead Bus The ability of a generator breaker control device to
Closing sense, and safely close onto a load which has no
other generators or sources of power tied to it.
Dead Bus Closing must not allow two generators to
attempt closure to the dead bus at the same time,
since an out of phase paralleling situation would
likely occur. The GCP–1 uses its Local Operating
Network to ensure safe dead bus closing among all
units tied to this network. The units have a single
dead bus token, which allows the unit possessing it
to close to the dead bus. Only one token exists on
the network, so there is no possibility of multiple
units closing to the dead bus simultaneously. Dead
Bus Closing is always active in single unit
configurations.
Droop A reduction in the reference of a controlled
parameter as the amplitude of that parameter
increases (negative feedback). The GCP–1 uses
Kilowatt Droop as a manual means of loading the
generator when paralleling to another generator, or
to the mains.
Dwell A term used to describe the amount of time
Time required during synchronization in which one power
source is within a specified phase angle window of
another source it is synchronizing to.
Hard A shutdown condition used by the GCP–1 for
Shutdown various alarm settings which will cause the unit to
immediately open its generator breaker if on load,
and shut down by immediately opening its fuel
solenoid output when reaching or exceeding the
alarm parameters.
Isochronous A term which is used to describe a generator set
which will maintain its frequency at a constant level
as the load on that generator changes. The GCP–1
typically uses isochronous load control when in
load sharing, or when operating as a single unit.
This assures a constant frequency under all
generator loads which are within the capacity of the
generator.
Inverse Time A time delay used for over current and reverse
Delay power detection, which utilizes both time and
amplitude of the condition to determine the active
trip level. The inverse time delay accounts for rapid
high amplitude conditions to cause a trip, as well
as long duration low amplitude conditions.
Isolated Bus A bus which is electrically isolated from the mains.
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KVA Kilovolt-Amps. The power rating of the generator
set KVA is determined by multiplying the rated
voltage of the generator by the rated current.
KVAR Kilovolt-Amps Reactive. Reactive load is produced
by a phase angle differential between the volts and
the amps of the generator. KVAR can either be a
product of inductive or capacitive loads when
operating on an isolated bus, or can be produced
by the generator when operating in parallel with
another power source such as the mains.
kW Kilowatts. Watts are the product of the voltage of
the generator and the current, which is produced
within the voltage cycle. kW load is resistive in
nature.
Load Typically the kW load on the generator at any given
time.
Load Surge A condition in which a step load on the generator,
which is operating in a mains parallel mode (base
load or process) above a certain amplitude can be
used to trigger a Loss of Mains condition.
Loss of A condition in which the sensed mains PT input to
Mains the GCP–1 falls below certain voltage and/or
frequency setpoints for a given period of time. Load
Surge can also be used to detect a Loss of Mains
condition. The GCP–1 can be configured to trigger
a Loss of Mains (LOM) reaction to these
conditions, and provide on site power generation to
supplement the load until such time as the mains
return and are stable.
Mains To synchronize and close an operating generator to
Parallel the mains. The GCP–1 can be configured for
Mains Parallel operation.
Master The Highest Priority unit in an operating automatic
system. The Master Control controls load sharing,
VAR/PF sharing, sequencing, synchronization to
the mains, mains breaker closure/opening, and
multiple unit starting.
Manual A switch input to the GCP–1 which puts the control
in a manual operating mode. When in manual, the
GCP–1 does not communicate with other units on
the network, and if in a multiple unit system, will not
issue a dead bus closing command. Being in
manual also cancels any Loss of Mains detection
for that particular unit.
Network A unique address assigned to each unit, which is
Address operating in an automatic system. The network
address is that particular units “name” on the
network so that it can be properly identified by other
units operating on the same network.
Network A unique number assigned to each unit operating
Priority in automatic on the network. Network priority
defines the sequence in which units will be taken
on/off load when operating in an automatic
sequencing configuration (load sharing or process
control). Automatic sequencing will place units on
load as required starting at the highest network
priority (lowest numerical value), and adding units
of lower priority (higher numerical value) as the
load on that system increases above certain
defined limits. Automatic sequencing will also
 remove units from the load in a reverse order of
that used for sequencing units on load, that is from
lowest priority (highest numerical value) to highest
priority (lowest numerical value). In addition to all
this, the unit with the highest network priority on the
network is considered the master, and all other
units with lower priorities are slaves to that master.
Test
No Parallel An operating mode of the GCP–1 which will not
allow the generators to operate in parallel with the
mains under any circumstances. All transitions to
and from the mains are completed using an open
transition action.
VAR/PF
Control
Parallel To synchronize and close an operating generator to
another generator, or to the mains.
Power A right triangle which is used to determine the
Triangle amplitude relationship between KVA, KW, and
KVAR
generator or the mains. This will allow a safe
smooth breaker closure of that generator to the
power source. The GCP–1 uses Phase and
Voltage Matching to ensure there is a minimum of
potential across the breaker prior to closure.
A discrete input to the GCP–1 which is used to
start the engine for test and initial start check out.
The test input is also used with the run with load or
process inputs, and a software setpoint, to put the
GCP–1 into a soft transfer mode.
The ability to control a level of VAR or PF on a
generator while in parallel with the mains. The
GCP–1 has VAR/PF control features which allow
the user to set a desired VAR or PF level on the
generator while in parallel with the mains. The VAR
or PF level is maintained by changing the excitation
level of the generator. This is accomplished by
changing the voltage reference level of the AVR
from the GCP1.

A switch input which selects a mode of control VAR/PF The ability to share the VAR and PF load on
Control used while in parallel with the mains. When Sharing multiple units operating on an isolated bus. Like
operating in process control, the GCP–1 receives a load sharing, the GCP–1 VAR/PF sharing
4-20 mA, or 1-5 VDC input from an external measures the VARs of the load on the isolated bus,
transducer. This transducer monitors a variable and divides this value by the total VAR capacity of
which is affected by the generator operation. the generators tied to the load. A proportional
Variables such as imported power to a site, VAR/PF level is then maintained between all units
exported power to the mains, exhaust temperature, tied to the load based on their rated VAR capacity.
and fuel gas pressure levels are typical for
monitoring with a transducer. The GCP–1 uses an
internal reference level for the process input, and
compares this reference to the transducer
input.The GCP then raises or lowers the amount of
load on the generator to maintain the process
transducer input to the referenced value.

Proportional A mode of load control used by the GCP–1 while

Load Sharing operating multiple units on an isolated bus.
Proportional Load Sharing measures the total KVA
capacity of all the units on the bus and divides the
total KVA load on the bus by this capacity. This
value is then sent over the network as a load
reference for all units operating in parallel on the
bus. The result of this is the ability of various KVA
rated units operating at their respective proportion
of the total load on the bus. This allows consistent
load sharing among units of various sizes
throughout their entire operating load range.

Run With A discrete input to the GCP–1 which signals the

Load unit to operate the generator on load. The way that
the control puts the generator on load depends
upon software configuration, and the type of
system the GCP–1 is configured for.

Slave A GCP–1 with lower network priority (Higher

numerical value) than the master.

Soft A shutdown condition used by the GCP–1 for

Shutdown various alarm settings which will cause the unit to
softly unload and cooldown when reaching or
exceeding the alarm parameters.

Soft Transfer A Load Control Mode of the GCP–1 which allows

the unit, or group of units to transfer power from
the mains to the on site generators. Upon reaching
either a base load reference, or process control
reference level, the GCP–1 will issue a command
to open the mains breaker. This results in a
complete transition of power from the mains to the
on site generators.

Synchronize To match the frequency, phase angle, and voltage

of a generator to another power source such as a

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