ELECTRONIC MODULAR CONTROL PANEL II+ (EMCP II+) FOR PEEC ENG Caterpillar


Systems Operation

Usage:

Location Of EMCP II+ System Components


Instrument Panel

(1) GSC+; generator set control +.

(2) SP; speed potentiometer. or GS; governor switch (optional).

(3) SAS; start aid switch (optional).

(4) ECS; engine control switch.

(5) ALM; alarm module (optional).

(6) CAM; custom alarm module (optional). or SLM; synchronizing lights module (optional).

(7) PLS; panel light switch (optional).

(8) ESPB; emergency stop push button.

(9) VAR; voltage adjust rheostat.

Most of the EMCP II+ components are located on either the instrument panel or on the sub-panel. Other EMCP II+ components that exist on or near the engine are: engine oil pressure sensor (EOPS), engine coolant temperature sensor (ECTS), engine oil temperature sensor (EOTS) (optional), magnetic speed pickup (MPU) and engine coolant loss sensor (ECLS) (optional).


Panel Interior - Instrument Panel and Sub-Panel
Instrument Panel:

(1) GSC+; generator set control +.

(2) SP; speed potentiometer. or GS; governor switch (optional).

(3) SAS; start aid switch (optional).

(4) ECS; engine control switch.

(5) ALM; alarm module (optional).

(6) CAM; custom alarm module (optional). or SLM; synchronizing lights module (optional).

(7) PLS; panel light switch (optional).

(8) ESPB; emergency stop push button.

(9) VAR; voltage adjust rheostat.

(10) RM; relay module (part of GSC+).
Sub-Panel:

(11) AUX; auxiliary terminal strip.

(12) PWM; analog to PWM converter (optional).

(13) ATB+; AC transformer box +.

(14) CB2; circuit breaker 2.

(15) KWR; kilowatt level relay.

(16) ENFR; engine failure relay (optional).

(17) AUXREL; auxiliary relay (optional).

(18) SMMS1; starting motor magnetic switch 1.

(19) SMMS2; starting motor magnetic switch 2 (optional).

(20) GPHI; ground post high voltage.

(21) SR; slave relay (ETR only).

Component Description

Generator Set Control + (GSC+)


Display Area Of Generator Set Control + (GSC+)
(1) Dedicated shutdown indicators. (2) Spare fault indicators. (3) Fault shutdown indicator. (4) Fault alarm indicator. (5) Upper display. (6) Lower display. (7) Keypad.

The main component of the EMCP II+ system is the generator set control + (GSC+). The GSC+ is designed to operate when powered by only 24 DCV or 32 DCV battery systems. The GSC+ monitors and controls many of the generator set (genset) functions. The functions and features of the GSC+ are:

* Provides generator AC output information including power metering.
* Controls starting and stopping of the engine.
* Shows engine conditions and generator output information on two displays. The displays also show fault codes and GSC+ programming information.
* Monitors the system for faults. If a fault occurs, the GSC+ performs a controlled fault shutdown or provides a fault alarm annunciation. The GSC+ uses indicators and displays to describe the fault to the operator or service technician.
* Contains programmable features for certain applications or customer requirements.

GSC+ Serial Number


Location of GSC+ Serial Number Rear View Of Gsc+

The serial number of the GSC+ is a ten digit number which is unique for each GSC+. The preceding illustration shows the location of the serial number on the back of the GSC+. The serial number is also shown to service personnel when the GSC+ is in option OP2-2. The shown serial number and the actual serial number will always match. See AC Factory Calibration Setpoint Viewing OP2-2 within the topic Service Mode.

Fault Indicators

The ten fault indicators are used to show and describe a fault that is present. The fault indicators are divided into four groups: fault alarm indicator (4), spare fault indicators (2), fault shutdown indicator (3) and dedicated shutdown indicators (1).

The yellow fault alarm indicator (4) FLASHES when the GSC+ detects a fault that is an alarm fault. The alarm fault does not cause the engine status to change. If the engine was running when the alarm fault occurred, it will continue to run and is able to start. Fault alarm indicator (4) is accompanied by an alarm fault code that is shown on upper display (5) when the alarm codes key is pressed.

The red fault shutdown indicator (3) FLASHES when the GSC+ detects a fault that is a shutdown fault. The engine is shut down if it is running and is not allowed to start. Fault shutdown indicator (3) is accompanied by a fault code that is immediately shown on upper display (5).

The yellow spare fault indicators (2) FLASH when the conditions associated with that spare fault are active. The three spare faults are programmable to show a coolant loss, oil temperature, spare fault (customer generated switched input) or no assignment. For more information see the topic Service Mode. The yellow fault alarm indicator (4) or the red fault shutdown indicator (3) will accompany the spare fault indicators (2). This shows whether the spare fault input has been programmed to be an alarm or shutdown condition.

The red dedicated shutdown indicators (1) represent the following shutdown faults: low oil pressure, emergency stop, high water temperature, engine overspeed and engine overcrank. When the GSC+ detects a fault in one of these areas, the dedicated shutdown indicator (that corresponds to the fault) FLASHES. The engine is shut down if it is running and is not allowed to start. There are no fault codes associated with the dedicated shutdown indicators because each indicator has an interpretive label.

Many of the dedicated shutdown faults depend upon certain setpoints in the GSC+. See Engine/Generator Programming OP5-0 within the topic Service Mode. To restart the engine after a shutdown, see the topic Shutdown Mode. The conditions required for each dedicated fault and the results of each dedicated fault are:

Low Oil Pressure - The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC+. There are two low oil pressure setpoints, one for when the engine is at idle speed and the other for when the engine is at rated speed. When this fault occurs, the low oil pressure indicator FLASHES, the engine is shut down and is not allowed to start until the fault is corrected.

Emergency Stop - The operator presses the emergency stop push button (ESPB) on the instrument panel. When this condition occurs, the emergency stop indicator FLASHES, the engine is shut down and is not allowed to start until the condition is corrected.

High Water Temperature - The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC+. When this fault occurs, the high water temperature indicator FLASHES, the engine is shut down and is not allowed to start until the fault is corrected.

Engine Overspeed - The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC+. When this fault occurs, the engine overspeed indicator FLASHES, the engine is shut down and is not allowed to start until the fault is corrected.

Overcrank - The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC+. When this fault occurs, the overcrank indicator FLASHES and the engine is not allowed to start until the fault is corrected.

NOTE: The GSC+ can be programmed to override the shutdown for low oil pressure and high water temperature faults. When overridden, these faults are treated as alarm faults. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY (instead of flashing) and the engine continues to run and start (instead of shutting down). The dedicated shutdown indicator that is ON CONTINUOUSLY means that the setpoint for shutdown has been exceeded, but the GSC+ is programmed to override the shutdown fault and treat the fault as an alarm fault. As provided from the factory, the GSC+ treats low oil pressure and high water temperature as shutdowns. The operator or service technician must make a conscious decision to override these shutdown faults and have the GSC+ treat them as alarm faults.

Upper Display


Upper Display (5) With All Segments Shown

The primary function of upper display (5) is to show AC voltage, current and frequency information of the generator output. There are several options available on the upper display for AC metering. The options can be viewed one at a time by pressing the AC Meter key on the keypad. The options are:

* Voltage (average), generator frequency, current (total).
* Voltage (line-line), generator frequency, current (line) for any one phase.
* Voltage (line-line) for all three phases at once.
* Current (line) for all three phases at once.

NOTE: When total current increases above 9999A, the GSC+ will show current in kA units.

* Voltage (line-neutral) for all three phases at once.

NOTE: Line-neutral voltages are not shown when setpoint P032 is set to 1 (delta gensets).

Upper display (5) is also used to show the various fault codes for system faults. For more information on fault codes, see the topic Fault Description.


Upper Display Showing:

480 volts, average line-line voltage of all three phases.60 hertz, generator frequency.3000 amps, total line current of all three phases.


Upper Display Showing:

480 volts, line-line voltage of phase A-B.60 hertz, generator frequency.1000 amps, line current of phase A.

NOTE: The other two phases can also be viewed in a similar manner.


Upper Display Showing:

480 volts, line-line voltage of phase A-B.480 volts, line-line voltage of phase B-C.480 volts, line-line voltage of phase C-A.


Upper Display Showing:

1000 amps, line current of phase A.1000 amps, line current of phase B.1000 amps, line current of phase C.


Upper Display Showing:

277 volts, line-neutral voltage of phase A.277 volts, line-neutral voltage of phase B.277 volts, line-neutral voltage of phase C.

NOTE: Line-neutral voltages are not shown when setpoint P032 is set to 1 (delta gensets).

Lower Display


Lower Display (6) With All Segments Shown

Lower display (6) shows values for power metering, engine parameters and the relay status.

The left side of the lower display serves as a genset power meter. The following functions are scrolled automatically:

* Total real power (kW).
* Total reactive power (kVAR).
* Percentage of rated power (% kW).
* Power factor (average).
* Total energy output (kWHr).

Briefly pressing the power meter key (less than five seconds) will cause the display to stop scrolling and show a particular parameter continuously. Additional power meter functions scroll if the power meter key is held for more than five seconds and then released. The functions are:

* Total real power (kW).
* Real power phase A (kW).
* Real power phase B (kW).
* Real power phase C (kW).
* Total apparent power (kVA).
* Total reactive power (kVAR).
* Percentage of rated power (% kW).
* Power factor (average).
* Power factor phase A.
* Power factor phase B.
* Power factor phase C.
* Total energy output (kWHr).
* Total reactive energy output (kVARHr).

NOTE: All real power values are signed with a "+" or a "-". A negative value indicates reverse power.

NOTE: Real power phase A, B, and C as well as power factor phase A, B, and C are not shown when setpoint P032 is set to 1 (delta gensets).


Lower Display Showing:
691 kW, total real power of generator output.


Lower Display Showing:
230 kW, real power of phase A.
NOTE: Phases B and C can also be viewed in a similar manner.


Lower Display Showing:
831 kVA, total apparent power.


Lower Display Showing:
462 kVAR, total reactive power of generator output.


Lower Display Showing:
80 %kW, percentage of rated power of generator output.


Lower Display Showing:
.831 PF, average power factor of generator output
NOTE: Power factor for individual phases are viewed in a similar manner.


Lower Display Showing:
1000 kWH, total energy of generator output.

NOTE: Total energy output greater than 999,999 kWH will be shown as MWh in two steps in order to maintain a resolution of 1 kWH. The first step will show MWh as a whole number up to six places. The second step will show MWh as a decimal to three places. For example: 1,000,001 kWH will be shown as 1000 MWh (first step), followed by .001 MWh (second step).


Lower Display Showing:
64 psi engine oil pressure.

The right side of lower display (6) shows the value of certain engine parameters. The parameters shown are: engine oil temperature (optional), system battery voltage, engine hours, engine speed, engine oil pressure, and engine coolant temperature. The value for one of these conditions is shown for two seconds and then the display scrolls to the value for the next condition. A small pointer identifies the engine condition that corresponds to the value that is showing. When the engine meter key is pressed, lower display (6) stops scrolling and continuously shows one particular value. Now the pointer flashes above the condition whose value is showing.


Lower Display Showing:
K1, K3 and K5 as active. K2, K4, K6, K7 and K8 are not active.

The relay status indicators are on the bottom of the lower display. When a GSC+ relay is activated, the corresponding indicator (K1, K2, etc.) is shown on lower display (6). When a relay is not activated, the corresponding indicator (K1, K2, etc.) is not shown.

Keypad


Keypad (7)

Keypad (7) is used to control the information that is shown on upper display (5) and lower display (6). The seven keys have two sets of functions, normal functions and service functions. For a description of the service functions of the keys; see the topic Service Mode. The normal functions of the keys are:

Power Meter Key - This key controls the viewing of power meter information on the lower display. Pressing the key for at least five seconds causes all the power meter data to scroll once. Then the default power meter data resumes scrolling. Briefly pressing this key (less than five seconds) will stop the scrolling of the power meter functions until the key is pressed again.

AC Meter Key - This key controls the viewing of AC parameters on the upper display. Pressing the key causes the display to show a different set of parameters.

Engine Meter Key - This key controls the viewing of engine parameters on the lower display. Pressing the key, stops the scrolling of engine conditions and continuously shows the value for one particular engine condition. The pointer flashes to indicate scrolling is stopped. Pressing the key again, resumes the scrolling of engine conditions.

Lamp Test Key - Pressing this key performs a lamp test on the GSC+ and the optional alarm module. On the GSC+: the ten fault indicators are ON CONTINUOUSLY, every segment of upper display (5) and lower display (6) are ON. On the optional alarm module: all of the indicators are ON and the horn sounds. The lamp test function automatically turns off if this key is pressed and held for longer than 10 seconds.

Alarm Codes Key - If fault alarm indicator (4) is FLASHING, pressing this key causes upper display (5) to show the corresponding alarm fault code. Pressing this key again, resumes the showing of generator AC output information on upper display (5). If fault alarm indicator (4) is OFF, this key has no function. For more information on alarm fault codes, see the topic Fault Description.

Exit Key - This key only functions when the GSC+ is in service mode. See the topic Service Mode.

Service Mode Key - Pressing this key causes the GSC+ to enter service mode. See the topic Service Mode.

Relays


Relay Module On Rear Of GSC+


Relays In Relay Module
(1) Jumper block.

The relays are located in the relay module on the rear of the GSC+. The relays are permanently attached within the relay module and are not removable. The entire relay module is replaced if a relay is faulty. For more information, see the DC Schematics in the Schematics & Wiring Diagrams section.

Some of the contacts of the relays are internally connected to the terminals of the relay module and are available for customer use. The voltage and current specifications for each terminal (relay) are listed in the following chart.

NOTE: Jumper block (1) is used to select the voltage range of the voltmeter of the GSC+. Jumper block (1) is installed for systems with 700 volts full scale AC inputs. Jumper block (1) is NOT installed for systems with 150 volts full scale AC inputs or for any unit with external potential transformers. The relay module comes factory equipped with jumper block (1) installed. See the topic AC Voltage Range Selection in the Testing And Adjusting section.

The relays and the functions are:

K1 - Oil Step Relay (OSR):

When the relay is active the normally open contacts close. This signals the PEEC electronic engine control to accelerate the engine to rated speed.

The relay has no normally closed contacts.

K2 - Generator Fault Relay (GFR):

When the relay is active the normally open contacts close. This trips the optional circuit breaker when a shutdown fault occurs.

The relay has no normally closed contacts.

K3 - Crank Termination Relay (CTR):

When the relay is active the normally open contacts close. This activates the optional AUX relay (customer use).

When the relay is inactive the normally closed contacts close.

K4 - Starting Motor Relay (SMR):

When the relay is active the normally open contacts close. This activates the starting motor magnetic switch and enables the automatic position of an optional start aid switch.

When the relay is inactive the normally closed contacts close. This activates an optional battery charger.

K5 - Run Relay (RR):

When the relay is active the normally open contacts close. This activates the manual position of an optional start aid switch.

When the relay is inactive the normally closed contacts close. This provides an engine shutdown signal to the PEEC electronic engine control.

K6 - Air Shutoff Relay (ASR): Not used in PEEC applications. Relay is active during fault shutdowns.

When the relay is active the normally open contacts close.

When the relay is inactive, the normally closed contacts close.

K7 - Fuel Control Relay (FCR): Not used in PEEC applications. Relay is active during starting and running conditions.

When the relay is active the normally open contacts close.

The relay has no normally closed contacts.

K8 - Programmable Spare Relay (PSR): This relay is for customer use. It is programmable to activate for a variety of conditions. For more information, see the topic Service Mode.

When the relay is active, the normally open contacts close.

When the relay is inactive, the normally closed contacts close.

Instrument Panel Switches


Instrument Panel Switches
(1) SAS; start aid switch (optional). (2) SP; speed potentiometer or GS; governor switch (optional). (3) PLS; panel light switch (optional). (4) ECS; engine control switch. (5) VAR; voltage adjust rheostat. (6) ESPB; emergency stop push button.

Engine control switch (ECS) (4) determines the status of the control panel. In the AUTO position (3 o'clock), the GSC+ allows the operator to remotely control and monitor the generator set with a Customer Communication Module (see the topic Optional Modules). The GSC+ also allows the engine to start whenever the remote initiating contact (IC) is closed. The engine also shuts down after the initiate contacts open. A cooldown time is programmable (setpoint P019) to give a 0 to 30 minute cooldown period before the engine shuts down. The cooldown time is factory set at five minutes. In the MANUAL START position (6 o'clock), the engine starts and runs as long as the ECS is in this position. In the COOLDOWN/STOP position (9 o'clock), after cooldown the PEEC electronic engine control turns OFF the fuel shutoff solenoid which shuts the engine down. In the OFF/RESET position (12 o'clock), the engine shuts down immediately and any fault indicators are reset (except emergency stop).

If red emergency stop push button (ESPB) (6) is pressed, the fuel shutoff solenoid is de-energized. To restart: turn ESPB (6) clockwise until it releases, turn the ECS to OFF/RESET and then to MANUAL START.

Voltage adjust rheostat (VAR) (5) is used to adjust generator voltage to the desired level.

Speed potentiometer (2) is used to raise or lower the engine speed. It connects to the PWM converter which then connects to the PEEC electronic engine control. The PEEC adjusts the engine speed.

Optional panel light switch (PLS) (3) turns ON and OFF the panel lamps.

Optional start aid switch (SAS) (1) is present only on required gensets. Two types of start aid systems exist:

* Manual - for metered shot start aid systems.
* Automatic - for continuous flow start aid systems.

On manual start aid types, when SAS (1) is placed and held in the ON position (momentary contact), the metered shot start aid system is activated. A specific amount of ether is metered into a holding chamber. When SAS (1) is released, a solenoid allows ether to flow to the engine. The metered shot start aid system deactivates when:

* The contacts of the crank termination relay (CTR) open at an engine speed of approximately 400 rpm.
* Or the engine coolant temperature is sufficient to open the start aid temperature switch (SATS).
* Or SAS (1) is released to the OFF position.


NOTICE

Crank the engine before activating (keep SAS in OFF position) the metered shot start aid system. Damage to the engine is possible by activating the system when the engine is not turning.


On automatic SAS types, the continuous flow start aid system operates in the automatic or the manual mode. When SAS (1) is placed in the AUTO position, the automatic mode is activated. The system automatically injects ether only during the crank cycle. When SAS (1) is placed and held in the MAN position (momentary contact), the manual mode is activated. This allows the operator to control the amount of time that ether is injected during cranking. The manual mode also allows the operator to inject additional ether after crank termination (used on cold running engines which continue to detonate). The automatic mode of the continuous flow start aid system deactivates when:

* The contacts of the crank termination relay (CTR) open at an engine speed of approximately 400 rpm (automatic mode only).
* Or the engine coolant temperature is sufficient to open the start aid temperature switch (SATS).
* Or SAS (1) is returned to the OFF position.

EMCP II+ Sensors

The GSC+ monitors certain engine sensors: the engine oil pressure sensor, engine coolant temperature sensor, engine coolant loss sensor (optional), the engine oil temperature sensor (optional), and the engine magnetic pickup (speed sensor).

Engine Oil Pressure Sensor


Engine Oil Pressure Sensor

The engine oil pressure sensor is an input of the GSC+. The purpose of the sensor is to tell the GSC+ what the engine oil pressure is. The GSC+ shows the engine oil pressure on the lower display and also uses the sensor information to determine when a low oil pressure fault exists. The engine oil pressure sensor is mounted on the outside of one of the engine oil galleries. The exact location depends upon the engine model.

The engine oil pressure sensor is a pulse width modulated (PWM) type of sensor. This sensor continuously generates a PWM signal, in which the duty cycle varies from 10 to 90% in proportion to the oil pressure of the engine. The GSC+ receives the PWM signal and measures the duty cycle to determine the oil pressure of the engine. The base frequency of the signal is constant at 500 ± 150 Hz. The signal wire (connector contact C) of the oil pressure sensor connects to connector contact 8 of the GSC+. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC+ (connector contact 9).

There are five setpoints related to engine oil pressure that are programmed into the GSC+. The related setpoints are: P003, P004, P012, P013 and P014. See Engine/Generator Programming OP5-0 within the topic Service Mode.

Engine Coolant Temperature Sensor


Engine Coolant Temperature Sensor

The engine coolant temperature sensor is an input of the GSC+. The purpose of the sensor is to tell the GSC+ what the engine coolant temperature is. The GSC+ shows the engine coolant temperature on the lower display and also uses the sensor information to determine when a high or low coolant temperature fault exists. The engine coolant temperature sensor is mounted in the water jacket, usually towards the front of the engine. The exact location depends upon the engine model.

The engine coolant temperature sensor is a pulse width modulated (PWM) type of sensor. This sensor continuously generates a PWM signal, in which the duty cycle varies from 10 to 95% in proportion to the coolant temperature of the engine. The GSC+ receives the PWM signal and measures the duty cycle to determine the coolant temperature of the engine. The base frequency of the signal is constant at 455 Hz (370 to 550 Hz). The signal wire (connector contact C) of the coolant temperature sensor connects to connector contact 7 of the GSC+. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC+ (connector contact 9).

There are four setpoints related to engine coolant temperature that are programmed into the GSC+. The related setpoints are: P003, P004, P015 and P016. See Engine/Generator Programming OP5-0 within the topic Service Mode.

Engine Oil Temperature Sensor


Engine Oil Temperature Sensor

The engine oil temperature sensor is optional and is an input of the GSC+. The purpose of the sensor is to tell the GSC+ what the engine oil temperature is. The GSC+ shows the engine oil temperature on the lower display and also uses the sensor information to determine when a high oil temperature fault exists. The engine oil temperature sensor is mounted on the outside of one of the engine oil galleries. The exact location depends upon the engine model.

The engine oil temperature sensor is a pulse width modulated (PWM) type of sensor. This sensor continuously generates a PWM signal, in which the duty cycle varies from 10 to 95% in proportion to the oil temperature of the engine. The GSC+ receives the PWM signal and measures the duty cycle to determine the oil temperature of the engine. The base frequency of the signal is constant at 455 Hz (370 to 550 Hz). The signal wire (connector contact C) of the oil temperature sensor connects to connector contact 14 of the GSC+. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC+ (connector contact 9).

There are five setpoints related to engine oil temperature that are programmed into the GSC+. The related setpoints are: P003, P004, P025, P026 and P027. See Engine/Generator Programming OP5-0 within the topic Service Mode.

Engine Coolant Loss Sensor


Engine Coolant Loss Sensor

The engine coolant loss sensor is optional and is an input of the GSC+. The purpose of the sensor is to tell the GSC+ when the engine has lost coolant. The GSC+ uses the sensor information to determine when a low coolant level fault exists. The engine coolant loss sensor is usually mounted near the top of the engine radiator. The exact location depends upon the engine model.

The engine coolant loss sensor sends the GSC+ either a battery negative (B-) signal for normal level or a +5 DCV signal for low level. The signal wire (connector contact C) of the coolant loss sensor connects to connector contact 13 of the GSC+. The sensor is supplied operating power (8 DCV) at connector contact A from the GSC+ (connector contact 9).

There are three setpoints related to engine coolant loss that are programmed into the GSC+. The related setpoints are: P004, P005 and P006. See Engine/Generator Programming OP5-0 within the topic Service Mode.

Engine Magnetic Pickup


Engine Magnetic Pickup

The engine magnetic pickup is an input of the GSC+. The purpose of the sensor is to tell the GSC+ what the engine speed is. The GSC+ shows the engine speed on the lower display and also uses the sensor information for tasks such as activating an engine overspeed shutdown, terminating engine cranking and determining the oil step speed. The engine magnetic pickup is mounted on the flywheel housing of the engine.

The sensor creates a sine wave signal from passing ring gear teeth at the rate of one pulse per tooth. The sensor sends the GSC+ a sine wave signal in which the frequency is in direct proportion to the speed of the engine. The GSC+ receives the sine wave signal and measures the frequency (one pulse per gear tooth) to determine the speed of the engine. The wires of the sensor connect to connector contacts 1 and 2 of the GSC+ within a shielded cable. The drain wire of the shielded cable is connected to the AUX terminal strip.

There are four setpoints related to engine speed that are programmed into the GSC+. The related setpoints are: P009, P010, P011 and P012. See Engine/Generator Programming OP5-0 within the topic Service Mode.

PWM Converter


PWM Converter
(1) Droop potentiometer.

For stand alone applications with droop or isochronous operation or for parallel applications with droop governing, the PWM converter is provided as standard equipment. The PWM converter is used to change the analog signal of the speed potentiometer (SP) into a pulse-width-modulated PWM signal that the engine electronic control can recognize. The PWM converter is mounted on the sub-panel within the control panel.

The PWM converter continuously generates two PWM signals, speed and droop. The base frequency of the PWM signals is constant at 415 to 528 Hz. The duty cycle of the speed signal varies from 5 to 95% in proportion to the signal being received from the speed potentiometer which is adjusted by the operator. The duty cycle of the droop signal varies from 5 to 95% in proportion to the signal being received from the droop potentiometer (1) of the PWM converter which is adjusted by service personnel. Using droop potentiometer (1), droop can be adjusted from 0% to approximately 10%.

The PWM converter is supplied operating power (battery) at converter terminals -B and +B. Converter terminal 1 is an input and connects to terminal 3 of the speed potentiometer. Converter terminal 2 is an input and connects to terminal 2 (wiper) of the speed potentiometer. Converter terminal 3 is an input and connects to terminal 1 of the speed potentiometer. Converter terminal S is an output and provides a speed signal to the engine electronic control. Converter terminal D is an output and provides a droop signal to the engine electronic control.

NOTE: For isochronous operation, the droop potentiometer must be adjusted to zero (fully clockwise).

NOTE: For applications requiring load management with a utility, requiring load sharing with other generators, or requiring automatic synchronizing, a load share module must replace the PWM converter.

Programmable Outputs

The GSC+ provides 3 programmable outputs for customer use:

* kW Level Output
* Spare Output
* Programmable Spare Relay Outputs

kW Level Output

The kW level output is a feature that can be enabled or disabled by programming setpoint P138. When active, the kW level output draws (sinks) 100 mA maximum. When inactive, the kW level output is pulled to battery negative. The kW level output (GSC+ connector contact 34) will be activated whenever the total power output of the generator passes the programmed threshold (setpoint P139). This threshold can be programmed from 0 to 110 percent of the nameplate power (setpoint P030) of the generator. An activation time delay from 0 to 120 seconds can also be programmed (setpoint P140).

Once activated, the kW relay level output will be deactivated when the total power output of the generator drops below a programmed threshold (setpoint P141). This threshold is different from the activation threshold and can be programmed from 0 to 110 percent of the total power rating of the generator. A deactivation time delay from 0 to 120 seconds can also be programmed (setpoint P140).

For more information on programming the setpoints for this output function, see Engine/Generator Programming OP5-0 within the topic Service Mode.

NOTE: The GSC+ diagnoses a fault in the kW level output circuit. See CID 859 within the topic Diagnostic Fault Codes of the Testing and Adjusting section.

Spare Output

The spare output responds (high or low) to a selected trigger condition. The response and the trigger condition are programmable.

The GSC+ must be programmed (setpoint SP13) as to whether the active state of the spare output is to be high or low. An active low state means that the output is pulled to battery negative when active. The output draws (sinks) 100mA maximum when in the low state. An active high state means that the output will be allowed to float high (approximately 5.0 VDC when no devices are connected to the spare output). When in the high state the spare output is floating and is capable of driving high impedance (36 000 ohm minimum) logic circuits only. When in the high state, the spare output will not drive low impedance loads such as relays.

The GSC+ must be programmed (setpoint SP14) as to what condition triggers the spare output (GSC+ connector contact 36) to the active state. The possible trigger conditions that can activate the spare output are listed in Spare Input/Output Programming OP6 within the topic Service Mode.

For more information on programming the setpoints for this output function, see Spare Input/Output Programming OP6 within the topic Service Mode.

NOTE: A common use of the spare output is to activate the shunt trip coil of the AC circuit breaker during engine cooldown.

NOTE: The GSC+ diagnoses a fault in the spare output circuit. See CID 334 within the topic Diagnostic Fault Codes of the Testing and Adjusting section.

Programmable Spare Relay Outputs

The programmable spare relay is one of the relays located in the relay module on the rear of the GSC+. The programmable spare relay outputs respond to a selected trigger condition. The response and the trigger condition are programmable.

The GSC+ must be programmed (setpoint 15) as to whether the programmable spare relay outputs are active or inactive when triggered. In an active state, the normally open contacts will close and the normally closed contacts will open.

The GSC+ must be programmed (setpoint SP16) as to what condition triggers the programmable spare relay outputs to the active state. The possible trigger conditions that can activate the programmable spare relay outputs are listed in Spare Input/Output Programming OP6 within the topic Service Mode.

For more information on programming the setpoints for this output function, see Spare Input/Output Programming OP6 within the topic Service Mode.

NOTE: The GSC+ diagnoses a fault in the spare output circuit. See CID 448 within the topic Diagnostic Fault Codes of the Testing and Adjusting section.

Modes Of Operation


Display Area Of Generator Set Control + (GSC+)
(1) Dedicated shutdown indicators. (2) Spare fault indicators. (3) Fault shutdown indicator. (4) Fault alarm indicator. (5) Upper display. (6) Lower display. (7) Keypad.

The GSC+ has four modes of operation. A brief description of each follows. See the individual topic for more detailed information.

Normal Mode: The GSC+ uses normal mode for the normal operation of the genset. The operator can identify normal mode by observing the display area. When in normal mode: all the dedicated and fault shutdown indicators are OFF, the fault alarm indicator is OFF and "SERV" is NOT SHOWING on the upper display.

Alarm Mode: The GSC+ automatically goes into alarm mode to alert the operator that an alarm fault (non-critical) is occurring. The operator can identify alarm mode by observing the display area. When in alarm mode, the fault alarm indicator is FLASHING. The alarm fault code will be shown when the alarm code key is pressed.

Shutdown Mode: The GSC+ automatically goes into shutdown mode to shut the engine down and alert the operator that a shutdown fault (critical) is occurring. The operator can identify shutdown mode by observing the display area. When in shutdown mode, a dedicated or fault shutdown indicator is FLASHING.

Service Mode: The GSC+ goes into service mode when the operator presses the service mode key on the keypad. The operator or service person uses service mode to: assist with troubleshooting of diagnostic faults, satisfy special applications, satisfy customer needs and to verify or calibrate or adjust genset functions. The operator can identify service mode by observing the display area. When in service mode, "SERV" is SHOWING on the upper display.

NOTE: Service mode can not be entered when the ECS is in the AUTO position.

Normal Mode

The purpose of normal mode is to monitor and control the genset. The GSC+ controls the engine according to the information received from the operator (panel switches, controls) and from the engine sensors. Some of the functions performed by the GSC+ while in normal mode are: engine starting, monitoring of important genset conditions, showing the operator the important genset conditions, fault detection and engine stopping. The operator can identify normal mode by observing the display area. When in normal mode: all shutdown indicators are OFF, the fault alarm indicator is OFF and "SERV" is NOT SHOWING on the upper display. When the GSC+ is in normal mode, the engine is able to start or run.

NOTE: The optional Customer Communication Module (CCM) can remotely control certain genset functions. This remote control can only occur when the ECS is in the AUTO position. For more information, see Customer Communication Module (CCM) within the topic Optional Modules.

Engine Starting Sequence

1. The GSC+ receives an engine start signal. The possible engine start signals are:
* ECS turned to MANUAL START by the operator.
* The remote initiate contacts (IC) close while the ECS is in the AUTO position.
* The optional Customer Communication Module (CCM) sends a start command while the ECS is in the AUTO position.
2. The GSC+ checks the system before beginning the cranking sequence. The GSC+ checks that:
* No system faults are present.
* All previous shutdown faults have been reset (removed by turning the ECS to OFF/RESET).
* The engine is not already running.
3. The GSC+ activates the starting motor relay (SMR) and the run relay (RR). The activated RR removes (opens) the shutdown signal from the PEEC electronic engine control.
4. The GSC+ activates the fuel control relay (FCR). Not used in PEEC applications.
5. The GSC+ cycle cranks (factory default is 10 seconds crank and 10 seconds rest) the engine until it starts or until the cycle crank time reaches the setpoint (P017) for total cycle crank time.
6. While the starting motor is cranking, the GSC+ shows the status of the K4 (SMR), K5 (RR), K7 (FCR) relays on the relay status indicators of the lower display.
7. The GSC+ deactivates the starting motor relay (SMR) and activates the crank termination relay (CTR) when the engine speed reaches the setpoint (P011) for crank terminate speed (factory default is 400 rpm).
8. The GSC+ activates the oil step relay (OSR) when the oil pressure reaches the setpoint (P014) for low oil pressure at idle speed. The factory default is 70 kPa (10 psi). The OSR signals the PEEC electronic engine control to accelerate the engine to rated speed.

NOTE: The optional Customer Communication Module (CCM) can remotely activate or deactivate the OSR when the low oil pressure setpoint is exceeded.

9. The GSC+ shows:
* AC information for one or more phases on the upper display.
* Power meter information on the lower display.
* Engine system information on the lower display.
* The K1 (OSR), K3 (CTR), K5 (RR), and K7 (FCR) relay status on the lower display.

Engine Stopping Sequence

1. The GSC+ receives an engine stop signal. The possible engine stop signals are:
* ECS turned to STOP by the operator.
* The remote initiate contacts (IC) open while the ECS is in the AUTO position.
* The optional Customer Communication Module (CCM) sends a stop command while the ECS is in the AUTO position and the remote initiate contacts are open.
2. After receiving the stop signal, the GSC+ checks that no system faults are present.
3. The GSC+ begins the cooldown time (setpoint P019, factory default is five minutes).
4. If programmed to do so, the GSC+ activates the spare output. This output can activate a slave relay during cooldown which in turn activates the optional circuit breaker and takes the generator off load.
5. After cooldown (setpoint P019), the GSC+ deactivates the run relay (RR). The NC contacts of the RR now send a shutdown signal (ground) to the PEEC electronic engine control. The PEEC turns OFF the fuel shutoff solenoid which shuts the engine down.

The oil step relay (OSR) is deactivated, after the engine oil pressure decreases to less than the setpoint for low oil pressure shutdown at idle speed (P014).

Also the GSC+ deactivates the fuel control relay (FCR). Not used in PEEC applications.

6. As soon as engine speed reaches 0 rpm, the GSC+ deactivates the crank terminate relay (CTR) and a restart is now allowed.

If a start signal is received before 0 rpm is reached, the fuel is turned on and the engine is allowed to run. If it does not run, the starting motor relay (SMR) does not activate until the crank termination relay (CTR) is deactivated at 0 rpm.

7. The GSC+ shows the status of the relays on the relay status indicators of the lower display. All relay indicators should be OFF.

NOTE: If desired, the engine can be shutdown immediately by turning the ECS to OFF/RESET. The cooldown timer is bypassed and the spare data output is deactivated.

Alarm Mode

The purpose of alarm mode is to alert the operator that an alarm fault is occurring. An alarm fault is non-critical but potentially serious. An alarm fault precedes certain dedicated shutdown faults or can be protective relaying functions that have been enabled as an alarm fault.

When an alarm fault exists, the GSC+ automatically activates alarm mode and alerts the operator by FLASHING the fault alarm indicator. To identify what the alarm fault is, the operator presses the alarm codes key and then a corresponding fault code is shown on the upper display. This fault code can be an AL fault code, a SP fault code or a diagnostic fault code. In addition to the alarm indicator, one or more of the Spare 1, Spare 2, or Spare 3 indicators may be flashing. For more information on fault codes, see the topic Fault Description. When the GSC+ is in alarm mode the engine is able to start or run.

The AL fault codes shown on the GSC+ indicate the current status of the genset. As soon as the fault is corrected or if the fault goes away, the AL fault codes are no longer shown by the GSC+. However, diagnostic fault codes are logged in the GSC+ fault log for viewing later by service personnel.

NOTE: If a shutdown fault is overridden (by operator programming) to be an alarm fault, then the corresponding dedicated shutdown indicator is ON CONTINUOUSLY if the particular fault occurs. The ON CONTINUOUSLY state means that the normal shutdown response has been overridden by the operator and the shutdown fault is treated as an alarm fault. A fault code is not shown on the upper display for the overridden shutdown faults. The dedicated shutdown indicator remains ON CONTINUOUSLY until the fault is corrected and the engine control switch is turned to the OFF/RESET position. The dedicated shutdown faults that can be overridden are: low oil pressure and high coolant temperature. For more information, see P003 within the topic Engine/Generator Programming OP5-0. Also, see the topic Shutdown Mode.

Alarm faults do not have an immediate adverse effect on the genset. However, the operator should investigate the cause of the alarm fault condition at the earliest opportunity. If the operation of the genset is mandatory, the starting and stopping procedures are exactly the same as in normal mode. The GSC+ will respond to operator input from the panel switches and the engine sensors.

Alarm Mode Sequence

1. An alarm fault occurs.

2. The GSC+ detects the alarm fault and FLASHES the fault alarm indicator. The GSC+ does not change the status or operation of the genset.

3. Pressing the alarm codes key causes the upper display to show a corresponding fault code.

4. Correct the alarm fault; see the topic Fault Identification in the Testing And Adjusting section.

5. When the alarm fault is no longer occurring (is corrected), the GSC+ turns OFF the fault alarm indicator and removes the fault code from the upper display. The GSC+ now returns to normal mode.

Shutdown Mode

The purpose of shutdown mode is to prevent damage to the engine or generator when a shutdown fault is occurring. A shutdown fault is critical. When a shutdown fault occurs, the GSC+ automatically activates shutdown mode until the shutdown fault is corrected. When in shutdown mode, the GSC+ shuts the engine down, prevents engine starting and alerts the operator.

The GSC+ alerts the operator and identifies the shutdown fault by FLASHING the corresponding shutdown indicator. The name of the shutdown indicator identifies the shutdown fault. The shutdown indicators are:

* Low oil pressure
* Emergency stop
* High water temperature
* Engine overspeed
* Engine overcrank
* Fault shutdown
* Spare 1, Spare 2, or Spare 3 indicator (accompanied by the fault shutdown indicator)

If the fault shutdown indicator is the only indicator FLASHING, additional information is available. A fault code is shown on the upper display which more precisely identifies the cause of the shutdown fault. For more information, see the topic Fault Description.

Shutdown Mode Sequence

1. A shutdown fault occurs and the GSC+ detects it.
2. To shut off the fuel, the GSC+ deactivates the run relay (RR). The NC contacts of the RR now send a shutdown signal (ground) to the PEEC electronic engine control. The PEEC turns OFF the fuel shutoff solenoid which shuts the engine down.

Also the GSC+ deactivates the fuel control relay (FCR). Not used in PEEC applications.

3. To prevent engine cranking, the GSC+ deactivates the starting motor relay (SMR).
4. The GSC+ activates the genset fault relay (GFR) to activate the optional shunt trip coil on the circuit breaker.

NOTE: The spare output may also be programmed to activate when a shutdown occurs. This output can drive a relay to open the circuit breaker or a transfer switch. See Spare Input/Output Programming OP6 within the topic Service Mode.

5. The GSC+ activates the air shutoff relay (ASR) for 15 seconds, for an emergency stop fault, engine overspeed fault, or speed sensor fault (CID 190).
6. As the engine comes to a stop, the GSC+ deactivates the crank termination relay (CTR) when engine speed reaches 0 rpm. The oil step relay (OSR) is deactivated when the engine oil pressure reaches the setpoint (P014) for low oil pressure shutdown at idle speed [70 kPa (10 psi)].
7. If engine speed does not decrease at least 100 rpm within five seconds, the GSC+ activates the air shutoff relay (ASR) for 15 seconds. (The ASR was already activated for an emergency stop fault, engine overspeed fault, or speed sensor fault).
8. The GSC+ FLASHES the corresponding shutdown indicator. If the fault shutdown indicator is FLASHING, a fault code is shown on the upper display. See the topic Fault Description.
9. If the fault shutdown is the only indicator FLASHING, additional information is available. A fault code is shown on the upper display that more precisely identifies the cause of the shutdown fault. For more information, see the topic Fault Description
10. The lower display continues to show the engine data.
11. The relay status indicators show:
* K2 (GFR)
* K6 (ASR) for 15 seconds - for an emergency stop fault, engine overspeed fault, speed sensor fault or if engine speed does not decrease at least 100 rpm.

Engine Start Sequence (After Shutdown)

1. Correct the shutdown fault. See the topic Fault Identification in the Testing And Adjusting section.

2. Reset the GSC+ by turning the ECS to OFF/RESET. If no shutdown fault is active, the GSC+ returns to normal mode and the engine is able to start.

Service Mode


GSC+ Display Area With Service Mode Descriptions Of Keypad
(1) Dedicated shutdown indicators. (2) Spare fault indicators. (3) Fault shutdown indicator. (4) Fault alarm indicator. (5) Upper display. (6) Lower display. (7) Keypad.

The purpose of service mode is: to assist with troubleshooting of diagnostic faults, to satisfy special applications, to satisfy customer needs, and to verify or calibrate or adjust genset functions. Service mode has selectable options for viewing, entry, clearing, programming, verification and calibration of information by service personnel. The ten options are:

OP1, Fault log viewing.

OP2-0, Engine/Generator setpoint viewing.

OP2-1, Protective relaying setpoint viewing.

OP2-2, AC factory calibration setpoint viewing.

OP3, Password entry.

OP4, Fault log clearing.

OP5-0, Engine/Generator programming.

OP5-1, Protective Relaying programming.

OP6, Spare Input/Output programming.

OP7, Hourmeter programming.

OP8, Voltmeter/Ammeter programming.

OP9, Engine setpoint verification.

OP10, AC offset adjustment.

The keypad and the display of the GSC+ are used for activating service mode and selecting the desired option. When in service mode, the keys of the keypad have a different function and a different name. The name and location of each key when in service mode is shown in the preceding illustration. Also a film (label) on the vandal door of the control panel identifies each key when in service mode. The service functions of the keys are:

Scroll Right Key - This key is used to view and scroll information. This key represents the number 1 when entering the password.

Scroll Up Key - This key is used to scroll up through information or to increase the value of information. This key represents the number 2 when entering the password.

Scroll Down Key - This key is used to scroll down through information or to decrease the value of information. This key represents the number 3 when entering the password.

NOTE: To rapidly scroll through a large range of information, press and hold the appropriate scroll key.

Select Key - This key is used to select the option or the information that is to be viewed or changed. Also, this key is used to start or stop the scrolling of information.

Enter Key - This key is used to enter information that has been changed into the memory of the GSC+.

Exit Key - This key is used to exit service mode and return the display to normal. The "SERV" indicator on the upper display is NOT SHOWING when the GSC+ is NOT in service mode.

Service Mode Key - This key is used to access (enter) service mode. The "SERV" indicator on the upper display FLASHES whenever the GSC+ is in service mode and the keypad performs service mode functions.

Procedure To Enter Service Mode

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

1. Press the SERVICE MODE key on the keypad of the GSC+. The "SERV" indicator on the upper display FLASHES whenever the GSC+ is in service mode.

2. The desired option (OP1 through OP10) can now be selected. Each option is described in the topics that follow.

3. To return to normal mode, press the EXIT key a few times until the "SERV" indicator is not showing.

NOTE: To enter service mode options OP4 through OP8, the engine must be shutdown. Turn the ECS to the STOP position.

Service mode options OP4 through OP10 are password protected to reduce the possibility of information being altered by mistake. OP3 is the password entry option and the password must be correctly entered before access is gained to OP4 through OP10; see the topic Password Entry OP3. Options OP1 and OP2 are for the viewing of information and are not password protected.

Fault Log Viewing OP1

OP1 is the option for viewing of diagnostic fault codes that are recorded in the fault log of the GSC+. The fault log contains a history of diagnostic faults that have occurred in the genset system since the last service call (the last clearing of diagnostic fault codes). Also, the number of occurrences are totalled and shown on the upper display. The purpose of the fault log is to assist service personnel when troubleshooting the genset system.

Each diagnostic fault code consists of a component identifier (CID), a failure mode indicator (FMI) and an active/inactive status indicator ("DIAG") that are shown on the upper display. The CID tells which component is faulty and the FMI describes what type of the failure has occurred. "DIAG" FLASHES when the particular CID FMI fault is active.

Only inactive diagnostic faults are stored in the fault log. An active diagnostic alarm fault ("DIAG" is FLASHING) becomes inactive ("DIAG" is ON CONTINUOUSLY) when the fault is no longer occurring. An active diagnostic shutdown fault ("DIAG" is FLASHING) becomes inactive ("DIAG" is ON CONTINUOUSLY) when the fault is no longer occurring and ECS is turned to OFF/RESET. The GSC+ stores a maximum of 12 inactive diagnostic fault codes in the fault log. If an additional diagnostic fault becomes inactive, the GSC+ automatically clears the earliest inactive diagnostic fault code and puts the additional inactive diagnostic fault code in the fault log.

The GSC+ automatically clears any inactive diagnostic fault codes that have been stored in the fault log for more than 750 hours. For example; if a CID 190 FMI 3 fault code is logged at 10 hours and a CID 100 FMI 4 fault code is logged at 20 hours, then the GSC+ clears the CID 190 FMI 3 fault code when the hourmeter is at 760 hours. The CID 100 FMI 4 fault code remains logged until the hourmeter is at 770 hours. This feature prevents the fault log from becoming cluttered with fault codes that service personnel have corrected but forgot to clear.

When a diagnostic fault changes from active to inactive, the GSC+ functions as follows:

a. The diagnostic fault is recorded in the fault log of the GSC+.
b. The DIAG indicator changes from FLASHING (active diagnostic fault) to ON CONTINUOUSLY (inactive diagnostic fault) if no other active faults are present.
c. The fault alarm indicator or fault shutdown indicator changes from FLASHING to OFF.

Procedure To View The Fault Log

NOTE: For a list of all diagnostic fault codes, see the Diagnostic Fault Codes chart in the Testing And Adjusting section.

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SELECT key. The CID FMI fault codes for diagnostic faults are scrolled on the upper display (if more than one fault code is in the log). Each fault code has the number of occurrences showing above the COUNT indicator. The lower display shows the hourmeter values of the first and last occurrence of each fault.

3. Press SELECT key. The fault codes stop scrolling.

4. Press SELECT key. Fault codes resume scrolling.

5. Press EXIT key. "OP 1" is showing on lower display.

6. Press EXIT key. The display returns to normal.

Engine/Generator Setpoint Viewing OP2-0

OP2-0 is the option for viewing the engine/generator setpoints. The engine/generator setpoints affect the proper operation and serviceability of the engine, and the accuracy of the information shown on the display. The setpoints viewed (stored in the GSC+) should match the specified setpoints of the 136-9048 Control Panel Chart packaged within the control panel. These setpoints are from P001 through P033 and are programmable. For a description of each of these setpoints, see the topic Engine/Generator Programming OP5-0.

Protective Relaying Setpoint Viewing OP2-1

OP2-1 is the option for viewing the protective relaying setpoints. The protective relaying setpoints determine the response of the GSC+ when one or more of the protective relay functions occur. The protective relay functions are provided by the GSC+ to reduce the possibility of damage occurring to the generator or customer equipment. These setpoints are from P101 through P142 and are programmable. For a description of each of these setpoints, see the topic Protective Relaying Programming OP5-1.

AC Factory Calibration Setpoint Viewing OP2-2

OP2-2 is the option for viewing the AC factory calibration setpoints and other specific data. None of these items are programmable by service personnel.

The information shown on the display is:

* GSC+ Serial Number - The serial number of the GSC+ is a ten digit number which is unique for each GSC+. The serial number is also printed on a label on the back of the GSC+. The displayed serial number will always match the serial number on the label.
* GSC+ Software Identifier - The software identifier indicates the software level within the GSC+. The identifier is nine characters in the form of "XXXXXXX-XX".
* Setpoints P201 through P222 - These are the AC factory calibration setpoints. They contain information used during factory calibration procedures. These setpoints are not programmable by service personnel.

Procedure To View The Setpoints

NOTE: Viewing the setpoints is done with the engine running or stopped. Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key. "OP 2-0" is showing.

a. To view the setpoints within OP2-0 go to the next step.

b. To view OP2-1 or OP2-2, press the SCROLL UP key once or twice more. The display will show "OP 2-1" or "OP 2-2". Go to next step.

3. Press SELECT key.

For "OP 2-0": "P001" is showing, followed with the value of the setpoint.

For "OP 2-1": "P101" is showing, followed with the value of the setpoint.

For "OP 2-2": the ten digit serial number of the GSC+ is showing.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint is showing with its value. Repeat this step until all the desired setpoints and their values are viewed.

5. Press EXIT key. "OP 1" is showing on lower display.

6. Press EXIT key. The display returns to normal.

Password Entry OP3

OP3 is the option for entering the password that is required for accessing OP4 through OP10. Service mode options OP4 through OP10 are password protected to reduce the possibility of information being altered by mistake. Options OP1 and OP2 are for the viewing of information and are not password protected.

Password entry consists of actuating the scroll keys in the correct sequence by service personnel. The password is the same for every GSC+ and is not changeable. After the password is entered, the OP4 through OP10 options can be accessed. If a mistake is made during password entry, "PE FAIL" is briefly shown on the upper display and then the password entry process begins again.

Procedure To Enter The Password

NOTE: Service mode cannot be entered when the ECS is in the AUTO position. Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Press SERVICE MODE key to enter service mode. "OP 1" is showing on the lower display. For more information see the topic Service Mode.

2. Press SCROLL UP key four times. "OP 3" is showing.

3. Press SELECT key. "P E ___ " is showing with the first dash flashing.

4. Press SCROLL RIGHT key. "P E 1 ___ " is showing with the second dash flashing.

5. Press SCROLL DOWN key. "P E 1 3 ___ " is showing with the third dash flashing.

6. Press SCROLL UP key. "P E 1 3 2 __ " is showing with the fourth dash flashing.

7. Press SCROLL DOWN key. "P E 1 3 2 3 _ " is showing with the fifth dash flashing.

8. Press SCROLL RIGHT key. "P E 1 3 2 3 1" is showing.

9. Press ENTER key. "P E P A S S" is showing.

10. Press EXIT key. "OP 4" is showing.

NOTE: After the password is entered, any option can be accessed any number of times. The password remains in effect until service mode is exited.

Fault Log Clearing OP4

OP4 is the option for clearing an inactive diagnostic fault from the fault log of the GSC+. After a diagnostic fault is investigated and/or corrected, it should be cleared from the fault log to avoid confusion during future service calls. After all diagnostic faults are cleared and the GSC+ is in normal mode, the DIAG indicator is not shown on the upper display. Also see the topic Fault Log Viewing OP1.

Procedure For Clearing Faults

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SELECT key. A CID FMI fault code and the counts (number of occurrences) are showing. The lower display shows the hourmeter values of the first and last occurrences of the fault.

3. Press SELECT key. The CID FMI fault code, count and hourmeter value all flash.

4. Press and hold ENTER key for two seconds.

If there is only one CID FMI fault code, the CID FMI that was flashing disappears and the upper display is blank except for the flashing "SERV" indicator. "OP 1" is showing on the lower display. Proceed to the next step.

If there is more than one CID FMI fault code, the CID FMI that was flashing disappears and the upper display shows the next CID FMI with its count and hourmeter value. Repeat steps 3 and 4 until all faults are erased. The lower display then shows "OP 1". Proceed to the next step.

5. Press EXIT key. "OP 1" is showing on lower display.

6. Press EXIT key. The display returns to normal.

Engine/Generator Programming OP5-0

OP5-0 is the option for programming the engine/generator setpoints. The engine/generator setpoints affect the proper operation and serviceability of the engine, and the accuracy of the information shown on the display. The setpoints are programmed (set) in the GSC+ at the factory.

However, the setpoints may need to be changed when the GSC+ is moved from one engine to another or to satisfy customer requirements. The setpoints (stored in the GSC+) must match the specified setpoints of the 136-9048 Control Panel Chart packaged within the control panel. These setpoints are from P001 through P033 and are programmable. Each of the setpoints is described in the following OP5-0 Setpoint chart.

Procedure For Engine/Generator Programming

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key one time. "OP 5-0" is showing on the lower display.

3. Press SELECT key one time. "P001" is showing, followed with the value of the setpoint.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint is showing with its value. Repeat this step until the desired setpoint is showing.

5. Press SELECT key. The value of the setpoint is flashing.

6. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

NOTE: To rapidly scroll through a large range of values, press and hold the appropriate scroll key.

7. Press ENTER key. The value of the setpoint stops flashing. Repeat steps 4, 5, 6 and 7 until all the desired setpoints are adjusted.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Protective Relaying Programming OP5-1

OP5-1 is the option for the programming of the protective relaying setpoints. The protective relaying setpoints determine the response of the GSC+ when one or more of the protective relay functions occur. The protective relay functions are provided by the GSC+ to reduce the possibility of damage occurring to the generator or customer equipment. The setpoints are programmed (set) in the GSC+ at the factory to the default values. The setpoints may be changed to satisfy customer or application requirements. These setpoints are from P101 through P142 and are programmable. Each of the setpoints is described in the following OP5-1 Setpoint chart.

Procedure For Protective Relaying Programming

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key two times. "OP 5-1" is showing on the lower display.

3. Press SELECT key one time. "P101" is showing, followed with the value of the setpoint.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint is showing with its value. Repeat this step until the desired setpoint is showing.

5. Press SELECT key. The value of the setpoint is flashing.

6. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

NOTE: To rapidly scroll through a large range of values, press and hold the appropriate scroll key.

7. Press ENTER key. The value of the setpoint stops flashing. Repeat steps 4, 5, 6 and 7 until all the desired setpoints are adjusted.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Spare Input/Output Programming OP6

OP6 is the option for programming of the spare inputs, spare indicators, spare output, and the programmable spare relay outputs. These spare inputs and outputs are provided in order to satisfy the needs of the customer.

Spare Inputs

The spare inputs are referred to as SP1, SP2, SP3 and SP4. The spare inputs are accessed on the auxiliary terminal strip (AUX) within the control panel on the left wall. The terminations at the auxiliary terminal strip for the spare inputs are:

SP1 is marked as SW1.

SP2 is marked as SW2.

SP3 is marked as SW3.

SP4 is marked as SW4.

The active input state, response taken and time delay for each spare input is programmable. The GSC+ responds to the active state of an input and the response can be delayed. Setpoints SP01 through SP12 are used for the programming of the spare inputs. Each of the setpoints is described in the following OP6 Setpoints chart.


Typical Active High Input Configuration For Spare Input 1 (SP1).


Typical Active Low Input Configuration For Spare Input 1 (SP1).

The GSC+ has to be programmed as to whether the active input state is high (+5 DCV to B+) or low (B-). When an input is programmed for a HIGH active state, a high at the input is considered a spare fault and a low at the input is considered a normal condition.

When an input is programmed for a LOW active state, a low at the input is considered a spare fault and a high at the input is considered a normal condition. Setpoints SP01, SP04, SP07 and SP10 are used for the programming of the active input state of the spare inputs. Each of the setpoints is described in the following OP6 Setpoints chart.

NOTE: If an input is left floating (for example an open switch), the internal circuitry of the GSC+ pulls the input high and the GSC+ responds accordingly.

The GSC+ has to be programmed for how to respond to an active spare fault. The response is to treat the condition as either a fault shutdown or a fault alarm. Setpoints SP02, SP05, SP08 and SP11 are used for the programming of the response. Each of the setpoints is described in the following OP6 Setpoints chart.

NOTE: Spare faults that are programmed to shutdown, are ignored by the GSC+ when engine speed is less than crank termination speed.

The GSC+ has to be programmed for how much time to delay the response to a spare fault (active input). After a spare fault occurs, the GSC+ does not respond (indicators are not activated, codes are not shown and engine operation is not changed) until the time delay has elapsed. Setpoints SP03, SP06, SP09 and SP12 are used for the programming of the time delay. The time delay is selectable from 0 to 250 seconds. Each of the setpoints is described in the following OP6 Setpoints chart.

Alarm Mode Sequence Of Operation - When a fault occurs in a spare input (input active) and it is programmed as an alarm fault:

a. The GSC+ waits for the time delay to elapse.
b. The fault alarm indicator FLASHES.
c. The corresponding code SP1, SP2, SP3 or SP4 is shown on the upper display of the GSC+ when the alarm codes key is pressed.
d. The engine continues to run or is able to start.

Shutdown Mode Sequence Of Operation - When a fault occurs in a spare input (input active) and it is programmed as a shutdown fault:

a. The GSC+ waits for the time delay to elapse.
b. The fault shutdown indicator FLASHES.
c. The corresponding code SP1, SP2, SP3 or SP4 is immediately shown on the upper display of the GSC+.
d. The engine is shut down or is disabled from starting.

The fault shutdown indicator remains FLASHING and the spare fault code remains shown until the ECS is turned to OFF/RESET. After turning the ECS to OFF/RESET and correcting the cause of the spare fault, the engine is able to start and run.

NOTE: Spare faults are not logged into the GSC+ fault log.

NOTE: If it is not desired to use the spare inputs, program the spare inputs for a LOW active state and connect nothing to the spare input wiring.

Spare Indicators

The spare indicators are located on the face of the GSC+ and are referred to as Spare 1, Spare 2, and Spare 3. The spare indicators are programmable. A large selection of trigger conditions is available to activate the spare indicators. Setpoints SP17, SP18 and SP19 are used for the programming of the trigger condition. Each of the setpoints is described in the following OP6 Setpoints chart.

Spare Output

The spare output responds (high or low) to a selected trigger condition. The response and the trigger condition are programmable. The spare output is accessed on the auxiliary terminal strip (AUX) within the control panel on the left wall. The spare output is marked as SPARE on the auxiliary terminal strip.


Typical Active Low Configuration For Spare Output.


Typical Active High Configuration For Spare Output.

The GSC+ has to be programmed as to whether the active state of the spare output is to be high or low. An active low state means that the output is pulled to battery negative when active. The output draws approximately 100mA when in the low state. An active high state means that the output will be allowed to float high (approximately 5.0 DCV when no devices are connected to the spare output). When in the high state the spare output is floating and is capable of driving high impedance (36 000 ohm minimum) logic circuits only. When in the high state, the spare output will not drive low impedance loads such as relays. Setpoint SP13 is used for the programming of the active state of the spare output. The setpoint is described in the following OP6 Setpoints chart.

The GSC+ has to be programmed as to what condition triggers the spare output to the active state. A large selection of trigger conditions is available to activate the spare output. Setpoint SP14 is used for the programming of the trigger condition. The setpoint is described in the following OP6 Setpoints chart.

NOTE: A common use of the spare output is to activate the shunt trip coil of the AC circuit breaker during engine cooldown.

NOTE: The GSC+ diagnoses a fault in the spare output circuit. See CID 334 in the topic Diagnostic Fault Codes of the Testing And Adjusting section.

Programmable Spare Relay Outputs

The programmable spare relay outputs respond to a selected trigger condition. The response and the trigger condition are programmable. The programmable spare relay (K8) is located in the relay module on the rear of the GSC+. RM-25 is the termination for PSR normally open. RM-26 is the termination for PSR normally closed.

The GSC+ must be programmed as to whether the programmable spare relay outputs are active or inactive when triggered. In an active state, the normally open contacts will close and the normally closed contacts will open. Setpoint SP15 is used for the programming of the active state of the spare relay output. The setpoint is described in the following OP6 Setpoints chart.

The GSC+ must be programmed as to what condition triggers the programmable spare relay outputs to the active state. A large selection of trigger conditions is available to activate the spare relay output. Setpoint SP16 is used for the programming of the trigger condition. The setpoint is described in the following OP6 Setpoints chart.

NOTE: The GSC+ diagnoses a fault in the programmable spare relay output circuit. See CID 448 in the topic Diagnostic Fault Codes of the Testing And Adjusting section.

Procedure For Spare Input/Output Programming

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key three times. "OP 6" is showing on the lower display.

3. Press SELECT key. "SP01" is showing, followed with the value of the setpoint.

4. Press SCROLL UP or SCROLL DOWN key. The next setpoint with its value is showing. Repeat this step until the desired setpoint is showing.

5. Press SELECT key. The value of the setpoint is flashing.

6. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint.

7. Press ENTER key. The value of the setpoint stops flashing. Repeat steps 4, 5, 6 and 7 until all the desired setpoints are adjusted.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Hourmeter Programming OP7

OP7 is the option for programming the hours shown on the hourmeter. The hours can be increased but not decreased. This allows the hours on a new GSC+ to exactly match the hours of the GSC+ it is replacing. This improves the tracking of engine maintenance (such as oil changes) when the GSC+ is replaced. Also, if the GSC+ is moved from one engine to another, the hours can be changed to match the new engine (provided the reprogrammed hours are more than the original hours).

If the hourmeter shows all dashes, the hours can not be reprogrammed. If the hourmeter shows all dashes instead of a reasonable numeric value, see CID 268 (GSC+ Internal Memory) within the topic Diagnostic Fault Codes of the Testing and Adjusting section.

Procedure For Hourmeter Programming

This procedure uses as an example a new GSC+ with 0 hours. The hours are to be set to a value of 1234. This procedure applies to any value of hours desired (as long as the hours are increased).

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key four times. "OP 7" is showing on the lower display.

3. Press SELECT key. The present hourmeter value (0 in this example) is showing.

4. Press SELECT key. "000000" is showing with the first digit flashing.

5. Press SCROLL RIGHT key two times. "00000" is showing with the third digit flashing.

6. Press SCROLL UP key. "001000" is showing with the third digit flashing.

7. Press SCROLL RIGHT key. "001000" is showing with the fourth digit flashing.

8. Press SCROLL UP key two times. "001200" is showing with the fourth digit flashing.

9. Press SCROLL RIGHT key. "001200" is showing with the fifth digit flashing.

10. Press SCROLL UP key three times. "001230" is showing with the fifth digit flashing.

11. Press SCROLL RIGHT key. "001230" is showing with the sixth digit flashing.

12. Press SCROLL UP key four times. "001234" is showing with the sixth digit flashing.

13. Press ENTER key. "001234" flashes on the lower display and "ArE YOU SUrE" is showing on the upper display.

* For yes, press ENTER key. "001234" stops flashing.
* For no, press SELECT key. "000000" with the first digit flashing is showing. Repeat this procedure to program the hourmeter again.

NOTE: If the original hourmeter value is to be kept in the GSC+ memory when the display shows "ArE YOU SUrE", press exit key two times for a normal display. The original hourmeter value remains in the GSC+.

NOTE: If the hours entered are less than that already stored in the GSC+, then the upper display briefly shows "Error". The display then shows the original hours that are stored in the GSC+ with the first digit flashing.

14. Press EXIT key. "OP 1" is showing on lower display.

15. Press EXIT key. The display returns to normal. The programmed value for the hourmeter should show on the lower display as the engine data scrolls.

Voltmeter/Ammeter Programming OP8

OP8 is the option for programming the calibration value of the voltmeter and ammeter. When either the GSC+ or the AC transformer box + (ATB+) is replaced, the calibration values, written on the ATB+ bar code sticker, must be programmed into the GSC+ to assure accurate voltage and current values.

There are six transformers in the ATB+ that the GSC+ monitors for voltage and current information. Each transformer has individual characteristics that affect the voltage and current measurements by the GSC+. At the factory, these characteristics are measured, assigned a calibration value and recorded on the bar code sticker which is located on the lower left side of the ATB+. When the genset is assembled at the factory, the calibration values on the bar code sticker are programmed into the GSC+. The calibration value of a transformer is from 0 to 255 in increments of one.

Procedure For Voltmeter/Ammeter Programming

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

NOTE: Any active shutdown fault (any shutdown indicator FLASHING) must be made inactive in order to access service mode. To temporarily change a shutdown fault from an active shutdown fault to an inactive, turn the ECS to the OFF/RESET position. To permanently change a shutdown fault from an active shutdown fault to an inactive, the shutdown fault must no longer be occurring (must be corrected) and the ECS must be turned to the OFF/RESET position. If the jumper from terminal 6 to terminal 9 is not installed on the ECS, the GSC+ does not power up in OFF/RESET and any active shutdown fault must be corrected before entering service mode.

1. Turn the ECS to the STOP position to shutdown the engine. Enter service mode and enter the password. "OP 4" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key five times. "OP 8" is showing on the lower display.

3. Press SELECT key. "AC01" is showing, followed with the value (0 to 255) of the setpoint.

4. Press SELECT key. The value of the setpoint is flashing.

5. Press SCROLL UP or SCROLL DOWN key to adjust the value of the setpoint to match the value shown on the ATB+ for phase A voltage.

6. Press ENTER key. The value of the setpoint stops flashing.

7. Press SCROLL UP key. Repeat steps 3, 4, 5 and 6 for setpoints AC02 through AC06.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Engine Setpoint Verification OP9

OP9 is the option for verifying that EMCP II+ operates correctly when a fault occurs with low oil pressure, high coolant temperature or engine overspeed. An engine overspeed fault causes the GSC+ to shut the engine down. A low oil pressure or high water temperature fault causes the GSC+ to either shut the engine down or sound the alarm, according to the programmed setpoint P003 (shutdown override for engine fault).

OP9 is only for verification of certain engine setpoints. OP5-0 is used for the actual programming of these setpoints. The setpoints verified by these procedures are:

P003 - Shutdown Override For Engine Fault - GSC+ response to a low engine oil pressure or high coolant temperature fault.

0 is for engine shutdown.

1 is for alarm only (shutdown override, no engine shutdown).

Default is 0 for engine shutdown

P010 - Engine Overspeed - Engine speed used by the GSC+ to declare that an engine overspeed fault exists. The engine overspeed setpoint (for all 60 Hz applications) is 1.18 times the rated speed.

The range of values is from 500 to 4330 rpm, in increments of 10.

Default is 2120 rpm.

P013 - Low Oil Pressure Shutdown At Rated Speed - Oil pressure used by the GSC+ to declare that a low oil pressure shutdown fault exists with engine at rated speed (the engine speed must have exceeded the oil step speed for nine seconds).

The range of values is from 34 to 420 kPa (5 to 61 psi), in increments of 1.

Default is 205 kPa (30 psi).

NOTE: When oil pressure drops to within 34 kPa (5psi) of the P013 setpoint, a low oil pressure alarm is issued by the GSC+ and the optional alarm module (with the exception of the NFPA 99 RAN).

P015 - High Water Temperature Shutdown - Coolant temperature used by the GSC+ to declare a high coolant temperature shutdown fault exists (after a 10 second delay).

The range of values is from 85 to 123°C (185 to 253°F), in increments of 1.

Default is 107°C (225°F).

NOTE: When coolant temperature rises to within 6°C (11°F) of the P015 setpoint, a high water temperature alarm is issued by the GSC+ and the optional alarm module (with the exception of the NFPA 99 RAN).

The following conditions are required before the engine setpoints are verified:

* The setpoints listed previously must be correct for the engine application. For the correct setpoints, check the 136-9048 Control Panel Chart packaged within the control panel. To view the setpoints, see Engine/Generator Setpoint Viewing OP2-0 within the topic Service Mode. To program the setpoints, see Engine/Generator Programming OP5-0 within the topic Service Mode.
* The engine is checked at idle and rated speed. No faults should be present at the initial start up. If necessary, troubleshoot and correct any fault.

Procedure For Overspeed Verification

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

1. Start and run the engine at rated speed. Enter service mode and enter the password. "OP 9" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SELECT key. The value (2120 is the default value) of overspeed setpoint P010 is showing on the upper display. "SC1" is showing on the lower display, followed with the present engine speed value.

3. Press SELECT key. The setpoint value is flashing on the upper display.

4. Press SCROLL DOWN key to decrease the setpoint value (2120 is the default value) that is flashing on the upper display. The setpoint value decreases by 10 rpm with each press of the scroll down key. Continue pressing until the setpoint value decreases past the present engine speed value that is showing on the lower display.

When the setpoint value is less than the present engine speed value, the engine shuts down with the indicator for engine overspeed flashing. The GSC+ is no longer in service mode.

Procedure For Low Oil Pressure Verification

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

1. Start and run the engine at rated speed. Enter service mode and enter the password. "OP 9" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SELECT key. The value (2120 is the default value) of overspeed setpoint P010 is showing on the upper display. "SC1" is showing on the lower display, followed with the present engine speed value.

3. Press SCROLL UP key one time. The value [205 kPa (30 psi) is the default value] of the P013 setpoint for low oil pressure shutdown at rated speed is showing on the upper display. "SC2" is showing on the lower display, followed with the present oil pressure value.

4. Press SELECT key. The setpoint value is flashing on the upper display.

5. Press SCROLL UP key to increase the setpoint value that is flashing on the upper display. The setpoint value increases by five with each press of the scroll up key. Continue pressing until the setpoint value increases past the present oil pressure value that is showing on the lower display.

When the setpoint value is greater than the present oil pressure value, the engine shuts down with the indicator for low oil pressure flashing. The GSC+ is no longer in service mode.

Procedure For High Water Temperature Verification

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

1. Start and run the engine at rated speed. Enter service mode and enter the password. "OP 9" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SELECT key. The value (2120 is the default value) of overspeed setpoint P010 is showing on the upper display. "SC1" is showing on the lower display, followed with the present engine speed value.

3. Press SCROLL UP key two times. The value [107°C (225°F) is the default value] of the P015 setpoint for high water temperature shutdown is showing on the upper display. "SC3" is showing on the lower display, followed with the present coolant temperature value.

4. Press SELECT key. The setpoint value is flashing on the upper display.

5. Press SCROLL DOWN key to decrease the setpoint value that is flashing on the upper display. The setpoint value decreases by five degrees with each press of the scroll down key. Continue pressing until the setpoint value decreases past the present coolant temperature value that is showing on the lower display.

When the setpoint value is less than the present coolant temperature value, the engine shuts down with the indicator for high water temperature flashing. The GSC+ is no longer in service mode.

AC Offset Adjustment OP10

OP10 is the option for adjusting the voltmeter readings of the GSC+. The AC voltage measurements of the GSC+ are calibrated at the factory and should never require adjustment.

NOTE: It is NOT recommended that the AC voltmeter be altered. Performing this procedure reduces the accuracy of the GSC+ voltmeter.

NOTE: The adjusted voltages are for display only and will NOT be transmitted over the CAT data link to other modules (such as the Customer Communication Module). Also, the adjusted voltages are NOT used for determining the fault thresholds for protective relaying functions. In both cases, the unadjusted values for AC voltage are still determined by the GSC+ (but not shown), and will be used instead of the displayed values.

Procedure For AC Offset Adjustment

The adjusted voltages and currents are shown on the left side of the upper display, and the amount of offset (as a percent) is shown on the right side of the upper display. The user can adjust each voltage and current by up to ±5.0% in increments of 0.04%.

NOTE: Service mode cannot be entered when the ECS is in the AUTO position.

1. Start and run the engine at rated speed. Enter service mode and enter the password. "OP 9" is showing on lower display. For more information, see the topic Service Mode and see the Procedure To Enter The Password within the topic Password Entry OP3.

2. Press SCROLL UP key one time. "OP 10" is showing on the lower display.

3. Press SELECT key. "AC CAL" is showing on lower display. The present phase A (line to neutral) voltage is showing on the left side of the upper display. The offset (percentage) is showing on the right side of the upper display.

4. Press SELECT key. The offset percentage value is flashing on the right side of the upper display.

5. Press SCROLL UP or SCROLL DOWN key to adjust the voltage value to the desired value. The percentage value continues to flash.

6. Press ENTER key. The percentage value stops flashing.

7. Press SCROLL UP key. Repeat steps 3, 4, 5 and 6 for the other setpoints.

8. Press EXIT key. "OP 1" is showing on the lower display.

9. Press EXIT key. The display returns to normal.

Fault Description

A fault is any condition that does not conform (an abnormal condition) to the rules (program) by which the GSC+ operates. A fault is either active (occurring now) or inactive (previously occurred). Some examples of a fault are:

* Coolant temperature is 123°C (254°F) - this is a high water temperature fault.
* Engine speed is 4500 rpm - this is an engine overspeed fault.
* Broken wire in engine harness - this is a diagnostic fault.
* A failed oil pressure sensor - this is a diagnostic fault.

There is a degree of severity attached to every fault, which also describes the GSC+ response to the fault. Faults are either an alarm (non-critical) fault or a shutdown (critical) fault.

An alarm fault provides an early warning to the operator of a possible future shutdown fault. For an alarm fault, the GSC+ automatically activates alarm mode and the fault alarm indicator FLASHES. For more information see the topic Alarm Mode.

A shutdown fault tells the GSC+ to shut the engine down in order to prevent engine or generator damage. For a shutdown fault, the GSC+ automatically activates shutdown mode which shuts down the engine and FLASHES the corresponding shutdown indicator. For more information see the topic Shutdown Mode.

Most faults have a code. There are three types of fault codes. The type is derived from the GSC+ input that is involved. The three types of fault codes are:

* AL Fault Codes - shown as "AL1" through "AL15" on the upper display. Includes:

Specific engine fault conditions (for example, low engine oil pressure alarm).

Protective relaying functions (for example, underfrequency fault).

* SP Fault Codes - shown as "SP1" through "SP4" on the upper display.
* Diagnostic Fault Codes - Numerous numeric values are possible, but all are identified by the illumination of "CID" and "FMI" on the upper display.

EXCEPTION: There are no fault codes for the shutdown faults that correspond to the dedicated shutdown indicators. Each of these shutdown faults are identified to the operator by the nomenclature nearest to the dedicated shutdown indicator (for example, low oil pressure shutdown).

AL Fault Codes

AL Fault Codes are shown as "AL1" through "AL15" on the upper display. They include specific engine fault conditions (for example, low engine oil pressure alarm), and protective relaying functions (for example, underfrequency fault).

AL fault codes depend on certain setpoints, see the topic Service Mode for more information on setpoints. AL fault codes are not stored in the fault log of the GSC+. Many of the AL fault codes are programmable as a fault alarm or as a fault shutdown. The AL fault codes are accompanied by either the fault alarm indicator, or the fault shutdown indicator on the GSC+ to show the severity of the fault. The AL fault codes and their related setpoints are described in the paragraphs that follow.

AL1 - High Water Temperature Alarm: When the engine coolant temperature increases to within 6°C (11°F) of setpoint P015 (high water temperature shutdown), the GSC+ issues a high water temperature alarm. The fault alarm indicator will FLASH and the "AL1" fault code is shown on the upper display after the alarm codes key is pressed.

P015 is the setpoint for high water temperature shutdown. This setpoint tells the GSC+ at what coolant temperature to declare that a high water temperature shutdown fault exists. When the setpoint is reached, the dedicated shutdown indicator for high water temperature FLASHES and the engine is shutdown.

AL2 - Low Engine Coolant Temperature Alarm: When the engine coolant temperature decreases to setpoint P016 (low water temperature alarm), the GSC+ issues a low water temperature alarm. The fault alarm indicator will FLASH and the "AL2" fault code is shown on the upper display after the alarm codes key is pressed.

P016 is the setpoint for low water temperature alarm. This setpoint tells the GSC+ at what coolant temperature to declare that a low water temperature alarm fault (AL2) exists.

AL3 - Low Engine Oil Pressure Alarm: When engine oil pressure drops to within 34kPa (5psi) of the P013 or P014 setpoint, the GSC+ issues a low oil pressure alarm. The fault alarm indicator will FLASH and the "AL3" fault code is shown on the upper display after the alarm codes key is pressed.

P013 is the setpoint for low oil pressure shutdown at rated speed. This setpoint tells the GSC+ at what oil pressure to declare that a low oil pressure shutdown fault exists when the engine is at rated speed. When the setpoint is reached, the dedicated shutdown indicator for low oil pressure FLASHES and the engine is shutdown.

P014 is the setpoint for low oil pressure shutdown at idle speed. This setpoint tells the GSC+ at what oil pressure to declare that a low oil pressure shutdown fault exists when the engine is at idle speed. When the setpoint is reached, the dedicated shutdown indicator for low oil pressure FLASHES and the engine is shutdown.

AL4 - Fault Detected By Engine ECM: The AL4 fault occurs when the electronic control module (ECM) for the engine detects an alarm fault or a shutdown fault. The engine ECM tells the GSC+ whether the AL4 fault is an alarm fault or a shutdown fault. This includes faults that require derating of the engine. The engine ECM is factory programmed to NOT DERATE in genset applications. The occurrence of an AL4 fault code could mean that the engine ECM is not programmed correctly. Refer to the Troubleshooting service module for the particular engine. The AL4 fault is disabled (P023) on MUI engines and gas engines.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL4" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL4" fault code is shown on the upper display after the alarm codes key is pressed.

AL5 - Low Engine Coolant Level Fault: When the engine coolant level drops below the probe of the coolant loss sensor, the GSC+ issues a low coolant level fault (AL5). The GSC+ can be programmed (P006) to treat this fault as an alarm, a shutdown, or the fault can be disabled (P005). In addition, the GSC+ can be programmed (SP17, SP18 or SP19) to light one of the spare fault indicators on the front of the GSC+ when this fault occurs.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL5" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL5" fault code is shown on the upper display after the alarm codes key is pressed.

AL6 - High Engine Oil Temp Fault: When the engine oil temperature increases to within 6°C (11°F) of setpoint P026 (oil temperature threshold), the GSC+ issues a high engine oil temperature fault. The GSC+ can be programmed (P027) to treat this fault as an alarm, a shutdown, or the fault can be disabled (P005). In addition, the GSC+ can be programmed (SP17, SP18 or SP19) to light one of the spare fault indicators on the front of the GSC+ when this fault occurs.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL6" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL6" fault code is shown on the upper display after the alarm codes key is pressed.

AL7 - Generator Over Voltage Fault (protective relaying function): When line to line voltage between any two phases of the generator rises above the P102 or P105 setpoints, the GSC+ issues an over voltage fault. The GSC+ can be programmed (P101, P104) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P103, P106) with a time delay from 0 to 120 seconds. The fault threshold (P102, P105) can be adjusted from 100 to 125 percent of the nameplate voltage (P028).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL7" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL7" fault code is shown on the upper display after the alarm codes key is pressed.

NOTE: If the AC offset adjustment (OP10) has been performed, then the adjusted voltages are NOT used for determining the fault thresholds for protective relaying functions. The unadjusted values for AC voltage are still determined by the GSC+ (but not shown), and will be used instead of the displayed values.

AL8 - Generator Under Voltage Fault (protective relaying function): When the line to line voltage between any two phases of the generator drops below the P108 or the P111 setpoints, the GSC+ issues an under voltage fault. The GSC+ can be programmed (P107, P110) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P109, P112) with a time delay from 0 to 120 seconds. The fault threshold (P108, P111) can be adjusted from 60 to 100 percent of the nameplate voltage (P028).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as an hutdown fault, the fault shutdown indicator will FLASH and the "AL8" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL8" fault code is shown on the upper display after the alarm codes key is pressed.

NOTE: The AL8 fault is disabled when the engine control switch (ECS) is in the STOP/COOLDOWN position.

NOTE: If the AC offset adjustment (OP10) has been performed, then the adjusted voltages are NOT used for determining the fault thresholds for protective relaying functions. The unadjusted values for AC voltage are still determined by the GSC+ (but not shown), and will be used instead of the displayed values.

AL9 - Generator Over Frequency Fault (protective relaying function): When generator frequency rises above the P114 or P117 setpoints, the GSC+ issues an over frequency fault. The GSC+ can be programmed (P113, P116) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P115, P118) with a time delay from 0 to 120 seconds. The fault threshold (P114, P117) can be adjusted from 60 to 72 Hz (for 50 Hz applications, 50 to 60 Hz).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL9" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL9" fault code is shown on the upper display after the alarm codes key is pressed.

NOTE: The frequency shown on the GSC+ will FLASH when it is greater than or equal to 70 Hz.

AL10 - Generator Under Frequency Fault (protective relaying function): When generator frequency drops below the P120 or P123 setpoints, the GSC+ issues an under frequency fault. The GSC+ can be programmed (P119, P122) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P121, P124) with a time delay from 0 to 120 seconds. The fault threshold (P120, P123) can be adjusted from 36 to 60 Hz (for 50 Hz applications, 30 to 50 Hz).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL10" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL10" fault code is shown on the upper display after the alarm codes key is pressed.

NOTE: The AL10 fault is disabled when the engine control switch (ECS) is in the STOP/COOLDOWN position.

AL11 - Generator Reverse Power Fault (protective relaying function): When reverse power rises above the P126 setpoint, the GSC+ issues a reverse power fault. The GSC+ can be programmed (P125) to enable or disable this fault as a shutdown. In addition, the fault can be programmed (P127) with a time delay from 0 to 30 seconds. The fault threshold (P126) can be adjusted from 0 to 20 percent of the nameplate power (P030).

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL11" fault code is immediately shown on the upper display.

Al12 - Generator Phase Over Current Fault (protective relaying function): When any single generator phase current rises above the P129 or P134 setpoints, the GSC+ issues a phase over current fault. The GSC+ can be programmed (P128, P133) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P130, P135) with a time delay from 0 to 250 seconds. The fault threshold (P129, P134) can be adjusted from 100 to 160 percent of the nameplate current (P029).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL12" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL12" fault code is shown on the upper display after the alarm codes key is pressed.

AL13 - Generator Total Over Current Fault (protective relaying function): When generator total current (sum of three phases) rises above the P131 or P136 setpoints, the GSC+ issues a total over current fault. The GSC+ can be programmed (P128, P133) to enable or disable this fault as an alarm, a shutdown or both. In addition, the fault can be programmed (P132, P137) with a time delay from 0 to 250 seconds. The fault threshold (P131, P136) can be adjusted from 100 to 160 percent of three times the nameplate current (P029).

When enabled both as an alarm and a shutdown fault, the fault thresholds and time delays can be programmed independently to allow the alarm fault to serve as an early warning for the shutdown fault.

When programmed as a shutdown fault, the fault shutdown indicator will FLASH and the "AL13" fault code is immediately shown on the upper display.

When programmed as an alarm fault, the fault alarm indicator will FLASH and the "AL13" fault code is shown on the upper display after the alarm codes key is pressed.

AL14 - Phase A No Voltage Input Fault (protective relaying function): When phase A voltage is not being received at the GSC+ input (GSC+ connector contact 10), the GSC+ issues a phase A no voltage input fault. The phase A voltage input is needed to accurately measure the generator output. The accuracy of some power metering functions and AC frequency measurement may be reduced. The GSC+ automatically treats a lost voltage input on phase A as an alarm fault. This response is not programmable.

When this fault occurs, the fault alarm indicator will FLASH and the "AL14" fault code is shown on the upper display after the alarm codes key is pressed.

AL15 - GSC+ Configuration Error: The GSC+ checks the relationship between the frequency of the generator output voltage and the engine speed. This relationship is shown in the following formula:

The GSC+ automatically treats a configuration error as an alarm fault. This response is not programmable. This fault is corrected by programming the proper values into setpoints P009 (number of ring gear teeth) and P033 (number of generator poles).

When this fault occurs, the fault alarm indicator will FLASH and the "AL15" fault code is shown on the upper display after the alarm codes key is pressed.

NOTE: If setpoint P033 (number of generator poles) is set to 0, the AL15 fault is disabled.

SP Fault Codes

SP fault codes are associated with the spare inputs and are either alarm faults or shutdown faults. The four spare inputs and a spare output are for satisfying the needs of the customer. The spare inputs are programmable in regards to active state (high or low), severity (alarm or shutdown) and delay time. See Spare Input/Output Programming OP6 within the topic Service Mode. The spare inputs and the corresponding SP fault codes are referred to as SP1, SP2, SP3 and SP4.

Alarm Mode Sequence Of Operation - When a fault occurs in a spare input (input active) and it is programmed as an alarm fault:

a. The GSC+ waits for the time delay to elapse.
b. The fault alarm indicator FLASHES.
c. When the alarm codes key is pressed, the corresponding code SP1, SP2, SP3 or SP4 is shown on the upper display.
d. The engine continues to run or is able to start.

Shutdown Mode Sequence Of Operation - When a fault occurs in a spare input (input active) and it is programmed as a shutdown fault:

a. The GSC+ waits for the time delay to elapse.
b. The fault shutdown indicator FLASHES.
c. The corresponding code SP1, SP2, SP3 or SP4 is immediately shown on the upper display of the GSC+.
d. The engine is shut down or is disabled from starting.

The fault shutdown indicator remains FLASHING and the SP fault code remains shown until the ECS is turned to OFF/RESET. After turning the ECS to OFF/RESET and correcting the cause of the spare fault, the engine is able to start and run.

NOTE: Spare faults are not logged into the GSC+ fault log.

NOTE: Spare faults that are programmed to shutdown, are ignored by the GSC+ when engine speed is less than crank terminate speed.

Diagnostic Fault Codes

Diagnostic fault codes are associated with failed electrical components or circuits that provide information to or receive information from the GSC+. These faults are either alarm faults or shutdown faults. For more information, see the topic Alarm Mode and the topic Shutdown Mode.

Alarm Mode Sequence Of Operation - When a diagnostic fault occurs that is an alarm fault:

a. The GSC+ activates the alarm mode.
b. The fault alarm indicator FLASHES.
c. When the alarm codes key is pressed, the corresponding diagnostic code (CID FMI) is shown on the upper display.
d. The engine continues to run or is able to start.

Shutdown Mode Sequence Of Operation - When a diagnostic fault occurs that is a shutdown faul:

a. The GSC+ activates shutdown mode.
b. The fault shutdown indicator FLASHES.
c. The corresponding diagnostic code (CID FMI) is immediately shown on the upper display.
d. The engine is shut down or is disabled from starting.

The diagnostic fault code (CID FMI) closely identifies the cause of the fault. Each diagnostic fault consists of two identifiers and an indicator. The identifiers are shown on the upper display. Service personnel interpret the identifiers to assist with troubleshooting.

The identifiers and indicator are:

* Component Identifier (CID) - The CID is a three digit code that tells which component is faulty. The CID is shown on the upper display. For example; "190" means the circuit for the engine magnetic pickup (MPU) is faulty. For a list of CID codes, see the topic Diagnostic Fault Codes in the Testing And Adjusting section.
* Failure Mode Identifier (FMI) - The FMI is a two digit code that tells what type of failure has occurred. The FMI is shown on the upper display at the same time as the CID. For example; "3" means the signal voltage is too high. For a list of FMI codes, see the topic Diagnostic Fault Codes in the Testing And Adjusting section.
* DIAG indicator - When "DIAG" is FLASHING, the diagnostic fault code (CID FMI) shown on the upper display is active (present now). When "DIAG" is ON CONTINUOUSLY there is an inactive diagnostic fault and the CID FMI are recorded in the fault log. Also, see Fault Log Viewing OP1 within the topic Service Mode. When "DIAG" is absent (not showing), there are NO diagnostic fault codes detected or recorded.


Upper Display Showing A "CID 190 FMI 3" Diagnostic Fault Code

The combination of CID, FMI and DIAG indicator describes one diagnostic fault. For example; if the upper display shows:

a. "190 3"
b. DIAG indicator is FLASHING

Then the signal that is being received by the GSC+ from the engine speed sensor (CID is 190) is too high (FMI is 3) at this time ("DIAG" is FLASHING).

NOTE: The alarm response or shutdown response of four diagnostic faults is programmable by service personnel. An alarm response is normal (P004 = 0), unless programmed for a shutdown response (P004 = 1). See Setpoint P004 within the topic Engine/Generator Programming OP5-0. The diagnostic faults are: oil pressure sensor (CID 100), coolant temperature sensor (CID 110), coolant loss sensor (CID 111) and sensor power supply (CID 269).

The GSC+ has a fault log to help with troubleshooting of diagnostic faults. Inactive diagnostic fault codes (CID FMI) are recorded in the fault log for viewing at a later time. Also, the number of occurrences are totalled and shown on the upper display with the CID and FMI codes. An active diagnostic alarm fault ("DIAG" is FLASHING) becomes inactive ("DIAG" is ON CONTINUOUSLY) when the fault is no longer occurring and also for diagnostic shutdown faults the ECS must be turned to OFF/RESET. The GSC+ stores a maximum of 12 diagnostic fault codes in the fault log. If an additional diagnostic fault becomes inactive, the GSC+ automatically clears the earliest diagnostic fault code and puts the additional diagnostic fault code in the fault log. Inactive diagnostic fault codes that are more than 750 engine hours old are cleared automatically by the GSC+. Only diagnostic fault codes are recorded in the fault log. AL fault codes and SP fault codes are not recorded in the fault log. See Fault Log Viewing OP1 within the topic Service Mode.

After a diagnostic fault is investigated and/or corrected, clearing it from the fault log will avoid confusion during a future service call. When all diagnostic faults are cleared from the fault log and no active diagnostic faults exist the DIAG indicator is OFF (absent). See Fault Log Clearing OP4 within the topic Service Mode.

Optional Modules

Alarm Modules


Alarm Module
(1) Amber indicators. (2) Red indicators. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.

The alarm module (ALM) is an attachment located on the instrument panel. Red indicators (2) and amber indicators (1) are the visual indicators. Horn (5) is the audible indicator. The ALM is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

There are six versions of the basic module. The modules are either alarm modules or a remote annunciator. The term remote annunciator is used but, it is the same basic alarm module. The versions are:

* Standby NFPA 99 alarm module.
* NFPA 99 remote annunciator, used with standby NFPA 99 alarm module.
* Standby NFPA 110 alarm module, used with NFPA 110 remote annunciator panel. See Remote Annunciator Panel (NFPA 110).
* Prime power single engine alarm module.
* Prime power multi engine alarm module.
* EMCP II+ remote annunciator.

The only difference between these modules is in the graphics film on the front of the panel and the jumper wires on the rear. See the DC Schematic in the Schematics And Wiring Diagrams section. The NFPA 99 remote annunciator and the EMCP II+ remote annunciator also have a lamp test switch. The following description of operation refers to the alarm/remote annunciator module as the annunciator module.

The purpose of the alarm modules (ALM) is to give a warning of conditions that are becoming a problem before conditions are bad enough to shut down the engine or keep it from starting.

If, with the ECS in the COOLDOWN/STOP or AUTO positions, an alarm fault develops prior to or while the genset is running, that fault is indicated by the optional alarm module and/or the remote annunciator.

Description Of Operation

NOTE: In the following description the word annunciator is used to mean either alarm module or remote annunciator module.

The annunciator module receives data from three sources: switch inputs, internal circuitry and a serial data link from the GSC+.

Switch Inputs

Up to four inputs are available for switch (i.e., Low Fuel Level) connections. Switch inputs are activated when connected to battery negative (-B). See Table 1.

Internal Circuitry

Internal circuitry is used to determine and annunciate if the DC battery supply voltage is below the setpoint (factory set at 24 DCV).

Data Link

The annunciator module receives data from the generator set control + (GSC+) by a serial data link. The items included in this data stream of information are:

1 - Coolant temperature has exceeded the high temperature alarm setpoint programmed into the GSC+.
2 - Oil pressure is below the low oil pressure alarm setpoint programmed into the GSC+.
3 - Coolant temperature is below the low temperature alarm setpoint programmed into the GSC+.
4 - The engine control switch (ECS) is not in the AUTO or MAN/START position.
5 - Oil pressure is below the low oil pressure shutdown setpoint programmed into the GSC+.
6 - Coolant temperature has exceeded the high water temperature shutdown setpoint programmed into the GSC+.
7 - The engine has failed to start (overcrank).
8 - The engine speed exceeded the engine overspeed setpoint programmed into the GSC+.
9 - The engine shut down due to a coolant loss fault.
10 - The engine shut down due to a spare fault.
11 - The engine shut down due to an emergency stop fault.
12 - The engine shut down due to a diagnostic fault.

Data items 1 through 8 control the operation of the indicators and the horn as indicated in Table 1. Data items 9 through 12 control the operation of the horn only.

The maximum number of modules (alarm, CIM or RDM) connected to the serial data link is three. The maximum distance between a module and the GSC+ is 305 m (1000 ft).

Indicator And Horn Operation

When an alarm fault occurs, the indicator corresponding to that fault flashes at two hertz and the horn sounds. If the alarm fault is NOT LATCHED, the indicator and horn turn off as soon as the alarm fault ceases. If the alarm fault is LATCHED, the indicator continues to flash until the acknowledge/silence input is activated. See Table 1 for LATCHED alarm faults and the indicator and horn functions for each operating mode.

Normally switch input 3 (terminal 10) and switch input 4 (terminal 11) only operate indicators 7 and 8. However, it is possible for switch inputs 3 and 4 to also operate the horn. To do so, connect terminal 10 (sw input 3) to terminal 3 and connect terminal 11 (sw input 4) to terminal 4.

Alarm Silence

Activating the alarm silence switch (4) causes the horn to cease and the indicator to stay on continuously.

Data Link Malfunction

If the data link malfunctions, the indicators controlled by the data link flash at 0.5 hertz. The switch controlled indicators function normally.

Lamp Test

Activating the lamp test switch (3) results in sounding the horn and turning on all indicators continuously for 10 seconds or until the switch is deactivated.

Mode Selection

The annunciator module operates in one of the six modes described in Table 2. The modes are selected by connections made to the mode select inputs (terminals 5 and 6) and switch 2 input (terminal 9) as shown in Table 2.

Remote Annunciator Panel - NFPA 110


Alarm Module
(1) Amber indicators. (2) Red indicators. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.


NFPA 110 Remote Annunciator Panel
(6) Trouble indicator. (7) Horn. (8) Alarm silence switch. (9) Load indicator.

This remote panel functions in conjunction with the NFPA 110 alarm module. The alarm module is mounted in the right side of the instrument panel. When an alarm occurs on the alarm module or a fault occurs on the GSC+, horns (5) and (7) sound in both the alarm module and the remote annunciator. Trouble indicator (6) lights in the remote annunciator panel. The appropriate alarm indicator also lights in the alarm module or the appropriate fault indicator flashes in the GSC+. The remote annunciator is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

When alarm silence switch (4) or (8) is pressed on either the remote panel or the alarm module, the horns on both cease sounding. Also, trouble indicator (6) on the remote panel goes out. The indicator on the alarm module or GSC+ remains on. Another alarm fault will reactivate the horns and indicators as before.

Trouble indicator (6) also acts as a test switch on the remote panel. When indicator (6) is pressed, horn (7) and indicator (6) turn on. The alarm module is not affected by the test switch.

Load indicator (9) is triggered by a transfer switch or similar device. When the transfer switch provides a ground signal, load indicator (9) is ON.

Custom Alarm Module (CAM)


Custom Alarm Module (CAM)
(1) Amber indicators. (2) Red indicators. (3) Lamp test switch. (4) Alarm silence switch. (5) Horn.

The custom alarm module (CAM) is an attachment that can be mounted at the genset or at a remote location. The purpose of the CAM is to annunciate faults, alarms or other conditions from customer supplied inputs.

The CAM operates when powered only by 24 DCV or 32 DCV battery systems. The CAM is equipped with a horn, alarm silence switch, a lamp test switch and 8 switched inputs for customer use.

NOTE: A basic version of the CAM also exists. The basic version does not have a horn, an alarm/silence switch or a lamp test switch. The basic CAM is to be used with an existing fully equipped CAM or an existing alarm module (ALM).

Alarm Operation

A given switch input corresponds to 1 of 8 indicators on the face of the CAM. The indicators will FLASH at a rate of 2 hertz when the corresponding input is closed to battery negative. The red indicators are used to display shutdown conditions, and the amber indicators are used to display alarm conditions.

When an input corresponding to one of the red indicators is activated (connected to battery negative), the indicator will flash and the horn will sound. When the input is disconnected from battery negative, the horn will continue to sound and the red indicator will continue to flash until the alarm silence switch is pressed.

When an input corresponding to one of the amber indicators is activated, the indicator will flash (the horn does NOT sound). When the input is disconnected from battery negative, the amber indicator will turn off.

Alarm Silence Function

The alarm silence switch is activated by connecting the corresponding input to battery negative.

When an input is connected to battery negative, activating the alarm silence switch causes the horn to cease and causes the indicator to change from flashing to ON continuously. The alarm silence function will be overridden if the status of any of the eight switched inputs changes causing additional inputs to be closed to battery negative.

The alarm silence function will not be overridden if the change in status is the opening of any of the inputs from battery negative. The indicators will turn off when their corresponding input is disconnected from battery negative.

Lamp Test Function

Activating the lamp test switch results in sounding the horn and turning on all indicators continuously for 10 seconds or until the switch is deactivated. The lamp test input can be wired to the switch of another alarm module.

Customized Labeling

The condition being monitored by each indicator is determined by the customer. The 130-3326 Film provides a wide variety of labels for the customer to customize the CAM to their application.

Relay Driver Module (RDM)


(1) Relay driver module. (2) Relay board (optional).

The relay driver module (RDM) is an optional module that can be used to expand the number of available outputs on the GSC+. The RDM outputs are controlled by the customer communication module (CCM). The RDM provides nine additional outputs for customer use. The RDM outputs are individually controlled by a serial data link from the GSC+. These outputs may drive the optional relay board, or can be directly connected to horns, lamps, or other devices. The relay board contains nine relays each with one set of NO and NC contacts for customer use. These relays are distinct from and are in addition to the seven relays contained within the relay module on the rear of the GSC+.

Output Test

When an output test signal is received, the RDM activates all outputs for 10 seconds or until the test signal is deactivated. To do an output test, connect terminal 5 of the RDM to terminal 7 of the RDM with a jumper.

When the data link malfunctions, R1 output (terminal 2 of RDM) will FLASH at a rate of 0.5 Hz. Relays R2 through R9 will either maintain their present state or default to OFF. This is controlled by a jumper between terminals 6 and 7 of the RDM. If a jumper is NOT present when the serial data link has a fault, the relay outputs (R2 through R9) will maintain their present state. If the jumper is present, R2 through R9 will default to OFF.

Specifications:

* The maximum distance between the RDM and the GSC+ is 305 m (1000 ft.).
* The operating voltage range is from 15 to 45 DCV. The RDM is designed to operate when powered by only 24 or 32 DCV battery systems.
* The RDM is capable of operating with or without an earth ground.
* The RDM must share a common ground with the GSC+ and the relay board.
* The terminals on the RDM are 6.4 mm (.25 in.) push on blade type connectors.
* The terminals on the relay board are 6-32 screw terminals.
* The driver outputs of the RDM are intended to drive incandescent lamps or relay loads. The driver outputs sink up to 600mA at 15 to 45 DCV and are protected against short circuits to B±.
* The relay outputs of the relay board are protected by 1 amp fuses. The contacts are flashed silver and are rated at 1A at 28 DCV. The relay coils draw 20mA at 24 DCV.

NOTE: The GSC+ diagnoses a fault in the relay driver module circuit. See CID 475 in the topic Diagnostic Fault Codes of the Testing and Adjusting section. The CID 475 procedure also contains schematics for relay driver module installation purposes.

Synchronizing Lights Module


Synchronizing Lights Module
(1) Synchronizing lights. (2) Synchronizing switch.

The optional synchronizing lights (SL) module is located on the instrument panel (same location as for the optional alarm module).

Synchronizing lights (SL) are used as an aid in manually paralleling generator units independent of load. Each of two lights are connected across the generator to the load side of the generator output circuit breaker. The voltage of two phases are measured and the lights indicate when the voltages are in phase. When the voltages are in phase, closing the circuit breaker puts the generator on-line with the other generator unit(s).

NOTE: For a complete explanation on how to parallel two units, make reference to the Operation and Maintenance Manual for SR4B Generators and Control Panels, Form No. SEBU6918.

Synchronizing Module Installation

------ WARNING! ------

To avoid electrical shock and personal injury, shutdown all on-line gensets before installing or repairing the synchronizing module.

--------WARNING!------

NOTE: For connection of the synchronizing light module and connection of resistor taps in the module, see the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.

Make an orderly shutdown of all generators connected to the system. Then connect synchronizing module wires to the terminals as follows:

a. Wire L1 to terminal L1 of TS1 in the generator housing.
b. Wire L3 to terminal L3 of TS1 in the generator housing.
c. Wire T11 to terminal 2 of fuse F13 on the AC transformer box + (ATB+).
d. Wire T13 to terminal 2 of fuse F15 on the AC transformer box + (ATB+).

The customer is responsible for providing proper wire and fusing to connect L1 and L3 to the load side of the generator output circuit breaker. See the AC Schematic in the Schematics And Wiring Diagrams section.

Adjust the connection of wires T11 and T13 on the taps of synchronizing resistors SLR1 and SLR2 as required for the particular generator AC voltage.

208V line to line taps E to D (1760 Ohms)

240V line to line taps E to C (2400 Ohms)

300V line to line taps E to B (5600 Ohms)

380V line to line taps E to B (5600 Ohms)

400V line to line taps E to B (5600 Ohms)

416V line to line taps E to A (7200 Ohms)

480V line to line taps E to A (7200 Ohms)

NOTE: Remove the synchronizing module cover for access to the resistor taps.

Example: For a generator with 400 volts line to line, wire T11 connects to tap B of SLR1 and wire T13 connects to tap B of SLR2. See the Main Chassis Wiring Diagram in the Schematics And Wiring Diagrams section.

Customer Interface Module (CIM)


Customer Interface Module (CIM)
(1) Relay board. (2) Electronic control.

Reference: For more information, see the Schematics And Wiring Diagrams section.

The CIM provides an interface (separate relay contacts) between the GSC+ and switch gear. The two major components of CIM are relay board (1) and electronic control (2). Electronic control (2) connects to the same serial data link as the alarm annunciator. CIM operation is similar to the alarm annunciator except that the data link information is decoded into discrete outputs. The outputs then drive the relays located on relay board (1). The relay contacts can be used to sound a horn, flash a lamp or trigger some other action. Once an output is activated, it remains energized until the initiating faults are cleared. If a malfunction in the serial data link occurs, all electronic control outputs (therefore all relays also) flash at 0.5 Hz. The CIM is designed to operate when powered by only 24 DCV or 32 DCV battery systems.

The available serial data link information is:

* High coolant temperature alarm.
* Low oil pressure alarm.
* Low coolant temperature alarm.
* Engine control switch (ECS) NOT in auto.
* Low oil pressure shutdown.
* High coolant temperature shutdown.
* Overcrank.
* Overspeed.
* Diagnostic fault (GSC+).

Application Guidelines

Lamp Test

When a lamp test signal is received, the CIM activates all outputs for 10 seconds or until test signal is deactivated. Two lamp test signals are possible, the CIM lamp test is activated when:

* Terminal 5 is connected to terminal 7 of electronic control (2).
* The GSC+ lamp test signal is received over the data link.

NOTE: CIM ignores the GSC+ lamp test signal when terminal 6 is connected to terminal 7 of electronic control (2).

Outputs:

* The relays on relay board (1) are fuse protected. The contacts are flashed silver and are rated at 1 amp 28 DCV. The relays draw 20 mA (at 24 DCV).
* The driver outputs of electronic control (2) are intended to drive incandescent lamps or relay loads. The driver outputs draw up to 600 mA (15 to 45 DCV).

Specifications:

* For CIM installation, the maximum distance between electronic control (2) and the GSC+ is 305 m (1000 ft).
* The operating voltage range is 15 to 45 DCV (24 DCV nominal)
* CIM is capable of operating with or without earth ground.
* The terminals on electronic control (2) are 6.4 mm (.25 in) push-on connectors.
* Customer connections at relay board (1) are 6-32 screw terminals.

Customer Communication Module (CCM)


Customer Communication Module (CCM)

The customer communication module (CCM) provides a two-way communication link between the GSC+ and a host computer of the customer. The CCM converts data from standard RS-232C format to CAT data link format and vice versa. The purpose of the CCM is to allow an operator at the host computer to remotely control and monitor the generator set. The CCM can access and monitor the same information available on the GSC+ display.

The CCM can remotely control the following functions when the GSC+ is in the normal mode with the ECS in the auto position:

* Start the engine.
* Stop the engine, provided the remote initiate contact is not closed.
* Activate or deactivate the OSR, provided the low oil pressure shutdown setpoint has been exceeded.
* Activate or deactivate the GFR, provided the GSC+ has not detected a fault. (In this case, the GSC+ will already have activated the GFR.)
* Remotely abort the cooldown time.
* Remotely control the spare output.
* Remotely control the programmable spare relay.

NOTE: The CCM can only control the spare output in an active low type of configuration. For more information, see Spare Input/Output Programming OP6 within the topic Service Mode.

The addition of a specified modem allows two-way communication when the generator set and host computer are separated by great distances.

For more information regarding the CCM, see the Operation & Maintenance Manual, SEBU6874, Customer Communication Module For EMCP II.

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