Genset Controller GNS-2500 Series

Genset Controller
GNS-2500 Series
Single Applications
■■
Advanced Control &
Monitoring
• Engine Start/Stop Control
• Engine & Generator Monitoring &
Protection
• Remote Monitoring & Alerts
• Comprehensive Metering
• Auto Generator Start at Loss of Mains
■■Expanded Offering of I/O
• 9 Binary Inputs & 9 Outputs
• 2 Form A and 2 Form C Relays
• 4 Versatile ANALOGUE Input that
Support:
VDO, 5VDC, 10VDC, 0-20 mA,
Resistive & Thermocouple
■■Intuitive, Adaptable User
Interface
• Simultaneous Multi-Lingual
Support
• Local, Remote & No Display
Support
• Multiple Security Levels & Panel Lock
• User-friendly SmartVU
Configuration Software
■■High Degree of Connectivity &
Compatibility
• SAE J1939
• MODBUS
• RS-232/485
• SMS support
• Ethernet (Via Serial to Ethernet
Converter)
AMF Genset Controller
GAC’s GNS-2500 Genset Controller Series is a family of highly-flexible genset controllers for
standalone applications that meets all the requirements for AMF functions.
The GNS-2500 Series, designed for both ‘electronic’ and conventional engines, is ruggedly
constructed with simple-to-use microprocessor technology.
GAC’s new controller series provides superior genset control, protection, and metering; all
at a reasonable cost.
The series is available in 3 distinct configurations:
Manufactured by:
Governors America Corp.
1. Black Box – for use with external buttons and gauges.
2. Panel Mount – a conventional one box door-mounted design.
3. Two Box – the Black Box connected by CANbus to a separate control panel
■■Highly Developed Design
• Robust 600V Design
(min. 25% over voltage allowed)
• CE Approved
• NFPA110 Level Compatible
• Industrial Temperature Range
• Resistant to salt fog, humidity, dust,
dirt, and chemical contaminants
• Audible & Tactile F/B on Buttons
for Gloved Fingers
HUEGLI
TECH
SWITZERLAND

Genset Controller
GNS-2500
Description
The GNS-2500 monitors the mains voltage and frequency,
to detect loss of mains power. Once one of these mains
protections is tripped, the GNS will automatically start the
generator, open the MCB, then close the GCB. The MCB
can be configured to open at the immediate loss of mains
or at “generator ready to load”. Upon the return of stable
mains characteristics, the GNS-2500, using user-configurable
timing, will open the GCB then close the MCB. The GNS
is also programmed to provide warnings of impending loss
of mains and a test function.
Programming the GNS-2500 Series with GAC’s enhanced
SmartVU configuration software is both logical and
straightforward. Apart from I/O allocation, all parameters
can also be edited from the (PIN protected) front panel,
without need for a laptop. The controller senses engine
parameters directly via 4 analogue inputs and it can communicate
with the engine’s electronic control unit via J1939
CANbus protocol. The programmable inputs and outputs are
engineered to allow the user to easily customise the operation
as desired.
The GNS-2500 Series has been designed to offer excellent
value by including features which are often considered
‘extras’.
Standard features include:
• 9 programmable inputs and 9 programmable outputs;
• 4 analogue inputs that support a wide range of senders;
• 2 Form A and 2 Form C relays;
• robust electronic protection;
• fixed voltage detection schemes;
• remote control and monitoring;
• up to two built in RS-232/485 ports with expansion for field
service laptop support;
• Modbus and J1939 CANbus interface;
• SMS support; multiple, memory-resident language:
The standard temperature range is -20°C – 85°C but
versions operating down to -40°C are also available.
A cost-effective range of expansion modules is available
including remote Displays, Gauges and Annunciators with
logic control blocks, expandable I/O capabilities and additional
relays, all connected via J1939 CANbus.
As with all GAC products, the GNS-2500 Series can be
easily and cost effectively adapted to provide customised
solutions for OEMs.
Operating Modes
The GNS-2500 Series can be operated in Manual, Auto, or
Test modes, and has a full suite of engine and generator
protections. When in Manual mode, the GNS will start and
stop the engine based on user inputs. In Auto mode, the
GNS will start and stop the engine when failure of the mains
is detected. Test mode allows the user to test the genset
without affecting the normal mains supply to the load. An
Off mode is also included, to lock the controller and prevent
genset operation.
Alarms, Warnings, and Protections
The GNS features alarms and warnings to alert the user
while protecting the generator and engine. All protections
can be individually enabled or disabled. Shutdown conditions
include low oil pressure, low fuel level, high coolant
temperature, under/over speed, under/over voltage, under/
over current, under/over frequency, sensor failures, over
crank, and generator voltage unbalanced.
Engine Control
• Cranking control provides pre-lube, up to 4 pre-start
stages, adjustable number of crank attempts, duration,
pause delay and crank disconnect. Also provided is an
engine start counter.
• Engine timers include cool down, maintenance, pre-crank,
crank and several protections.
• Adjustable protection thresholds and delays for speed, oil
pressure, coolant temperature, and fuel level.
Metering
• Metered generator parameters include line voltage, line
to line voltage, current, frequency, reactive power, power
factor and actual power.
• Metered engine parameters include RPM, oil pressure,
coolant temperature, battery voltage, fuel level, service
hours, run hours, and number of starts. RPM, oil pressure,
and coolant temperature can be integrated via J1939
Inputs
The GNS is equipped with dedicated inputs for mains and
generator voltage, generator current, and a speed sensor.
The unit is also equipped with 4 configurable analogue
inputs and 9 configurable binary inputs. The analogue inputs
allow a wide range of sensors including voltage, current,
and resistive senders. Though easily reconfigured, three of
the analogue inputs are configured for Fuel Level, Engine
Temperature, and Oil Pressure. The GNS-2500 Series can
use J1939 messages for oil pressure, engine speed, and
coolant temperature in combination with the analogue inputs
for control and protection operations, thereby, freeing
up analogue inputs for other sensors.
2
HUEGLI
TECH
SWITZERLAND

Genset Controller
GNS-2500
Outputs
The GNS-2500 Series is equipped with 5 discrete binary
outputs and four relays. The discrete outputs can sink up
to 500mA of current to battery ground and support up to
32VDC. The GNS-2500 Series has four relays, two Form C
and two Form A. Though reconfigurable, the first Form C
relay is configured to control the fuel solenoid, the second
is configured to control the starter. By adding a jumper
(located on the back of the GNS), the fuel relay can be
configured to be directly controlled by the emergency stop
input – when the emergency stop input is activated, power
to the fuel solenoid is removed, thereby depriving the engine
of fuel.
All GNS-2500 Series analogue inputs, binary inputs, relays
and binary outputs assignments can be configured by the
user.
RS232/485, SAE J1939, Ethernet, Modbus
The standard GNS is equipped with a SAE J1939 port and
one serial port. The serial port can be configured for RS232
or RS485 operation. The RS232 can connect the GNS to an
external modem, external I/O, remote display, Ethernet converter
or PC using the industry standard MODBUS protocol.
A factory installed modem can be provided. The modem can
support pager and SMS functions. Note: the GNS-2500BE is
a stand-alone controller equipped with two RS232 ports and
can be operated without a display
Remote Annunciator, Output Relays, &
Programmable Logic
The optional GAC Remote Annunciator (RA20) and Contact
Relay Module (CRM20) provide external programmable
logic and annunciation for the GNS-2500 Series. The RA20 is
equipped with 20 x 3 colour LEDs and can be panel mounted.
The CRM20 is similar to the RA20 with the inclusion 20
Form C relays. Both of these devices have 30 blocks for
logic programming and can source data via Modbus over
two RS-232/485 ports and CANbus.
Start and Stop are used when the GNS is in Manual Mode;
as a safety feature, the GNS is programmed to require the
user to press the Fault Reset to resume operation of the
genset after a protection function has been activated. This
action acknowledges the shutdown condition. The Arrows
and Enter buttons are used to navigate the menu system.
GNS Display Real Time Information
• Operating Mode
• Line Voltage
• Line to Line Voltage
• Current
• Frequency
• Oil Pressure
• Engine Temperature
• Generator State
• Active Alarms and
Warnings
SmartVU
• Binary Inputs
• Binary Outputs
• Analogue Metering
• Power Metering
• Generator Metering
• History
• Power (Real Power, Apparent
Power, Power Factor)
• Mains Voltage
The GNS-2500 Series is configured using the accompanying
SmartVU PC configuration, control and monitoring tool.
This program allows the user to set and modify security,
operating set points, assign I/O, establish warning and alarm
thresholds, and control overall system behavior. Once configured,
the settings can be saved to a file for easy replication.
While connected to a GNS, SmartVU can be used to
monitor genset performance (see Figure 1).
Within SmartVU, the layout of the display is highly customisable.
The user chooses which meters are to be displayed,
and the location on the screen. The screen configuration
can be stored for later use.
SmartVU is capable of simultaneously communicating
with multiple GNS controls, and the layout of the screen is
customisable.
GNS-2500 Display
The GNS-2500 is equipped with a 64 x 128 graphical display,
10 LEDs, 11 buttons (with the exception of GNS-2504BE).
Depending on the configuration the display can support
multiple languages simultaneously. The user can switch
between the languages on the fly.
The LEDs represent Ready/Auto, Not in Auto, Running,
Warning, Supplying Load, Shutdown/Alarm, Mains and
Generator Status and MCB/GCB Open/Close. The display
has 11 contact switches for Start, Stop, Horn Silence, MCB/
GCB Open/Close and Fault Reset buttons, Directional Arrow
Keys, a Back Button and an Enter Button.
3
Figure 1
HUEGLI
TECH
SWITZERLAND

Genset Controller
GNS-2500
Diagram 1. System Wiring/Outline
LB178-2
L S H
CAN
G 8 9 6 G 7 5 2 G 4 3 G G 1
BINARY
ANALOG INPUTS
OUTPUTS
RS232/485
BATTERY
8-32 VDC
+D+
BINARY INPUTS
MAG
P/U
2 3 5 6 8 G +
BO1
RELAYS
BO2 BO3 BO4
G
-
1
4
7
9
-
LB178-3
LB178-1
NOTE:
1. U.O.S. ALL WIRES TO BE 22AWG TWISTED PAIR.
SINGLE LINE BREAKER CONTROL / FEEDBACK SHOWN.
2
L3
L2
18 AWG
N C B A
MAINS VOLTAGE
3
GENERATOR
CURRENT
A G B G C
RS-232 3-WIRE NULL MODEM CABLE.
4
N C B A
GENERATOR VOLTAGE
4
10 amp Fuse
D+
+
12/24VDC
Battery
ALTERNATOR
3
-
REMOTE START/STOP
ESTOP
MAGNETIC
PICK-UP
DIESEL/GAS ENGINE
STARTER
FUEL SOLENOID
MAINS
GENERATOR
G
L3
L2
L1
N
FUEL LEVEL
PRESTART
3
B+
3
3
ENGINE TEMP
OIL PRESSURE
B+
ALARM
READY TO LOAD
N
L1
3
MCB
GCB
2
L
FUEL SOLENOID
STARTER
FUEL LEVEL
ENGINE TEMP
OIL PRESSURE
4
HUEGLI
TECH
SWITZERLAND

Genset Controller
GNS-2500
Specifications
Environmental
Ambient Operating Temperature:
GNS-2504E............................................................Temp:-40 to +85°C
GNS-2502E............................................................Temp:-20 to +85°C
Relative Humidity...........................................95% non-condensing
Agency Approvals...........................................................................CE
Input Parameters
Power..............................................................................8VDC-32VDC
Polarity Negative....................................................................Ground
Speed Sensor Signal..............0.5 – 30 Volts RMS, 30-1200 ohms
9 Assignable Binary Inputs.................................................0-32VDC
4 Analogue Inputs ..........Wide range of senders, includingVDO
.......................(e.g.,OilPressure,CoolantTemp)
......................................5VDC, 10VDC, 0-20mA,
...................................Resistive Thermocouple
Generator Voltage ....................................480VAC RMS Nominal -
...........................600VAC Max phase to phase
........277VAC RMS Nominal phase to neutral
Mains Voltage............................................480VAC RMS Nominal -
...................................600VAC Max phase to phase
................277VAC RMS Nominal phase to neutral
Generator Current (CT Secondary).............................5A Nominal
Output Parameters
2 Form A Relay...................................................250VAC, 30VDC, 3A
2 Form C Relay.................................................125VAC, 28VDC, 12A
5 Binary Outputs..................................................0-32VDC,0-500mA
Display I/O
LEDs........................Ready/Auto, Not in Auto, Running, Warning,
..........................................Supplying Load, Shutdown/Alarm,
....................................................Mains and Generator Status
.......................................................and MCB/GCB Open/Close
Switches.................................Start, Stop, MCB/GCB Open/Close
......................................Horn Silence, Fault Reset, Enter,
...................................... 4Arrows (Up, Down, Left, Right)
Communications
PC Configuration & Monitoring...............Modbus on RS-232/485
ECU...............................................................................................J1939
Remote Devices..............................Modbus on RS-232 or RS-485
Reliability
Vibrations.......................................................................................TBD
Testing......................................................100% Functionally Tested
Physical
Overall Dimensions....................................................6” x 9” x 1.75”
...............................152mm x 229mm x 445mm
Panel Opening Size........................................................4.45” x 6.89”
................................................113mm x 175mm
Weight..........................................................................................1.3lbs
.........................................................................................0.59kg
Mounting.........................................................Front Panel Mounted
GNS-2504BE.....................................................Back Panel/DIN Rail
SmartVU Minimum Requirements
Microsoft Windows 2000-
Windows 7...................................Pentium II, 64M RAM, 10M Disk
...............................................................VGA, Serial Port
Options
• GNS-2502DE & 2504DE Remote Display
• EAM Ethernet Adapter
• GNS-2504BE Black Box Non-Display Control
• External Modem
• Custom Displays (up to 65 LEDs, up to 24 Switches)
• Remote Contact Relay Module
• Remote Annunciator Panel
• Remote Analogue Gauge Drivers
Local Distributor / Partner:
HUEGLI
TECH
SWITZERLAND
HUEGLI TECH AG (LTD)
Murgenthalstrasse 30
4900 Langenthal Switzerland
Phone: +41 62 916 50 30
Fax: +41 62 916 50 35
e-mail: sales@huegli-tech.com
www.huegli-tech.com
GNS-2500_DS_EN_04.2011
Features and specifications are subject to change without prior notice
© HUEGLI TECH