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Doc #SED-MAN-GC800-002
GC800: GENSET
CONTROLLER
Product Manual Version #0.00
Copyright
All rights reserved. No part of this publication may be reproduced, distributed or transmitted
by any means (including photocopying or storing in any medium by electronic means or other)
without the prior written permission of the copyright holder. Any reference to trademarked
product names used within this publication is owned by their respective companies.
SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document
without prior notice. For permission requests and applications to reproduce any part of this
publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
Web Support:
Email: support@sedemac.com
Website: www.sedemac.com
Telephonic Support:
+91-20-67313500
+91-8551039888
+91-8551041888
+91-8551043888
SEDEMAC
Safety Instructions
General Instructions
✓ This document includes important instructions that should be followed during installation and
maintenance of the generator set controller.
✓ For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an
authorized service personnel. Follow all applicable state and local electrical codes.
✓ Efficient and safe operation of the controller can be acquired only if the equipment is correctly
operated, configured and maintained.
*Many accidents arise due to ignorance or illiteracy towards the elemental rules of safety and
precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions
to the operator, service personnel or the equipment.
Electrical Safety
✓ Electric shock can cause severe personal injury or death.
✓ Ensure the generator set must be grounded before performing any installation or service.
✓ Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock.
Prevent contact with terminals, bare wires, connections, etc., while the generator and related
equipment are running. Do not tamper with interlocks.
✓ To handle the maximum electrical current, sizes of wire gauge used for electrical connections and
wirings must be appropriate to which they will be subjected to.
In Operation Safety
✓ Before installing genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.
Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical
shock.
✓ Remove electric power supply before removing controller or touching other electrical parts.
✓ Use extreme caution when working on electrical components. High voltage can cause injury or death.
✓ Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
✓ Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
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SEDEMAC
✓ Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. It may result in severe electrical shock.
✓ Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
✓ In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. Avoid direct contact with the
victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live
conductor. If the victim is unconscious, apply first aid and get immediate medical help.
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SEDEMAC
List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer their
respective description. This list does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
CHG Charging
CKT Circuit
CT Current Transformer
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
OV Over Voltage
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
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SEDEMAC
Table of Contents
1 Introduction .......................................................................................................................... 9
Key Highlights of the Product .......................................................................................... 9
Product Features............................................................................................................. 9
Specifications .................................................................................................................... 11
Terminals ....................................................................................................................... 11
Power Supply Specifications ......................................................................................... 12
Generator Voltages and Frequency Measurements ...................................................... 12
Load Current Measurement .......................................................................................... 13
Mains Voltage and Frequency Measurements .............................................................. 13
Digital Inputs ................................................................................................................. 14
Analog Resistive Sensor Inputs .................................................................................... 14
Analog Voltage/Current Input ........................................................................................ 15
Magnetic Pick Up Input ................................................................................................. 15
Digital Outputs ........................................................................................................... 15
Actuator Outputs ........................................................................................................ 16
D+ CHG ALT .............................................................................................................. 16
Sensor Common Point ............................................................................................... 16
Deep Sleep Mode Feature ......................................................................................... 17
Communication Ports ....................................................................................................... 17
Installation .......................................................................................................................... 18
Dimensions ................................................................................................................... 18
Mounting on panel......................................................................................................... 19
Terminal Description ...................................................................................................... 20
Typical Wiring Diagram ................................................................................................. 23
Module Display .................................................................................................................. 25
Monitoring Mode ........................................................................................................... 25
Description of Control keys .............................................................................................. 28
Functions of Control keys .............................................................................................. 28
Configuration Mode ........................................................................................................... 29
List of Configurable Parameters .................................................................................... 30
Module Operation .............................................................................................................. 43
Auto Mode ..................................................................................................................... 43
Manual Mode ................................................................................................................ 48
Paralleling Mode ........................................................................................................... 49
Alarms ................................................................................................................................ 50
Troubleshooting................................................................................................................. 54
Introduction to Communication Protocol ........................................................................ 57
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SEDEMAC
RS485 MODBUS Based Protocol...................................................................................... 57
Connection Details ..................................................................................................... 57
Precautions ................................................................................................................ 58
Function Code Used .................................................................................................. 58
Register Map ............................................................................................................. 60
Protocol for CAN-Based Communication ........................................................................ 66
Connection Details ..................................................................................................... 66
Structure of Communication ...................................................................................... 66
Packet Structure ........................................................................................................ 72
Notes ......................................................................................................................................... 73
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SEDEMAC
List of Figures
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SEDEMAC
List of Tables
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SEDEMAC
Table 32: Command from MODBUS master for Function 4........................................................ 58
Table 33: Normal response from genset controller slave for Function 4 ..................................... 59
Table 34: Command from MODBUS master for Function 16...................................................... 59
Table 35: Normal response from genset controller slave for Function 16 ................................... 59
Table 36: Command from MODBUS master for Function 3........................................................ 60
Table 37: Normal response from genset controller slave for Function 3 ..................................... 60
Table 38: Register map for input registers .................................................................................. 61
Table 39: Register map for holding registers .............................................................................. 65
Table 40: Interpretation of alarm status results ........................................................................... 66
Table 41: Structure of communication ........................................................................................ 66
Table 42: Structure of broadcasted message ............................................................................. 71
Table 43: Structure of command message ................................................................................. 71
Table 44: Structure of command message received over CAN .................................................. 72
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SEDEMAC
1 Introduction
This document elucidates information necessary for operating SEDEMAC's GC800 genset controller. It
empowers the user with the necessary information for using GC800 genset controller in an application
that involves communication of the genset controller with an external system similar as a server or a
remote data communication system.
SEDEMAC's GC800 boasts its modern technology with robust features of genset controller with user-
friendly HMI and full graphics LCD. GC800 controller is bundled with highly versatile software &
extensive I/O's and thereby support a wide variety of industry standard features in diesel/gasoline
engine gensets. GC800 controller's smart software offers flexibility to configure each individual input
and output for a specific function or application.
GC800 controller offer unique features such as electronic governing for engines with mechanical fuel
systems. With a SEDEMAC's Rotary Actuator as an add-on for air / fuel charge control, this controller
can subsume the electronic governing duty for the engine and offers tight speed governing performance
within ISO 8528: G3 class limits.
GC800 controller can be configured through SEDEMAC's laptop / desktop utility, named as
SEDEMAC's Smart Config. All parameters can also be configured using the keypad of the genset
controller.
Product Features
Following table gives a brief overview of different specifications of the GC800
Table 1: Features list
Features Specs for GC800
DG Alt I-Input Y
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SEDEMAC
USB I/O port for laptop access Y
EEPROM for extended event logs OR regional
Y
languages
CAN I/O Y
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SEDEMAC
Specifications
Terminals
GC800 controller host two types of terminal blocks as shown in Figure 2 and Figure 3 given below:
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SEDEMAC
Power Supply Specifications
Following table gives a brief overview of power supply specification
Table 4: Power supply specification
Controller's terminal
1, 2 (Ground and Battery positive respectively)
number
Supply voltage range 8 to 32 V-DC (Suitable for 12/24 V-DC system)
Cranking drop out
50 mS
period
Maximum reverse
-32 V-DC
voltage
Battery voltage
±1 % full scale
measurement accuracy
Battery voltage
measurement 0.1 V
resolution
~ 0.2 A @ 12 V-DC (Excluding all current loads for the high side driver’s
Maximum current
output and Rotary Actuator's output)
Standby current 80 mA @ 12 V-DC
Deep sleep current 20 mA @ 12 V-DC
For single phase genset application, it is mandatory to connect the genset phase
and neutral cables to the genset controller's phase R and Neutral terminals
respectively
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SEDEMAC
Load Current Measurement
Following table gives a brief overview of load current measurement
Table 6: Load current measurement
Controller's terminal
35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for phase R)
number
Measurement type True RMS
Maximum CT
secondary current 5A
rating
Burden 0.25 VA
Frequency range 3 to 75 Hz
Accuracy: 0.25% of full scale
Frequency accuracy
Resolution: 0.1 Hz
For single phase application, it is mandatory to connect the mains phase and neutral
cables to the genset controller's phase R and Neutral terminals respectively.
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SEDEMAC
Digital Inputs
Following table gives a brief overview of digital inputs
Table 8: Digital input
Controller's terminal 10, 11, 12, 21, 22
number
Number of inputs 5
Type Negative sensing (connect switch to ground)
Open circuit voltage (VBATT – 1) V-DC
Software configurable Low Lub Oil Pressure (LLOP) Switch, High Water Temperature (HWT) and
options many more. Please refer Table 21
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SEDEMAC
Analog Voltage/Current Input
Following table gives a brief overview of analog voltage/current input
Table 10: Analog voltage/current input
Controller's terminal number 23
Range 0 to 5 V-DC/ 4 to 20 mA
While creating a genset paralleling application, this input may be configured to accept a 2.5V ±2V -
DC speed bias signal generated by a load sharing module (LSM).
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine
speed sensing. The output of MPU is a sine-wave signal.
Digital Outputs
Following table gives a brief overview of digital outputs
Table 12: Digital outputs
Controller's terminal number 3, 4, 5, 6, 8, 9
Number of outputs 6
Software configurable options Start relay, Fuel relay and many more. Refer Table 26
Genset & mains contactor latching relays should be compiled against 4kVA
surge as per IEC-61000-4-5 standard.
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SEDEMAC
Actuator Outputs
Following table gives a brief overview of actuator outputs
Table 13: Actuator outputs
Figure 5: SEDEMAC's Actuator connector pin out (viewed from the terminal insertion side)
The Actuator outputs are used only for the SEDEMAC's Actuator, if installed. The SEDEMAC's Actuator
is a 4-wire Actuator that is used for creating an electronic governing application in case of a mechanical
fuel system engine. In diesel engines, the Rotary Actuator's shaft output gets mechanically connected
to the stop lever or the throttle lever of an in-line or rotary fuel injection pump. In case of petrol or
natural gas engines, the Rotary Actuator's shaft output gets connected to the throttle/charge control
valve.
D+ CHG ALT
Table 14: D+ CHG ALT
Controller's terminal number 7
The D+ CHG ALT is combine input and output terminal. When the genset starts, the terminal
provides controlled power output to excite the charging alternator. Once the charging alternator is
excited and starts providing voltage to battery, this terminal is used as input to sense the output
voltage of the charging alternator. In case of the charging alternator failure the GCU acts as per the
pre-configuration settings.
Communication Ports
Following table gives a brief overview of communication ports
Table 16: Communication ports
USB 2.0 Type B used for connection to PC running SEDEMAC Smart
USB
config.
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
RS485 Serial Port
Termination resistor of 120Ω is provided between output pin A & B
Common-mode operating range and bus-pin fault protection upto ±70V
Maximum distance of line is 1200m
Controller's terminal
15, 16
number for RS485
Baud rate used is 250 kbps
CAN Packet size used is 8 bytes
Termination resistor of 120Ω is provided
Controller's terminal
13, 14
number for CAN
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SEDEMAC
Installation
Dimensions
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SEDEMAC
Mounting on panel
To mount the controller into the panel, use the fixing clips provided along with the controller.
Follow the given steps:
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SEDEMAC
Terminal Description
Following figure shows the rear view of controller.
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SEDEMAC
Table 17: Details of GC800 terminals
Phoenix Female
Terminal
Name Description (Mating) Connector
Sr. No.
Part No.
15 RS485_B RS485 – B
16 RS485_A RS485 – A
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SEDEMAC
Phoenix Female
Terminal
Name Description (Mating) Connector
Sr. No.
Part No.
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SEDEMAC
Typical Wiring Diagram
The typical wiring diagram of GC800 for Auto Mains Failure application on engine with mechanical fuel
system:
Figure 10: GC800 genset controller power circuit (used in the Auto Mains Failure Mode)
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SEDEMAC
Figure 11: GC800 genset controller control circuit (used in the Auto Mains Failure Mode)
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SEDEMAC
Module Display
Following section describes the layout of screens.
Monitoring Mode
In monitoring mode, screens will scroll automatically after a configurable time which can be configured in
configuration menu or you can use the “Navigation UP/DOWN Keys” to scroll/browse the screens.
Table 18: Screens of engine status and operating mode
MANUAL AUTO
(This screen will be visible in Manual mode) (This screen will be visible in Auto mode)
(The “Y” and “B” phase will be visible only if (The “Y” and “B” phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
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SEDEMAC
(The “Y” and “B” phase will be visible only if (The “PF-Y” and “PF-B” will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
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SEDEMAC
(This screen will be visible only if “Engine (This screen will be visible only if “Lube Oil
temperature” sensor is configured) Pressure” sensor is configured)
EXAMPLE OF ALARMS
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SEDEMAC
4
2
3
Figure 12: Control keys function
1. Menu Navigation Up key
2. Menu Navigation Down key
3. Stop/Config Key
4. Start/Select Key
5. Auto/Manual mode selection key
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SEDEMAC
# Mode Key input Function
Configuration Mode
To configure the controller please follow the below mentioned instructions:
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SEDEMAC
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Auto Exercise
Disable/Enable
(EVENT 2)
Event Occurrence
Daily/Weekly/Monthly
(EVENT OCCURENCE)
Auto Exercise Event Day Runs Every day/Week
Event 2 (EVENT DAY) days/1 – 28
(AUTO Start Time
00:00 – 23:59 hour
EXERCISE-2) (START TIME)
Duration 0 hour 1 min – 99 hour 59
(DG ON DURATION) mins
Load Transfer
Disable/Enable
(LOAD TRANSFER)
Cyclic Mode
Disable/Enable
(CYCLIC MODE)
Cyclic Mode
Genset Off Time
(CYCLIC 1-720 min
(DG OFF DURATION)
CONFIG)
Genset On Time
1-720 min
(DG ON DURATION)
Source
Refer Table 21
(SOURCE)
Name Auxiliary Input X
Polarity Close to Activate/Open to
(POLARITY) Activate
Digital Input X
None/Notification/
Digital Inputs (DIG IN X) Action
Warning/Electrical Trip/
(INPUTS) X= A, B, C, D, (ACTION)
Shutdown
E
Never/From Engine Start/
Activation
From Monitoring On/
(ACTIVATION)
Always
Activation Delay
1 – 60 sec
(ACTIVATION DELAY)
Not used/Digital Input G/
Use Input As
Engine Temperature
(SENSOR SELECTION)
Sensor
(Digital) Source
Refer Table 21
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
None/Notification/
(Digital) Action
Warning/Electrical Trip/
((DIG) ACTION)
Shutdown
Never/From Engine Start/
(Digital) Activation
Analog Input 1 From Monitoring On/
((DIG) ACTIVATION)
Analog Inputs (ENG Always
TEMP/DIG G) (Digital) Activation Delay
1 – 60 sec
((DIG) ACTIVATION DELAY)
(ETS) High Level Shutdown
Disable/Enable
(SHUTDOWN)
(ETS) High Level Shutdown
Threshold 27 – 300 ̊C
(SHUTDOWN THRESHOLD)
(ETS) High Level Warning
Disable/Enable
(WARNING)
(ETS) High Level Warning
Threshold 25 – 298 ̊C
(WARNING THRESHOLD)
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
None/Notification/
(ETS) Circuit Fault Action
Warning/Electrical Trip/
(OPEN CKT ACTION)
Shutdown
(ETS) Engine Temperature
Refer Table 22
Sensor Calibration Table
Use Input As Not used/Digital Input H/
(SENSOR SELECTION) Fuel Level Sensor
(Digital) Source
Refer Table 21
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
None/Notification/
(Digital) Action
Warning/Electrical Trip/
((DIG) ACTION)
Shutdown
Never/From Engine Start/
(Digital) Activation
From Monitoring On/
((DIG) ACTIVATION)
Always
(Digital) Activation Delay
1 – 60 sec
((DIG) ACTIVATION DELAY)
Low Fuel Level Shutdown
Disable/Enable
(SHUTDOWN)
Low Fuel Level Shutdown
Analog Input 2 Threshold 0 – 78 %
(Fuel LVL/DIG (SHUTDOWN THRESHOLD)
H) Low Fuel Level Notification
Disable/Enable
(NOTIFICATION)
Low Fuel Level Notification
Threshold (NOTIFICATION 2 – 80 %
THRESH)
Fuel Tank Capacity
2 – 1000 litre
(FUEL TANK CAPACITY)
Fuel Theft Warning
Disable/Enable
(FUEL THEFT ALARM)
Fuel Theft Alarm Threshold
1 – 100 % per hour
(FUEL THEFT THRESHOLD)
None/Notification/
Circuit Fault Action
Warning/Electrical Trip/
(OPEN CKT ACTION)
Shutdown
Fuel Sensor Reference Engine Body/Battery
(FUEL SENSOR REFERENCE) Negative
Fuel Level Sensor Calibration
Refer Table 23
Table
Use Input As Not used/Digital Input F/
(SENSOR SELECTION) Lube Oil Pressure
(Digital) Source
Refer Table 21
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
Analog Input 3 None/Notification/
(Digital) Action
(LOP / DIG F) Warning/Electrical Trip/
((DIG) ACTION)
Shutdown
Never/From Engine Start/
(Digital) Activation
From Monitoring On/
((DIG) ACTIVATION)
Always
(Digital) Activation Delay
1 – 60 sec
((DIG) ACTIVATION DELAY)
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Low Level Shutdown
Disable/Enable
(SHUTDOWN)
Low Level Shutdown Threshold
0.0 – 9.8 bar
(SHUTDOWN THRESHOLD)
Low Level Warning
Disable/Enable
(WARNING)
Low Level Warning Threshold
0.2 – 10.0 bar
(WARNING THRESHOLD)
None/Notification/
Circuit Fault Action
Warning/Electrical Trip/
(OPEN CKT ACTION)
Shutdown
Lube Oil Pressure Sensor
Refer Table 24
Calibration Table
Use Input As Not used/Digital Input I/0-
(SENSOR SELECTION) 5V Sensor
(Digital) Source
Refer Table 21
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
None/Notification/
(Digital) Action
Warning/Electrical Trip/
((DIG) ACTION)
Shutdown
Never/From Engine Start/
(Digital) Activation
From Monitoring On/
((DIG) ACTIVATION)
Always
(Digital) Activation Delay
Analog Input 4 1 – 60 sec
((DIG) ACTIVATION DELAY)
(LOP / DIG I)
Shutdown
Disable/Enable
(SHUTDOWN)
Shutdown Threshold
0.0 – 9.8 (0.0 – 9.8 Bar)
(SHUTDOWN THRESHOLD)
Warning
Disable/Enable
(WARNING)
Warning Threshold
0.2 – 10.0 (0.2 – 10.0 Bar)
(WARNING THRESHOLD)
None/Notification/
Circuit Fault Action
Warning/Electrical Trip/
(OPEN CKT ACTION)
Shutdown
Lube Oil Pressure Sensor
Refer Table 25
Calibration Table
Output X Source
Refer Table 26
Outputs (OUT X) (SOURCE)
(OUTPUTS) X= A, B, C, D, On Activation
Energise/De - energise
E, F (ON ACTIVATION)
Crank Hold Time
1 – 15 sec
(CRANK HOLD TIME)
Crank Rest Time
Cranking timer 2 – 60 sec
(CRANK REST TIME)
(CRANKING
Manual Start Delay
TIMER) 0 – 30 sec
Timers (MANUAL START DELAY)
(TIMERS) Auto Start Delay
0 – 43200 sec
(AUTO START DELAY)
General timer Safety Monitoring Delay
10 – 60 sec
(GENERAL (SAFETY MONITOR DELAY)
TIMER) Mains Detect Delay
1 – 300 sec
(MAINS DETECT DELAY)
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Alternator Detect Delay
1 – 30 sec
(ALT DETECT DELAY)
Warm-Up Delay
0 – 60 sec
(WARM UP DELAY)
Return To Mains Delay
0 – 600 sec
(RETN-TO-MAINS DELAY)
Engine Cooling Time
0 – 300 sec
(ENG COOL TIME)
Stop Action Time
10 – 120 sec
(STOP ACTION TIME)
Additional Stopping Time
0 – 120 sec
(ADDN STOPPING TIME)
Load Transfer Delay
0 – 60 sec
(LOAD TRANSFER DELAY)
Power Save Mode Delay
5 – 1800 sec
(PWR SAVE MODE DELAY)
Screen Changeover Time
1 – 1800 sec
(SCRN CHNGOVER TIME)
Deep Sleep Mode Delay
5 – 1800 sec
(DEEP SLP MODE DELAY)
Sounder Alarm Time
1 – 300 sec
(SOUNDER ALARM TIMER)
Auto Exit Config Mode
10 – 1800 sec
(AUTO EXIT TIMER)
Alternator Present
No/Yes
(ALT PRESENT)
Number Of Poles
2/4/6/8
(NUMBER OF POLES)
AC system
1 Phase/3 Phase
(ALT AC SYSTEM)
Min Healthy Voltage
50 – 350 Volt Ph-N
Alternator (MIN HEALTHY VOLT)
Configuration Min Healthy Frequency
10 – 75 Hz
(ALT CONFIG) (MIN HEALTHY FREQ)
Phase Reversal Detection
Disable/Enable
(PHASE REVERSE DETECT)
None/Notification/
Phase Reversal Action
Warning/Electrical Trip/
(PHASE REVERSE ACTION)
Shutdown
Generator Auto Load Transfer
Disable/Enable
(GENERATOR) (AUTO LOAD TRANSFER)
Under-voltage Shutdown Enable
Disable/Enable
(UNDER VOLT SHUTDOWN)
Under-voltage Shutdown
Threshold 50 – 295 Volt Ph-N
Voltage (UV SHUTDWN THRESHLD)
Monitoring Under-voltage Warning Enable
Disable/Enable
(VOLT (UNDER VOLT WARNING)
MONITOR) Under-voltage Warning Threshold
55 – 300 Volt Ph-N
(UV WARNING THRESHOLD)
Over-voltage Shutdown Enable
Disable/Enable
(OVER VOLT SHUTDOWN)
Over-voltage Shutdown Threshold
105 – 350 Volt Ph-N
(OV SHUTDWN THRESHLD)
Over-voltage Warning Enable
Disable/Enable
(OVER VOLT WARNING)
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Over-voltage Warning Threshold
100 – 345 Volt Ph-N
(OV WARNING THERSHOLD)
Under-frequency Shutdown
Enable Disable/Enable
(UNDER FREQ SHUTDOWN)
Under-frequency Shutdown
Threshold 10.0 – 59.0 Hz
(UF SHUTDWN THRESHLD)
Under-frequency Warning Enable
Disable/Enable
(UNDER FREQ WARNING)
Under-frequency Warning
Frequency
Threshold 11.0 – 60.0 Hz
Monitoring
(UF WARNING THRESHOLD)
(FREQ
Over-frequency Shutdown Enable
MONITOR) Disable/Enable
(OVER FREQ SHUTDOWN)
Over-frequency Shutdown
Threshold 26.0 – 75.0 Hz
(OF SHUTDWN THRESHLD)
Over-frequency Warning Enable
Disable/Enable
(OVER FREQ WARNING)
Over-frequency Warning
Threshold 25.0 – 74.0 Hz
(OF WARNING THRESHOLD)
CT Ratio
0 – 8000 / 5
(CT RATIO)
None/Notification/
Over-current Action
Warning/Electrical Trip/
(OVER CURR ACTION)
Current Shutdown
Monitoring Over-current Threshold
5 – 10000 Amp
(CURRENT (OVER CURR THRESHOLD)
MONITOR) Over-current Delay
1 – 600 sec
(OVER CURR DELAY)
CT Correction Factor 0.900 – 1.100
CT Location On Load Cable/On Alt
(CT LOCATION) Output Cable
Generator Rating
0 – 8000 kW
(GEN RATING)
None/Notification/
Over-load Action
Warning/Electrical Trip/
(OVERLOAD ACTION)
Shutdown
Over-load Threshold
50 – 150 %
(OVERLOAD THRESHOLD)
Over-load Monitoring Delay
1 – 600 sec
(OVERLOAD MON DELAY)
Load
None/Notification/
Monitoring Unbalanced Load Action
Warning/Electrical Trip/
(LOAD (UNBAL LOAD ACTION)
Shutdown
MONITOR)
Unbalanced Load Threshold
5 – 200 %
(UNBAL LOAD THRESHOLD)
Unbalanced Load Delay
1 – 600 sec
(UNBAL LOAD DELAY)
Extended Over-load Trip
Disable/Enable
(EXT OL TRIP)
Ext Over-load Trip Threshold
(EXT OL THRESHOLD) 50 – 150 %
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SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Mains Monitoring Enable
Disable/Enable
(MAINS MONITORING)
Mains AC system
1 Phase/3 Phase
(MAINS AC SYSTEM)
Configuration
Phase Reversal Detection
(MAINS Disable/Enable
(PHASE REVERSE DETECT)
CONFIG)
Phase Reversal Action
None/Notification
(PHASE REVERSE ACTION)
Partial Healthy Detection
Disable/Enable
(PARTL HLTHY DETECT)
Under-voltage
No/Yes
Under-voltage (ENABLE)
Monitoring Trip
50 – 298 Volt Ph-N
(UNDER VOLT (TRIP)
MON) Return
52 – 300 Volt Ph-N
(RETURN)
Mains Over-voltage
No/Yes
(MAINS) Over-voltage (ENABLE)
Monitoring Trip
102 – 350 Volt Ph-N
(OVER VOLT (TRIP)
MON) Return
100 – 348 Volt Ph-N
(RETURN)
Under-frequency
Under- No/Yes
(ENABLE)
frequency
Trip
Monitoring 10.0 – 59.0 Hz
(TRIP)
(UNDER FREQ
Return
MON) 11.0 – 60.0 Hz
(RETURN)
Over-frequency
No/Yes
Over-frequency (ENABLE)
Monitoring Trip
26.0 – 75.0 Hz
(OVER FREQ (TRIP)
MON) Return
25.0 – 74.0 Hz
(RETURN)
Start Attempts
1–9
(START ATTEMPTS)
Disconnect On Oil Pressure
Sensor Disable/Enable
(DISCONN ON LOP SENS)
Pressure Sensor Monitoring
Threshold 0.5 – 10.0 bar
(DISCONN LOP THRESH)
Monitor Pressure Switch Before
Crank Crank Disable/Enable
Engine Disconnect (MON LLOP BEFR CRANK)
(ENGINE) (CRANK Monitor Pressure Sensor Before
DISCON) Crank Disable/Enable
(MON LOP BEFR CRANK)
Disconnect On Oil Pressure
Switch Disable/Enable
(DISCONN ON LLOP SW)
Pressure Switch Transient Time
0.0 – 3.0 sec
(LLOP SW TRANS TIME)
Crank Disconnect At Alt
Frequency 10 – 70 Hz
(DISCONN AT ALT FREQ)
Page 36 of 76
SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Crank Disconnect At Engine
Speed 150 – 4000 rpm
(DISCONN AT ENG SPEED)
Disconnect On Charging Alt
Voltage Disable/Enable
(DISCONN ON CA VOLT)
Charging Alt Disconnect Volt
Threshold 5.0 – 30.0 volt
(CHG ALT VOLT THRESH)
Engine Speed Sense Source Magnetic Pickup/
(SPEED SENSE SOURCE) Alternator frequency
Flywheel Teeth
1 – 300
(FLYWHEEL TEETH)
Under-speed Shutdown
Disable/Enable
(UNDER SPEED SHUTDOWN)
Speed Under-speed Threshold
0 – 3600 rpm
Monitoring (UNDER SPD THRESHOLD)
(SPEED Under-speed Delay
1 – 60 sec
MONITOR) (UNDER SPD DELAY)
Over-speed Threshold
700 – 4000 rpm
(OVER SPD THRESHOLD)
Over-speed Delay
1 – 20 sec
(OVER SPEED DELAY)
Gross Over-speed Threshold
100 – 200 %
(GROSS OS THRESHOLD)
None/Notification/
Low Battery Voltage Action
Warning/Electrical Trip/
(LOW VOLT ACTION)
Shutdown
Low Battery Voltage Threshold
8.0 – 31.0 volt
(LOW VOLT THRESHOLD)
Battery Low Battery Voltage Delay
5 – 1800 sec
Monitoring (LOW VOLT DELAY)
(BATTERY None/Notification/
High Battery Voltage Action
MONITOR) Warning/Electrical Trip/
(HIGH VOLT ACTION)
Shutdown
High Battery Voltage Threshold
9.0 – 32.0 volt
(HIGH VOLT THRESHOLD)
High Battery Voltage Delay
5 – 1800 sec
(HIGH VOLT DELAY)
None/Notification/
Charging Alternator Fail Action
Charging Warning/Electrical Trip/
(FAIL ACTION)
Alternator Shutdown
Monitoring Charging Alternator Fail
(CHARGE ALT Threshold 0.0 – 35.0 volt
MON) (FAIL THRESHOLD)
Charging Alternator Fail Delay
5 – 60 sec
(FAIL DELAY)
Preheat Timer
1 – 900 Sec
(PREHEAT TIMER)
Preheat Engine Temperature
Disable/Enable
(PREHEAT) (ENG TEMPERATURE)
Engine Temperature Threshold
10 – 300 ̊C
(ENG TEMP THRESH)
Maintenance Maintenance Alarm Action
Notification/Warning
(MAINTENANCE) Alarm (ACTION)
Page 37 of 76
SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
(MAINT Due At Engine Hours
10 – 65000 hour
ALARM) (DUE AT ENGINE HOURS)
Alarm Due
Date
Alarm Due Date DD/MM/YYYY
(ALARM DUE
DATE)
Actuator Application As E-Governor/As Start /
(ACTUATOR APPLN) Stop Device
General Actuator Speed
1 – 10 x 25 Hz
(GENERAL) (ACTUATOR SPEED)
Actuator Direction (Clockwise/Anti–
(ACTUATOR DIRECTION) Clockwise) to stop
Cranking steps
50 – 5000
(CRANKING STEPS)
Initial Low Speed Delay
0 – 180 sec
(INIT LOW SPEED DELAY)
Engine Start Initial Low Speed
500 – 1800 RPM
Strategy (ENG (INIT LOW SPEED)
START PID Trigger Speed
20 – 2800 RPM
STRGY) (CRANK SENSE SPEED)
Ramp Up Time
1 – 180 sec
(RAMP UP TIME)
PID On Time
1 – 180 sec
(PID ON TIME)
Fixed (0% Droop)/Speed
Set Speed Selection
Bias Input (0-5 V)/Load
(SET SPEED SELECTION)
Based Droop
Droop
0–4%
Rotary Actuator (DROOP)
(ROTARY Target Speed
500 – 4000 RPM
ACTUATOR) (TARGET SPEED)
Proportional Gain (Kp)
0 – 1000
Generator (PROPORTIONAL GAIN)
EGov Integral Gain (Ki)
0 – 2000
Configuration (INTEGRAL GAIN)
(GEN EGOV Derivative Gain (Kd)
0 – 1000
CNFG) (DERIVATIVE GAIN)
Friction Setoff
0 – 1000
(FRICTION SETOFF)
Gain Schedule Trigger
0.0 – 100.0 %
(GAIN SCHEDULE TRIGGER)
Loading Factor
0 – 1000
(LOADING FACTOR)
Unloading Factor
0 – 1000
(UNLOADING FACTOR)
Target Speed
500 – 4000 RPM
(TARGET SPEED)
Proportional Gain (Kp)
0 – 1000
Engine EGov (PROPORTIONAL GAIN)
Configuration Integral Gain (Ki)
0 – 2000
(ENG EGOV (INTEGRAL GAIN)
CNFG) Derivative Gain (Kd)
0 – 1000
(DERIVATIVE GAIN)
Friction Setoff
0 – 1000
(FRICTION SETOFF)
Page 38 of 76
SEDEMAC
Level 1 (On
Level 0 Level 2 (On screen) * Parameters (On screen)
screen)
Gain Schedule Trigger
0.0 – 100.0 %
(GAIN SCHEDULE TRIGGER)
Loading Factor
0 – 1000
(LOADING FACTOR)
Unloading Factor
0 – 1000
(UNLOADING FACTOR)
Start/Stop
Configuration Running Steps
0 – 500
(STR/STP DEV (RUNNING STEPS)
CNFG)
Miscellaneous
PASSWORD 1 #### 0 – 9 for each digit
Settings
(MISC
PASSWORD 2 #### 0 – 9 for each digit
SETTINGS)
Run Time
(In hours)
(RUN TIME)
Number Of Starts
(In numbers)
(NO. OF STARTS)
Genset
No Of Trips
(GENSET) (In numbers)
(NO. OF TRIPS)
Reset Counters ENG kWh (In kWh)
(RESET
ENG kVAh (In kVAh)
COUNTERS)
ENG kVArh (In kVArh)
Run Time
(In numbers)
(RUN TIME)
Mains
MAINS kWh (In kWh)
(MAINS)
MAINS kVAh (In kVAh)
MAINS kVArh (In kVArh)
Page 39 of 76
SEDEMAC
Digital Input Sources Selection
Following table gives a brief overview of selection criteria for digital input sources
Table 21: Digital input sources selection
# Source (On screen)
1 Not Used
2 User Configured
4 Low Lube Oil Pressure Switch (Low Lube Oil Press Switch)
7 Emergency Stop
9 Simulate Start
10 Simulate Stop
11 Simulate Auto
14 Simulate Mains
Page 40 of 76
SEDEMAC
Digital Output Source Selection
Following table gives a brief overview of selection criteria for digital output source
Table 26: Digital output source selection
# Output source (On screen)
1 Disable
2 Sounder Alarm
9 Mains Failure
10 Common Alarm
12 Common Shutdown
13 Common Warning
14 Cooling Down
23 Emergency Stop
24 Stop Solenoid
25 Fail To Start
26 Fail To Stop
27 Fuel Relay
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SEDEMAC
# Output source (On screen)
47 Start Relay
51 Maintenance Due
52 Stop Mode
53 Auto Mode
54 Manual Mode
55 Preheat Output
Page 42 of 76
SEDEMAC
Module Operation
There are two modes of operation
• Auto Mode
• Manual Mode
Auto Mode
To enter Auto mode press “AUTO” key. The controller can be used in two configurations while in Auto
mode.
• Auto Mains Failure (AMF)
• Remote start/stop
• Cyclic mode
• Auto Exercise
Page 43 of 76
SEDEMAC
Page 44 of 76
SEDEMAC
Remote start/stop
To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote
start/stop, and put the controller in the Auto mode provided mains monitoring should be disabled.
In this mode, the genset can be commanded to start and stop by continuously activating/deactivating
the preconfigured Remote start/stop input. The controller will latch genset contactor when controller
confirms that all the engine and genset parameters are within the configured thresholds. When the
preconfigured input is deactivated the controller will open the genset contactor.
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SEDEMAC
• In AMF mode, if the mains is unhealthy or cutoff or when the genset is running in Exercise mode,
genset will first run Exercise and then genset will continues to run in AMF mode. Load will be
transferred on genset even if Load Transfer is disabled in Exercise. Genset will exit from AMF
mode when the mains become healthy.
• If both exercises are scheduled at the same time, then Start time for second exercise will be
incremented by 1 min.
Cyclic mode
This mode is used for running the genset for a pre-specified time for a cycle of max 12 hours each.
The time of genset to be kept ON & OFF is configurable.
Mains is being monitored in this mode. Load is on mains when mains is healthy. If mains is detected
unhealthy, genset will start for DG ON time. Genset contactor will get latched when the genset is
healthy and the warm up time is elapsed. After completion of the ON time, genset will be shutdown
taking cooling down time. Then controller will start DG off time.
After completion of DG OFF time, DG ON time will start and this cycle will continue until mains is
detected healthy. During any of the times, if mains is detected healthy, both the timers are reset to
zero and load will shift to mains after taking return delay. This process continues in cyclic mode.
Page 46 of 76
SEDEMAC
Page 47 of 76
SEDEMAC
Manual Mode
Page 48 of 76
SEDEMAC
Paralleling Mode
GC800 controller offers unique feature of electronic governing for engines with mechanical fuel
systems. In conjunction with the external Load Sharing Module, GC800 controller can control speed of
engine and supports genset synchronisation and paralleling feature.
The Electronic speed governing (E-governor) system is especially applicable to engines used in genset.
This system provides precise, fast-acting control of engine speed. This system can be configured in
Isochronous mode or Paralleling mode. In paralleling mode of operation, the system maintains the
speed in accordance to the speed reference signal provided by supervisory control/Load Sharing
Module (LSM).
Paralleling concept
Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then
connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset
must match within prescribed limits before they can be paralleled. By considering linear relation
between speed of the engine and frequency of the alternator output, the speed must be controlled until
the genset is paralleled with the grid or other genset with the help of electronic governor. A Load
Sharing Module controls the speed and the voltage of the genset by controlling the AVR and E-governor
of the genset. To control these two devices the LSM provides the DC analog voltage signal to the both
devices. The analog voltage signal is generally in the range of 2.5V ±2V.
Paralleling mode
In case of paralleling mode operation of the genset, the E-governor module present in the GC800
controller accepts speed reference (speed bias) signal in terms of 2.5V ±2V analog DC voltage from the
supervisory LSM (Load sharing module).
Following is the stepwise procedure for configuring the GC800 for paralleling operation.
• Select the Governing Mode as PID. Select Set Speed Selection as “Speed Bias”
• Provide 2.5V ±2V analog signal from the LSM to GC800 controller at terminal no. 23, as a
speed reference signal (Refer figure 18)
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SEDEMAC
Alarms
GC800 controller allows to configure several Shutdown/Electrical trip, Warning and Notification alarms
such as Low Oil Pressure Shutdown, Over Load Warning and many more.
An alarm condition occurs when the preconfigured parameter is out of pre-set level. On initiation of an
alarm, the Alarm LED will start blinking and Sounder alarm will be activated if configured. The controller
will display name of alarms along with count on ALARMS screen and the nature of alarm on ENGINE
STATUS screen. For acknowledging the alarms, press “UP + DOWN” keys simultaneously. All the
alarms will be activated at the end of Safety Monitoring Start Delay duration. The controller will not
issue the start command if the Shutdown alarm left unacknowledged. Table 27 shows the types of
alarms action whereas table 28 shows types of alarms. Please refer the tables 27 and 28.
Table 27: Alarm actions
# Alarm Actions Description
1 Notification Controller will display message on the display screen and this will not
affect the genset start stop operation.
2 Warning Warning alarms serves to draw operator's attention to an undesirable
condition without affecting genset's operation in genset ON condition.
The genset cannot be started without acknowledging the warning alarms.
3 Electrical trip In this alarm action type load is taken off from the genset, engine cooling
timer begins, after which genset is stopped.
4 Shutdown In this alarm action type load is taken off from the genset and the genset is
immediately stopped by skipping Engine Cooling Time.
5 Low Fuel Level Indicates that the amount of fuel level is below the pre- Shutdown
Switch set threshold Warning
Electrical trip
Notification
6 Low Water Level Indicates that radiator water level is below the pre-set Shutdown
Switch threshold Warning
Electrical trip
Notification
7 Auxiliary Configured auxiliary input has triggered longer than pre- Shutdown
Input/user set duration Warning
defined name
Electrical trip
Notification
8 Anlg LOP Ckt The oil pressure sensor is detected as not being present Warning
Open
9 Engine Temp Ckt The temperature sensor is detected as not being present Warning
Open
10 Fuel Level Ckt The fuel level sensor is detected as not being present Shutdown
Open
11 Fuel Theft The fuel consumption has exceeded the pre-set Warning
threshold
12 Emergency Stop Configured as digital input has triggered longer than pre- Shutdown
set duration or when the immediate shutdown is required
13 Fail To Stop Indicates that genset has not stopped after sending Stop Shutdown
command
14 Fail To Start Indicates that genset has not started after the pre-set Shutdown
number of Start attempts
15 R Phase Over Indicates that genset L1(R) Phase voltage has exceeded Shutdown
Voltage the pre-set over voltage threshold. Warning
16 Y Phase Over Indicates that genset L2(Y) Phase voltage has exceeded Shutdown
Voltage the pre-set over voltage threshold Warning
17 B Phase Over Indicates that genset L3(B) Phase voltage has exceeded Shutdown
Voltage the pre-set over voltage threshold Warning
18 R Phase Under Indicates that genset L1(R) Phase voltage has fallen Shutdown
Voltage below pre-set under voltage threshold. Warning
19 Y Phase Under Indicates that genset L2(Y) Phase voltage has fallen Shutdown
Voltage below pre-set under voltage threshold Warning
20 B Phase Under Indicates that geset L3(B) Phase voltage has fallen Shutdown
Voltage below pre-set under voltage threshold Warning
21 DG Phase Alternator phase sequence (R-Y-B) is not correct Shutdown
Reversal Warning
Electrical trip
Page 51 of 76
SEDEMAC
Sr. Alarms Causes Action options
No.
Notification
22 Over Frequency Indicates that genset output frequency has exceeded the Shutdown
pre-set threshold Warning
23 Under Frequency Indicates that genset output frequency has fallen below Shutdown
the pre-set threshold Warning
24 Over Current Indicates that genset current has exceeded the pre-set Shutdown
shutdown threshold Warning
Electrical trip
25 Over Load Indicates that the measured kW load rating has Shutdown
exceeded the pre-set threshold Warning
Electrical trip
26 Unbalanced Load on any phase is greater or less than other phases Shutdown
Load by a threshold value Warning
Electrical trip
Notification
27 Over Speed Indicates that genset speed has exceeded the pre-set Shutdown
over speed threshold
28 Gross over Indicates that genset speed has exceeded the pre-set Shutdown
speed gross over speed threshold (This threshold is
configurable percentage value of over speed threshold)
30 Under Speed The engine speed has fallen below the pre-set RPM Shutdown
31 Extended Over Indicates that there was 100% load on the genset for one Electrical trip
Load Trip hour in the time interval of 12 hours
32 Charge Fail The charging alternator voltage has dropped below the Shutdown
supply voltage Warning
Notification
33 V-Belt Broken Indicates that there is failure of the V-belt, which is Shutdown
Switch driving the charging alternator Warning
Electrical trip
Notification
34 Battery Under The battery voltage has fallen below the pre-set Shutdown
Voltage threshold Warning
Electrical trip
Notification
35 Battery Over The battery voltage has exceeded the pre-set threshold Shutdown
Voltage Warning
Electrical trip
Notification
36 Filter Indicates that engine running hours has exceeded the Warning
Maintenance pre-set hours limit or maintenance due date has Notification
occurred and filter servicing is required.
37 Mains Phase Indicates the mains unhealthy condition Notification
Page 52 of 76
SEDEMAC
Sr. Alarms Causes Action options
No.
Reversal
38 High Oil Indicates that the oil pressure measured is above the Shutdown
Pressure Sensor pre-set threshold Warning
39 High Oil Indicates that the oil pressure measured is above the Shutdown
Pressure Switch pre-set threshold Warning
Electrical trip
Notification
Page 53 of 76
SEDEMAC
Troubleshooting
Table 29: Common faults and their remedial actions
Sr. Faults Remedial Actions
No.
1 The controller does not power ON. • Check the battery voltage.
• Check the fuse on the battery supply.
• Check continuity between battery positive and
controller terminal # 2.
• Check continuity between battery ground and
controller terminal # 1.
2 The controller fails to crank-start • Check the battery voltage.
the engine. • Enter “configuration mode” in controller and verify the
configuration for the “START” output. Also, check that
“START” output is working correctly by measuring its
output voltage.
• Enter “configuration mode” in controller and verify the
configuration of “CRANK DISCONNECT” method.
• Verify the configuration of “LLOP SWITCH” polarity.
Also, ensure that the 3+2n/4+2n switch & sensor are
working OK. Check their wiring.
3 The “Emergency Stop” alarm • Check if the “Emergency Stop” switch is working OK.
comes up even when the Check its wiring also.
“Emergency Stop” is not pressed. • Enter “configuration mode” in controller and verify the
configuration of “EMERGENCY STOP” polarity.
4 The controller generates • Check the respective switch/sensor and wiring.
unnecessary “Shutdown Alarms” or • Enter “configuration mode” in the controller and verify
“Warning Alarms” the respective threshold configuration.
5 The controller reports “Charge Fail” • To check if the controller's charging alternator terminal
alarm. is working or not:
I. Disconnect the charging alternator wiring to the
controller's terminal # 7.
II. Short the terminal # 7 to the ground through a DC
ammeter.
III. Crank-start the engine. The DC ammeter should
indicate the current in the range 200 - 400 mA for
~30 seconds.
IV. If yes, the controller's charging alternator terminal is
working OK.
• Disconnect and re-connect the charging alternator and
connection to the controller's terminal # 7.
• Check if the charging alternator is working OK or not.
6 *The governor Actuator chatters • Enter the “configuration mode” in the controller and
even after the engine stops. verify the configuration for the LLOP and LOP. Check
The controller shows genset “ON” their wiring also.
while genset is at rest. • Ensure that the mains voltage wiring is not connected
“Fail to Stop” alarm when genset is by mistake to the controller's genset voltage terminals.
at rest.
Page 54 of 76
SEDEMAC
Sr. Faults Remedial Actions
No.
7 The controller issues unnecessary • Ensure that the controller's output terminal is not
“crank-start” command immediately directly connected to the starter relay. The controller's
after power on. output should be given to an intermediate relay which
should in-turn power the starter relay. The controller
can get permanently damaged and will need to be
replaced if this precaution is not taken.
• Check start-relay connection with the suitable
controller terminal.
• Enter “configuration mode” in the controller and verify
the configuration for “START MODE” and the “START
RELAY” output polarity.
8 The engine runs, but the controller • **Check if the MPU signal (if used), and main
shows genset to be “OFF”. alternator voltage signal (R phase) are received by the
controller terminals.
• Check if the LOP and LLOP are working OK. Also
check their wiring to the controller.
9 The controller displays incorrect PF • Check wiring of the respective alternator phase
value or kW or load current. voltage and the CT to the controller.
• Check the CT ratio (if kW or current reading is faulty).
10 The controller displays incorrect • Check the wiring of the respective phase to the
mains voltage or incorrect main controller.
alternator voltage. • If the problem is not resolved, replace the controller
and try again.
11 Controller displays incorrect • Check respective sensor and its wiring.
reading for any of LOP, Fuel Level, • Enter “configuration mode” in the controller and verify
Temperature sensors. the calibration for the respective sensor in
configuration.
12 The controller displays incorrect • **Check the MPU connection and configuration (if
engine RPM. enabled).
• Check wiring of the main alternator’s R-phase and
neutral to the controller.
13 The controller screen freezes or • Reset the controller power.
hangs up.
Possible Issues in AUTO Mode
14 The controller does not start the • Check the wiring of the “Remote Start” signal to the
engine even when a “Remote Start” controller's respective digital input terminal.
command is sent from an external • Enter “configuration mode” in the controller and verify
device such as a telecom PIU. the configuration for the “Remote Start” digital input
terminal.
• Check that the controller is in “Auto” mode.
15 Controller does not stop engine • Check the wiring of the “Remote Stop” signal to the
even when a “Remote Stop” controller's respective digital input terminal.
command is sent from an external • Enter “configuration mode” in the controller and verify
device such as a telecom PIU. the configuration for the “Remote Stop” digital input
terminal.
• Check that the controller is in “Auto” mode.
Page 55 of 76
SEDEMAC
Sr. Faults Remedial Actions
No.
16 While in Auto mode, controller • Check the wiring of the mains R, Y and B phase to the
issues “Start” command even if the controller's respective input terminal.
mains present. • Enter “configuration mode” in the controller and verify
the configuration for the “MAINS MONITORING”.
Possible Issues with Electronic Governing
17 The controller dose not maintain • Check the wiring of the “SEDEMAC's Actuator” to the
the target RPM. controller's terminal.
The engine RPM is not stable or • Check if the mechanical linkage assembly is OK.
engine hunts. • Enter “configuration mode” in the controller and verify
The controller cranks the engine the configuration for “GOVERNOR”. Also, check the
but does not start the engine. PID control gains.
• Check that the Actuator moves to full throttle position
when the engine is cranked.
Page 56 of 76
SEDEMAC
Communications Protocol
Introduction to Communication Protocol
GC800 genset controller support two communication protocols: a custom protocol based on MODBUS
over a RS485 layer and a custom protocol over a CAN layer.
Connection Details
The RS485 port on GC800 controller supports the MODBUS RTU protocol.
The format for communication of each byte is as follow:
1 start bit, 8 data bits, least significant bit sent first, 1 parity bit for even/odd parity; no parity bit for no
parity, 1 stop bit, Cyclical Redundancy Check (CRC).
Figure 21: RS485 MODBUS connection with the help of two core shielded twisted pair cable
The transmission mode used by GC800 controller is MODBUS RTU (not
MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits,
with/without parity bit and 1 stop bit. The baud rate is selectable between 1200
kbps to 115200 kbps through the configuration options. Similarly, the slave ID
can be selected through the configuration options.
RS485 MODBUS communication configuration setting is as shown in Table 30
Table 30: RS485 MODBUS communication configuration setting
RS485 Communication
Slave ID 1-247
Baud Rate (bps) 1200/2400/4800/9600/19200/38400/57600/115200
Parity None/Even/Odd
Stop Bit 1, 2
SEDEMAC GC800 genset controller operates as a MODBUS slave that responds to certain commands
received from the MODBUS master.
RS485 MODBUS communication is initiated by a Master with a query to a Slave. The Slave which is
constantly looking for Queries from master will recognise only the Queries addressed to it and will
respond either by performing an action or by returning a response. Only the Master can initiate a query.
Page 57 of 76
SEDEMAC
Precautions
• Keep the slave ID of the GC800 controller and SMPS same, take the slave ID from the SMPS
and configure the same ID in GC800.
• Enable the GC800 in the configuration of the SMPS after hardware connections are made, so
the SMPS can communicate with the GC800.
• Connect the Pin # 16 & 15 (A & B) of the GC800 to the pin # A & B of the SMPS respectively
and not with any other pin.
• Use two core shielded cable for connection.
• Use different colour wires for Pin # 16 & 15 (A & B) for easy detection and connection.
• Route the Pin # 16 & 15 (A & B) wires properly ensuring they do not get short with any other
wires.
• Do not use multi strand wires for the connection
Supported functions and respective command-response structure is as shown below. If the command
received from the MODBUS master is other than the three functions mentioned below, an exception
message is generated.
2 First register address – high byte 16-bit register address, register address map
is described in Table 38
3 First register address – low byte
4 Number of registers to read – high byte Number of registers to read must be between
1 to 255
5 Number of registers to read – low byte
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SEDEMAC
Table 33: Normal response from genset controller slave for Function 4
Byte Field Remarks
... ...
2 First register address – high byte 16-bit register address, register address map
is described in Table 38
3 First register address – low byte
4 Number of registers to write – high byte Number of registers to write must be between
1 to 255
5 Number of registers to write – low byte
... ...
Table 35: Normal response from genset controller slave for Function 16
Byte Field Remarks
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SEDEMAC
2 First register address – high byte 16-bit register address, register address map
is described in Table 38
3 First register address – low byte
4 Number of registers written – high byte Number of registers that have been written
2 First register address – high byte 16-bit register address, register address map
is described in Table 38
3 First register address – low byte
4 Number of registers to read – high byte Number of registers to read must be between
1 to 255
5 Number of registers to read – low byte
6/7 Error check CRC
Table 37: Normal response from genset controller slave for Function 3
Byte Field Remarks
... ...
1+n Last register – high byte
Register Map
The register map for input registers is as shown in Table 38
Page 60 of 76
SEDEMAC
Table 38: Register map for input registers
Register
Value for GC800 Scale Factor Unit /Interpretation Bits/ Sign
Offset
Protocol revision 0 - - Unsigned
Generator L1-n voltage 1 0.1 V Unsigned
Generator L2-n voltage 2 0.1 V Unsigned
Generator L3-n voltage 3 0.1 V Unsigned
Generator L1-L2 voltage 4 0.1 V Unsigned
Generator L2-L3 voltage 5 0.1 V Unsigned
Generator L3-L1 voltage 6 0.1 V Unsigned
Generator R frequency 7 0.1 Hz Unsigned
Generator Y frequency 8 0.1 Hz Unsigned
Generator B frequency 9 0.1 Hz Unsigned
Generator power factor L1 10 0.01 -- Unsigned
Generator power factor L2 11 0.01 -- Unsigned
Generator power factor L3 12 0.01 -- Unsigned
Generator average power 13 0.01 -- Unsigned
factor
Mains L1-n voltage 14 0.1 V Unsigned
Mains L2-n voltage 15 0.1 V Unsigned
Mains L3-n voltage 16 0.1 V Unsigned
Mains L1-L2 voltage 17 0.1 V Unsigned
Mains L2-L3 voltage 18 0.1 V Unsigned
Mains L3-L1 voltage 19 0.1 V Unsigned
Mains R frequency 20 0.1 Hz Unsigned
Mains Y frequency 21 0.1 Hz Unsigned
Mains B frequency 22 0.1 Hz Unsigned
Load L1 current 23 0.1 A Unsigned
Load L2 current 24 0.1 A Unsigned
Load L3 current 25 0.1 A Unsigned
Load L1 watts 26 0.1 KW Unsigned
Load L2 watts 27 0.1 KW Unsigned
Load L3 watts 28 0.1 KW Unsigned
Load total watts 29 0.1 KW Unsigned
Load L1 va 30 0.1 KVA Unsigned
Load L2 va 31 0.1 KVA Unsigned
Load L3 va 32 0.1 KVA Unsigned
Load total va 33 0.1 KVA Unsigned
Load L1 var 34 0.1 KVAR Unsigned
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Register
Value for GC800 Scale Factor Unit /Interpretation Bits/ Sign
Offset
Load L2 var 35 0.1 KVAR Unsigned
Load L3 var 36 0.1 KVAR Unsigned
Load total var 37 0.1 KVAR Unsigned
Generator cumulative en- 38-39 1 KW Unsigned
ergy
Generator cumulative ap- 40-41 1 KVA Unsigned
parent energy
Generator cumulative reac- 42-43 1 KVAR Unsigned
tive energy
Mains cumulative energy 44-45 1 KW Unsigned
Mains cumulative apparent 46-47 1 KVA Unsigned
energy
Mains cumulative reactive 48-49 1 KVAR Unsigned
energy
Oil pressure 50 0.1 Bar Unsigned
Coolant temperature 51 0.1 Deg C Unsigned
Fuel level 52 1 % Unsigned
Charge alternator voltage 53 0.1 V Unsigned
Battery voltage 54 0.1 V Unsigned
Engine speed 55 1 RPM Unsigned
No of starts 56 1 -- Unsigned
No of trips 57 1 -- Unsigned
Eng run hrs 58 1 Hrs Unsigned
Eng run min 59 1 Min Unsigned
Mains run hrs 60 1 Hrs Unsigned
Mains run min 61 1 Min Unsigned
Alarm 1 62
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Radiator water level / low -- -- 5/16-8/16
fuel level
Resevred / Radiator water -- -- 1/16-4/16
level switch
-- --
Alarm 2 63
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
Page 62 of 76
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Register
Value for GC800 Scale Factor Unit /Interpretation Bits/ Sign
Offset
Alarm 3 64
Generator low voltage / re- -- -- 13/16-16/16
served
Generator high voltage / re- -- -- 9/16-12/16
served
Generator low frequency -- -- 5/16-8/16
Generator high -- -- 1/16-4/16
-- --
Alarm 4 65
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
Alarm 5 66
Charge alternator failure -- -- 13/16-16/16
Oil filter maintenance / filter -- -- 9/16-12/16
maintenance
Fuel filter maintenance / re- -- -- 5/16-8/16
served
Air filter maintenance /re- -- -- 1/16-4/16
served
Alarm 6 67
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- -- 9/16-12/16
Oil pressure circuit open -- -- 5/16-8/16
engine temperature Circuit
open
Reserved -- -- 1/16-4/16
-- --
Alarm 7 68
Fuel theft -- -- 13/16-16/16
Magnetic pick up fault -- -- 9/16-12/16
Extended over load trip / oil -- -- 5/16-8/16
pressure circuit
Reserved -- -- 1/16-4/16
Alarm 8 69
Auxiliary input a -- -- 13/16-16/16
Auxiliary input b -- -- 9/16-12/16
Auxiliary input c -- -- 5/16-8/16
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Register
Value for GC800 Scale Factor Unit /Interpretation Bits/ Sign
Offset
Auxiliary input d -- -- 1/16-4/16
Alarm 9 70
Auxiliary input e -- -- 13/16-16/16
Auxiliary input f -- -- 9/16-12/16
Auxiliary input g -- -- 5/16-8/16
Auxiliary input h -- -- 1/16-4/16
Alarm 10 71
Gen L1 phase low volt -- -- 13/16-16/16
Gen L1 phase high volt -- -- 9/16-12/16
Gen L2 phase low volt -- -- 5/16-8/16
Gen L2 phase high volt -- -- 1/16-4/16
Alarm 11 72
Gen L3 phase low volt -- -- 13/16-16/16
Gen L3 phase high volt -- -- 9/16-12/16
Dg phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
Alarm 12 73 --
Open fuel level -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Extended over load trip -- -- 5/16-8/16
High oil pressure detected -- -- 1/16-4/16
Input output diagnostics 74
Digital input a -- -- 16/16
Digital input b -- -- 15/16
Digital input c -- -- 14/16
Digital input d -- -- 13/16
Digital input e -- -- 12/16
Digital input f -- -- 11/16
Digital input g -- -- 10/16
Digital input h -- -- 9/16
Digital output a -- -- 8/16
Digital output b -- -- 7/16
Digital output c -- -- 6/16
Digital output d -- -- 5/16
Digital output e -- -- 4/16
Digital output f -- -- 3/16
Page 64 of 76
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Register
Value for GC800 Scale Factor Unit /Interpretation Bits/ Sign
Offset
Unimplemented -- -- 2/16
Unimplemented -- -- 1/16
Dg status 75
Load on dg -- True (1)/False (0) 16/16
Current dg status -- Running/Stop 15/16
Dg stopped normally -- True (1)/False (0) 14/16
Dg stopped with fault -- True (1)/False (0) 13/16
Dg mode -- Auto/Manual 12/16
Common shutdown -- -- 10/16
Common electric trip -- -- 9/16
Common warning -- -- 8/16
Common notification -- -- 7/16
Unimplemented -- -- 6/16-1/16
Command status 76 -- One of the Unsigned
following:
DG Started (1)
DG Stopped (2) DG
already On (3)
DG already Off (4)
DG in manual
Mode (5)
DG Not started(6)
Actual value = Observed value on MODBUS interface multiplied with scale factor
The interpretation of alarm status (registers 54-69 in Table 38) is as shown in Table 40.
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Table 40: Interpretation of alarm status results
Value of Register Interpretation
0 Alarm disabled
5 Notification
6 – 14 Reserved
15 Unimplemented
Connection Details
Baud rate used for communication is 250 kbps. The ID of the controller is fixed to 0x01. ID scheme for
CAN communication is Standard ID (not extended ID). Packet size used for communication is 8 bytes.
Structure of Communication
The controller continuously broadcasts measurement values, status of alarms/commands and derived
computations. Additionally, a set of commands can be sent to the controller. Response to the commands
is a part of the data that is broadcasted. Table 42 shows the structure of the broadcasted message.
Table 41: Structure of communication
Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Page 0 Protocol revision 0 - - Unsigned
Generator L1-n voltage 1 0.1 V Unsigned
Generator L2-n voltage 2 0.1 V Unsigned
Page1 Generator L3-n voltage 3 0.1 V Unsigned
Generator L1-L2 voltage 4 0.1 V Unsigned
Generator L2-L3 voltage 5 0.1 V Unsigned
Page2 Generator L3-L1 voltage 6 0.1 V Unsigned
Generator R frequency 7 0.1 Hz Unsigned
Generator Y frequency 8 0.1 Hz Unsigned
Page 3 Generator B frequency 9 0.1 Hz Unsigned
Generator power factor L1 10 0.01 -- Unsigned
Generator power factor L2 11 0.01 -- Unsigned
Page 66 of 76
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Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Page 4 Generator power factor L3 12 0.01 -- Unsigned
Generator average power 13 0.01 -- Unsigned
factor
Mains L1-n voltage 14 0.1 V Unsigned
Page 5 Mains L2-n voltage 15 0.1 V Unsigned
Mains L3-n voltage 16 0.1 V Unsigned
Mains L1-L2 voltage 17 0.1 V Unsigned
Page 6 Mains L2-L3 voltage 18 0.1 V Unsigned
Mains L3-L1 voltage 19 0.1 V Unsigned
Mains R frequency 20 0.1 Hz Unsigned
Page 7 Mains Y frequency 21 0.1 Hz Unsigned
Mains B frequency 22 0.1 Hz Unsigned
Load L1 current 23 0.1 A Unsigned
Page 8 Load L2 current 24 0.1 A Unsigned
Load L3 current 25 0.1 A Unsigned
Load L1 watts 26 0.1 KW Unsigned
Page 9 Load L2 watts 27 0.1 KW Unsigned
Load L3 watts 28 0.1 KW Unsigned
Load total watts 29 0.1 KW Unsigned
Page 10 Load L1 va 30 0.1 KVA Unsigned
Load L2 va 31 0.1 KVA Unsigned
Load L3 va 32 0.1 KVA Unsigned
Page 11 Load total va 33 0.1 KVA Unsigned
Load L1 var 34 0.1 KVAR Unsigned
Load L2 var 35 0.1 KVAR Unsigned
Page12 Load L3 var 36 0.1 KVAR Unsigned
Load total var 37 0.1 KVAR Unsigned
Page 13 Generator cumulative en- 38-39 1 KW Unsigned
ergy
Page 14 Generator cumulative ap- 40-41 1 KVA Unsigned
parent energy
Page 15 Generator cumulative reac- 42-43 1 KVAR Unsigned
tive energy
Page 16 Mains cumulative energy 44-45 1 KW Unsigned
Page 17 Mains cumulative apparent 46-47 1 KVA Unsigned
energy
Page 18 Mains cumulative reactive 48-49 1 KVAR Unsigned
energy
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Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Page 19 Oil pressure 50 0.1 Bar Unsigned
Coolant temperature 51 0.1 Deg C Unsigned
Fuel level 52 1 % Unsigned
Page 20 Charge alternator voltage 53 0.1 V Unsigned
Battery voltage 54 0.1 V Unsigned
Engine speed 55 1 RPM Unsigned
Page 21 No of starts 56 1 -- Unsigned
No of trips 57 1 -- Unsigned
Eng run hrs 58 1 Hrs Unsigned
Page 22 Eng run min 59 1 Min Unsigned
Mains run hrs 60 1 Hrs Unsigned
Mains run min 61 1 Min Unsigned
Page 23 Alarm 1 62
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Radiator water level / low -- -- 5/16-8/16
fuel level
Resevred / Radiator water -- -- 1/16-4/16
level switch
-- --
Alarm 2 63
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
Alarm 3 64
Generator low voltage/re- -- -- 13/16-16/16
served
Generator high voltage/re- -- -- 9/16-12/16
served
Generator low frequency -- -- 5/16-8/16
Generator high -- -- 1/16-4/16
-- --
Page 24 Alarm 4 65
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
Page 68 of 76
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Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Alarm 5 66
Charge alternator failure -- -- 13/16-16/16
Oil filter maintenance/filter -- -- 9/16-12/16
maintenance
Fuel filter maintenance/re- -- -- 5/16-8/16
served
Air filter maintenance/re- -- -- 1/16-4/16
served
Alarm 6 67
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- -- 9/16-12/16
Oil pressure circuit open -- -- 5/16-8/16
engine temperature Circuit
open
Reserved -- -- 1/16-4/16
-- --
Page 25 Alarm 7 68
Fuel theft -- -- 13/16-16/16
Magnetic pick up fault -- -- 9/16-12/16
Extended over load trip/oil -- -- 5/16-8/16
pressure circuit
Reserved -- -- 1/16-4/16
Alarm 8 69
Auxiliary input a -- -- 13/16-16/16
Auxiliary input b -- -- 9/16-12/16
Auxiliary input c -- -- 5/16-8/16
Auxiliary input d -- -- 1/16-4/16
Alarm 9 70
Auxiliary input e -- -- 13/16-16/16
Auxiliary input f -- -- 9/16-12/16
Auxiliary input g -- -- 5/16-8/16
Auxiliary input h -- -- 1/16-4/16
Page 26 Alarm 10 71
Gen L1 phase low volt -- -- 13/16-16/16
Gen L1 phase high volt -- -- 9/16-12/16
Gen L2 phase low volt -- -- 5/16-8/16
Gen L2 phase high volt -- -- 1/16-4/16
Alarm 11 72
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Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Gen L3 phase low volt -- -- 13/16-16/16
Gen L3 phase high volt -- -- 9/16-12/16
Dg phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
Alarm 12 73 --
Open fuel level -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Extended over load trip -- -- 5/16-8/16
High oil pressure detected -- -- 1/16-4/16
Page 27 Input output diagnostics 74
Digital input a -- -- 16/16
Digital input b -- -- 15/16
Digital input c -- -- 14/16
Digital input d -- -- 13/16
Digital input e -- -- 12/16
Digital input f -- -- 11/16
Digital input g -- -- 10/16
Digital input h -- -- 9/16
Digital output a -- -- 8/16
Digital output b -- -- 7/16
Digital output c -- -- 6/16
Digital output d -- -- 5/16
Digital output e -- -- 4/16
Digital output f -- -- 3/16
Unimplemented -- -- 2/16
Unimplemented -- -- 1/16
Dg status 75
Load on dg -- True (1) / False(0) 16/16
Current dg status -- Running / Stop 15/16
Dg stopped normally -- True (1) / False(0) 14/16
Dg stopped with fault -- True (1) / False(0) 13/16
Dg mode -- Auto / Manual 12/16
Common shutdown -- -- 10/16
Common electric trip -- -- 9/16
Common warning -- -- 8/16
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Page No. Value for GC800 Register Scale Unit/ Bits/ Sign
Offset Factor Interpretation
Common notification -- -- 7/16
Unimplemented -- -- 6/16-1/16
Command status 76 -- One of the Unsigned
following:
DG Started (1)
DG Stopped (2)
DG already On (3)
DG already Off (4)
DG in manual
Mode (5)
DG Not started (6)
0 Page ID
7 Reserved
0 Command ID
1 Command parameters
2 Reserved
3 Reserved
4 Reserved
5 Reserved
6 Reserved
7 Reserved
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Packet Structure
Table 44: Structure of command message received over CAN
Command Description Command Parameter (each of 1 Bytes) Bits/ Sign
ID
1 Start-Stop 0x01 - Start DG Unsigned
command 0x02 - Stop DG
Command Status is updated in status register
2 Operating 0x01 - Toggle Current mode of operation between Unsigned
mode change the Auto mode and the Manual mode.
command Auto Mode is to operate DG remotely.
Manual is to operate DG with through key-press
events.
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Notes
Page 73 of 76
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Disclaimer: Due to continuous development, the details provided in this document are
subject to change without any prior notice.
Manufacturing Plant
G-1, MIDC, Phase-III Chakan
Industrial Area, Nighoje
Pune 410501, India
Manufacturing Plant
Survey No. 64/5, Off Sinhagad Road
Vadgaon Budruk, Narhe
Pune 411041, India
Page 74 of 76