SEDEMAC

Operation Manual For GC1200 Series Genset Controllers

DOC # ENG-PD-APPKIT-GC1200-002
Rev # 02
Rev Date 4 Jul 2014

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Table of Contents
1 Introduction..............................................................................................................................................3
1.1 Key Highlights Of The Product............................................................................................................................3
2 Specifications............................................................................................................................................3
2.1 Terminals............................................................................................................................................................3
2.2 Power Supply Specifications...............................................................................................................................4
2.3 Generator Voltages And Frequency Measurements............................................................................................5
2.4 Generator Current Sensing.................................................................................................................................5
2.5 Mains Voltage And Frequency Sensing...............................................................................................................5
3 Inputs........................................................................................................................................................6
3.1 Digital Inputs......................................................................................................................................................6
3.2 Analog Resistive Sensor Inputs...........................................................................................................................6
3.3 Magnetic Pick Up Input (Optional).....................................................................................................................6
3.4 Analog Voltage Input..........................................................................................................................................6
3.5 Charge Fail Input.................................................................................................................................................6
4 Outputs.....................................................................................................................................................7
4.1 Digital Outputs...................................................................................................................................................7
4.2 Actuator Outputs (Optional)...............................................................................................................................7
5 Communication Ports................................................................................................................................7
6 Dimensions...............................................................................................................................................8
7 Installation................................................................................................................................................9
7.1 Terminal Description..........................................................................................................................................9
7.2 Typical Wiring Diagram ....................................................................................................................................11
8 Module Display ......................................................................................................................................14
8.1 Monitoring Mode.............................................................................................................................................14
9 Description Of Control Keys.....................................................................................................................23
10 Configuration Mode..............................................................................................................................24
10.1 Configurable Parameters................................................................................................................................24
11 Module Operation In Manual Control Mode..........................................................................................34
11.1 Starting The Engine.........................................................................................................................................34
11.2 Stopping The Engine.......................................................................................................................................34
11.3 Acknowledging The Alarms.............................................................................................................................35
11.4 Clearing The Alarms........................................................................................................................................35
11.5 Accessing Event Log........................................................................................................................................36
12 Troubleshooting....................................................................................................................................36

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1 Introduction
SEDEMAC GC1200 is a series of modern and feature rich genset controllers with user-friendly HMI and full
graphics LCD. The GC1200 controllers come bundled with highly versatile software & extensive I/O's, and
thereby support a wide variety of industry standard features in diesel / gas / gasoline engine gensets. They also
offer unique features such as electronic governing for engines with mechanical fuel systems. With a SEDEMAC
rotary actuator as an add-on for air/fuel charge control, the GC1200 controllers can subsume the electronic
governing duty for the engine and offer tight speed governing performance within ISO 8528:G3 class limits.
This document gives operating instructions for SEDEMAC's GC1200 series genset controllers (refered to as
GC12xx further in the document). Refer to the Software Manual for Configuration Utility For GC1200 series
Genset Controllers for details of the configuration utility.

1.1 Key Highlights Of The Product

• AMF, manual and remote start / stop modes for 1-ph & 3-ph gensets
• PC connectivity via USB port (default), RS232/485 (optional), CAN (optional)
• Backlit and full graphics display with power saving feature
• Multiple language display (optional)

2 Specifications

2.1 Terminals
The GC12xx has two types of terminal blocks as shown in figure below.

2.1.1 5 mm pitch connector suitable for 2 sq mm wire.

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Connector type/ Male (On genset Female (Mating) Male (On genset Female (Mating)
Manufacturer controller) controller)
Degson Phoenix
2-Pin 2EDGVC-5.08-02P-14- 2EDGK-5.08-02P-14- 1755516 1754449
00AH 00AH
4-Pin 2EDGVC-5.08-04P-24- 2EDGK-5.08-04P-24- NA NA
00AH 00AH

2.1.2 3.5 mm pitch connector suitable for 0.5 – 1.5 sq mm wire

Connector type/ Male (On genset Female (Mating) Male (On genset Female (Mating)
Manufacturer controller) controller)
Degson Phoenix
4-Pin 15EDGVC-3.5-04P-14- 15EDGK-3.5-04P-14- 1843622 1840382
00AH 00AH
6-Pin 15EDGVC-3.5-06P-14- 15EDGK-3.5-06P-14- 1843648 1840405
00AH 00AH
8-Pin 15EDGVC-3.5-08P-14- 15EDGK-3.5-08P-14- 1843664 1840421
00AH 00AH
10-Pin 15EDGVC-3.5-10P-14- 15EDGK-3.5-10P-14- 1843680 1840447
00AH 00AH

2.2 Power Supply Specifications

Connector pin number 1, 2 (Ground and Battery positive respectively)
Supply voltage range 8 to 32 VDC
Maximum reverse voltage -40VDC
Measurement accuracy 1% full scale
Resolution 0.1V

2.3 Generator Voltages And Frequency Measurements

Connector pin number 27, 28, 29, 30 (N, B, Y, R respectively)*
Measurement type True RMS
Phase to Neutral voltage 15VAC to 415VAC

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Phase to Phase voltage 15VAC to 750VAC

Voltage accuracy ±1% of full scale
1VAC for Phase to Neutral
Voltage resolution
2VAC for Phase to Phase
Frequency range 3Hz to 75Hz
Frequency accuracy 0.1Hz

Note: * For 1 phase genset application it is mandatory to connect the genset phase and neutral to genset controller's phase R and Neutral respectively.

2.4 Generator Current Sensing

Connector pin number 35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for phase R)
Measurement type True RMS
Maximum CT secondary 5A
current rating
Burden 0.25VA
Accuracy 1% of full scale (5A)

2.5 Mains Voltage And Frequency Sensing

Connector pin number 31, 32, 33, 34 (N, B, Y, R respectively)*
Measurement type True RMS
Phase to Neutral voltage 15VAC to 415VAC
Phase to Phase voltage 15VAC to 750VAC
Voltage accuracy 2% of full scale
Voltage resolution 1VAC for Phase to Neutral
2VAC for Phase to Phase
Frequency range 3Hz to 75Hz
Frequency accuracy 0.1Hz

Note: * For 1 phase genset application it is mandatory to connect the mains phase and neutral to genset controller's phase R and Neutral respectively.

3 Inputs

3.1 Digital Inputs

Connector pin number 10, 11, 12, 21, 22
Number of inputs 5
Type Negative sensing (connect to ground for activation)
Low level threshold 0.8V maximum
High level threshold 8V minimum
Open circuit voltage Vbat – 1VDC

3.2 Analog Resistive Sensor Inputs

Connector pin number 24, 25, 26 (Eng_temp, Fuel_Level sensor, LOP respectively)

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Number of inputs 3
Type Ratiometric sensing
Range 10 to 1000Ω
Accuracy 2% of full scale

3.3 Magnetic Pick Up Input (Optional)

Connector pin number 41, 42
Type Differential ended
Frequency range 10 to 10000Hz
Input voltage range 200mV to 70V
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The
output of MPU is a sine-wave signal.

3.4 Analog Voltage Input

Connector pin number 23
Type Analog voltage sensing
Range 0 to 5VDC
Accuracy 0.5% of full scale
This input may used for the “Paralleling” application where the genset is governed by SEDEMAC GC12xx.

3.5 Charge Fail Input

Connector pin number 7
Voltage range 0 to 30VDC
Excitation PWM (Current limited to 250mA)
Accuracy 1% of full scale
The charge fail input is a combined input and output terminal. When the genset starts, the terminal provides
excitation current to the charge alternator field winding. When the charge alternator is correctly charging the battery,
the voltage of the terminal is close to the battery supply voltage. In case of failure of charging alternator, the voltage
of this terminal is pulled down to a low voltage. This drop in voltage triggers the charge failure alarm. The level at
which this operates and whether this triggers a warning or shutdown alarm is configurable.

4 Outputs

4.1 Digital Outputs

Connector pin number 3, 4, 5, 6, 8, 9
Number of outputs 6
Type High side driver
Maximum current 0.75A

4.2 Actuator Outputs (Optional)

Connector pin number 17, 18, 19, 20
Type Stepper motor drive

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Maximum current 1A each coil

The actuator outputs are used only for the SEDEMAC actuator, if installed. The SEDEMAC actuator is a 4-wire
actuator that is used for creating an electronic governing application in case of a mechanical fuel system engine. In
diesel engines, the rotary actuator's shaft output gets mechanically connected to the stop lever or the throttle lever
of an inline or rotary fuel injection pump. In case of petrol or natural gas engines, the rotary actuator's shaft output
gets connected to the throttle / charge control valve.

5 Communication Ports
USB Used to flash the firmware
RS485 (optional) Used for data communication
Connector pin number for 15, 16
RS485
CAN (optional) Reserved for future use
Connector pin number for 13, 14
CAN

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6 Dimensions

Recommended mounting panel cut-out dimensions: 118 mm X 93 mm.

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7 Installation

7.1 Terminal Description

Following figure shows the rear view of module.

The following table provides the details of GC12xx terminals.

Terminal Name Description
Sr. No.
1 BATT - Battery ground
2 BATT + Battery positive
3 OUT A High side driver output – A
4 OUT B High side driver output - B
5 OUT C High side driver output - C
6 OUT D High side driver output - D
7 CHARGE FAIL IN Input for charging alternator
8 OUT E High side driver output - E
9 OUT F High side driver output - F
10 DIG_IN A Input from switch - A
11 DIG_IN B Input from switch - B
12 DIG_IN C Input from switch - C
13 CAN H (Optional) CAN high
14 CAN L (Optional) CAN low
15 RS485_B (Optional) RS485 - B
16 RS485_A (Optional) RS485 - A
17 GOV_ACT – OUT1 (Optional) Output for the SEDEMAC actuator

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Terminal Name Description

Sr. No.
18 GOV_ACT – OUT4 (Optional) Output for the SEDEMAC actuator
19 GOV_ACT – OUT2 (Optional) Output for the SEDEMAC actuator
20 GOV_ACT – OUT3 (Optional) Output for the SEDEMAC actuator
21 DIG_IN D Input from switch - D
22 DIG_IN E Input from switch - E
23 ANLG_V IN Analog 0 to 5V input - A
24 ANLG_IN ENG_TEMP Analog input from Engine Temperature Sensor
25 ANLG_IN Fuel_Level Analog input from Fuel Level Sensor
26 ANLG_IN LOP Analog input from Lube Oil Pressure Sensor
27 GEN_V IN NTRL Voltage input from Gen Neutral
28 GEN_V IN B Voltage input from Gen B
29 GEN_V IN Y Voltage input from Gen Y
30 GEN_V IN R Voltage input from Gen R
31 MAINS_V IN NTRL Voltage input from Mains Neutral
32 MAINS_V IN B Voltage input from Mains Phase B
33 MAINS_V IN Y Voltage input from Mains Phase Y
34 MAINS_V IN R Voltage input from Mains Phase R
35 CT – IN B1 CT input 1 from Phase B
36 CT – IN B2 CT input 2 from Phase B
37 CT – IN Y1 CT input 1 from Phase Y
38 CT – IN Y2 CT input 2 from Phase Y
39 CT – IN R1 CT input 1 from Phase R
40 CT – IN R2 CT input 2 from Phase R
41 MPU – IN 2 (Optional) Input 2 from engine speed sensor(Inductive)
42 MPU – IN 1 (Optional) Input 1 from engine speed sensor(Inductive)

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7.2 Typical Wiring Diagram

7.2.1 Manual Control Application

The typical wiring diagram of GC12xx for manual control application on engine with mechanical fuel system.

7.2.2 Auo Mains Failuer Application

The typical wiring diagram of GC12xx for Auto Mains Failuer application on engine with mechanical fuel system.

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8 Module Display
Following sections describe the layout of screens.

8.1 Monitoring Mode

In monitoring mode the screen will scroll automatically after a predefined time which can be configured in
configuration menu or you can use the “Navigation UP/DOWN Keys” to scroll/browse the screens.

8.1.1 Home

Screen 1: Home

8.1.2 Generator L-N Voltages

Screen 2: Generator L-N Voltages

(The “L2” & “L3” will be visible only If configured for 3 phase genset)

8.1.3 Generator L-L Voltages

Screen 3: Generator L-L Voltages

(This screen will be visible only If configured for 3 phase genset)

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8.1.4 Generator Currents

Screen 4: Generator Currents

(The “L2” & “L3” will be visible only If configured for 3 phase genset)

8.1.5 Mains L-N Voltages

Screen 5: Mains L-N Voltages

(The “L2” & “L3” will be visible only If configured for 3 phase mains)

8.1.6 Mains L-L Voltages

Screen 6: Mains L-L Voltages

(This screen will be visible only If configured for 3 phase mains)

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8.1.7 Generator Line kW

Screen 7: Generator Line kW

(The “L2” & “L3” will be visible only If configured for 3 phase genset)

8.1.8 Generator Total kW

Screen 8: Generator Total kW

(This screen will be visible only If configured for 3 phase genset)

8.1.9 Generator Line kVA

Screen 9: Generator Line kVA

(The “L2” & “L3” will be visible only If configured for 3 phase genset)

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8.1.10 Generator Total kVA

Screen 10: Generator Total kVA

(This screen will be visible only If configured for 3 phase genset)

8.1.11 Generator Line kVAr

Screen 11: Generator Line kVAr

(The “L2” & “L3” will be visible only If configured for 3 phase genset)

8.1.12 Generator Total kVAr

Screen12: Generator Total kVAr

(This screen will be visible only If configured for 3 phase genset)

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8.1.13 Generator Line PF

Screen 13: Generator Line PF

(The “PF2” & “PF3” will be visible only If configured for 3 phase genset)

8.1.14 Generator Total PF

Screen 14: Generator Total PF

(This screen will be visible only If configured for 3 phase genset)

8.1.15 Generator Frequency

Screen 15: Generator Frequency

8.1.16 Mains Frequency

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Screen 16: Mains Frequency

(This screen will be visible only If “Mains monitoring” is enabled)

8.1.17 Generator Cumulative Power

Screen 17: Generator Cumulative Power

8.1.18 Engine Speed

Screen 18: Engine Speed

8.1.19 Engine Run Time

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Screen 19: Engine Run Time

8.1.20 Battery Voltage

Screen 20: Battery Voltage

8.1.21 Coolant Temperature

Screen 21: Coolant Temperature

(This screen will be visible only If “Coolant temperature” sensor is configured)

8.1.22 Lube Oil Pressure

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Screen 22: Lube Oil Pressure

(This screen will be visible only If “LOP” sensor is configured)

8.1.23 Balance Fuel

Screen 23: Balance Fuel

(This screen will be visible only If “Fuel level” sensor is configured)

8.1.24 Date And Time

Screen 24: Date And Time

8.1.25 Product ID

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Screen 25: Product ID

8.1.26 System ID

Screen 26: System ID

8.1.27 Alarms

Screen 27: Alarms

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9 Description Of Control Keys

Display

Menu
Navigation
UP Key Alarm LED

Menu
Navigation
DOWN Key

AUTO/MANUAL
STOP Key START Key
Mode Select Key

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10 Configuration Mode
For first-time-configuration please refer Quick start guide otherwise please follow the below mentioned instructions.
To enter into the configuration mode press and hold “STOP” and “AUTO” keys simultaneously.

Screen 28: Configuration Mode

To enter into edit mode press “START” key. If you wish to read the configuration press “STOP” key.

Screen 29: Configuration mode: Authentication Page

Please enter your 4-Digit PIN here to access the configuration menu. Once you enter into the “EDIT” mode scroll to
the parameter that you wish to edit and press “START” key to edit the parameter. At this moment the parameter will
start blinking and you can change the parameter value using ”UP” and “DOWN” keys. (Refer section 10.1 for
configuring parameters)
After selecting the required value press ”START” key to save parameter or “STOP” key to discard the value.

10.1 Configurable Parameters

10.1.1 Table 1 – List Of Configurable Parameters

Level 0 Level 1 Level 2 Possible Value
Module General Languages 1 (English)
Start mode 0, 1 (Stop, Auto)
Lamp test enable 0, 1 (Disable, Enable)
GSM enable(Optional) 0, 1 (Disable, Enable)
Extended event log(Optional) 0, 1 (Disable, Enable)
Deep sleep enable 0, 1 (Disable, Enable)
Display Contrast 0-100%
Power save enable 0, 1 (Disable, Enable)
Communication Communication mode 0, 1, 2 (None, Modbus, GSM)
Modbus slave ID 0 - 247

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Level 0 Level 1 Level 2 Possible Value

Modbus baudrate Refer Table 8
Inputs Pressure Low oil pressure action 0, 1, 2 (None, Warning, Shutdown)
monitoring
Low oil pressure threshold 0-5 bar
Low oil pressure open circuit alarm 0, 1 (Disable, Enable)
Temperature High engine temperature action 0, 1, 2 (None, Warning, Shutdown)
monitoring
High engine temperature threshold 25-150 deg C
High engine temperature open circuit 0,1 (Disable, Enable)
alarm
Fuel level LFL shutdown enable 0, 1 (Disable, Enable)
monitoring
LFL shutdown threshold 0-80%
LFL warning enable 0, 1 (Disable, Enable)
LFL warning threshold 0-80%
Fuel tank capacity 0-500 Litres
Fuel theft alarm 0, 1 (Disable, Enable)
Fuel theft threshold 0-100%
Radiator water Low level action 0, 1, 2 (None, Warning, Shutdown)
level monitoring
DIG IN A Source Refer Table 2
Polarity 0, 1 (Close to activate, Open to activate)
Action (for user configured input 0, 1, 2,3 (None, Warning, Electrical trip,
source) Shutdown)
Activation (for user configured input Refer Table 3
source)
Activation delay (for user configured 0-60s
input source)
DIG IN B Source Refer Table 2
Polarity 0,1 (Close to activate, Open to activate)
Action (for user configured input 0, 1, 2,3 (None, Warning, Electrical trip,
source) Shutdown)
Activation (for user configured input Refer Table 3
source)
Activation delay (for user configured 0-60s
input source)
DIG IN C Source Refer Table 2
Polarity 0,1 (Close to activate, Open to activate)
Action (for user configured input 0, 1, 2,3 (None, Warning, Electrical trip,
source) Shutdown)
Activation (for user configured input Refer Table 3

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Level 0 Level 1 Level 2 Possible Value

source)
Activation delay (for user configured 0-60s
input source)
DIG IN D Source Refer Table 2
Polarity 0,1 (Close to activate, Open to activate)
Action (for user configured input 0, 1, 2,3 (None, Warning, Electrical trip,
source) Shutdown)
Activation (for user configured input Refer Table 3
source)
Activation delay (for user configured 0-60s
input source)
DIG IN E Source Refer Table 2
Polarity 0,1 (Close to activate, Open to activate)
Action (for user configured input 0, 1, 2,3 (None, Warning, Electrical trip,
source) Shutdown)
Activation (for user configured input Refer Table 3
source)
Activation delay (for user configured 0-60s
input source)
ANLG_IN LOP Sensor selection 0,1,2(None, DIG IN F, ANLG_IN LOP)
(Digital) Source Refer Table 2
(Digital) Polarity 0,1 (Close to activate, Open to activate)
(Digital, user configured source) Action 0, 1, 2,3 (None, Warning, Electrical trip,
Shutdown)
(Digital, user configured source) Refer Table 3
Activation
(Digital, user configured source) 0-60s
Activation delay
ANLG_IN Sensor selection 0,1,2(None, DIG IN G, ANLG_IN
Eng_Temp Eng_Temp)
(Digital) Source Refer Table 2
(Digital) Polarity 0,1 (Close to activate, Open to activate)
(Digital, user configured source) Action 0, 1, 2,3 (None, Warning, Electrical trip,
Shutdown)
(Digital, user configured source) Refer Table 3
Activation
(Digital, user configured source) 0-60s
Activation delay
ANLG_IN Sensor selection 0,1,2(None, DIG IN G, ANLG_IN
Fule_Level Fuel_Level)
(Digital) Source Refer Table 2
(Digital) Polarity 0,1 (Close to activate, Open to activate)

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Level 0 Level 1 Level 2 Possible Value

(Digital, user configured source) Action 0, 1, 2,3 (None, Warning, Electrical trip,
Shutdown)
(Digital, user configured source) Refer Table 3
Activation
(Digital, user configured source) 0-60s
Activation delay
LOP Sensor Refer Table 4
Calibration
Eng_Temp Refer Table 5
Sensor
Calibration
Fuel_Level Refer Table 6
Sensor
Calibration
Outputs OUT A Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
OUT B Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
OUT C Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
OUT D Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
OUT E Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
OUT F Source Refer Table 7
Polarity 0, 1 (de-energise, Energise)
Timers Cranking Crank time 0-15s
Crank rest time 0-60s
Monitoring Monitoring on delay 0-60s
Mains transient delay 0-30s
Generator transient delay 0-30s
Supervisory Start delay 0-30s
Return delay 0-600s
Cooling time 0-300s
Stop solenoid hold delay 0-120s
Failed to stop delay 0-120s
Transfer time 0-60s
Module Power save mode delay 0-1800s
Page timer 0-1800s
Deep sleep delay 0-1800s

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Level 0 Level 1 Level 2 Possible Value

Generator Alternator Alternator fitted 0, 1 (No, Yes)
configuration
Number of poles 0, 1, 2, 3 (2, 4, 6, 8)
Ac system 0, 1 (1Ph-2wire, 3Ph-4 Wire)
Loading voltage 90-250V
Loading frequency 40-65Hz
Voltage Under voltage shutdown enable 0, 1 (No, Yes)
monitoring
Under voltage shutdown threshold 0-250V
Under voltage warning enable 0, 1 (No, Yes)
Under voltage warning threshold 0-250V
Over voltage shutdown enable 0, 1 (No, Yes)
Over voltage shutdown threshold 120-400V
Over voltage warning enable 0, 1 (No, Yes)
Over voltage warning threshold 120-400V
Frequency Under frequency shutdown enable 0, 1 (No, Yes)
monitoring
Under frequency shutdown threshold 0-60Hz
Under frequency warning enable 0, 1 (No, Yes)
Under frequency warning threshold 0-60Hz
Over frequency shutdown enable 0, 1 (No, Yes)
Over frequency shutdown threshold 25-70Hz
Over frequency warning enable 0, 1 (No, Yes)
Over frequency warning threshold 25-70Hz
Current CT primary 0-8000
monitoring
Full load rating 0-8000A
Over current threshold 50-130%
Over current delay time 0-600s
Over current action 0, 1, 2, 3 (None, Warning, Electrical
trip, Shutdown)
Unbalanced load action 0, 1, 2, 3 (None, Warning, Electrical
trip, Shutdown)
Unbalanced load threshold 0-100%

Unbalanced load delay time 0-600s

Load monitoring Generator rating 0-800 kW

Load monitoring threshold 50-130%
Overload delay time 0-600s
Overload action 0, 1, 2 (None, Warning, Shutdown)

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Level 0 Level 1 Level 2 Possible Value

Mains Mains limits Mains under voltage enable 0, 1 (Disable, Enable)
Mains under voltage trip threshold 0-394
Mains under voltage return threshold 2-396
Mains over voltage enable 0, 1 (Disable, Enable)
Mains over voltage trip threshold 4-398
Mains over voltage return threshold 6-400
Mains under frequency enable 0, 1 (Disable, Enable)
Mains under frequency trip threshold 0-67
Mains under frequency return 1-68
threshold
Mains over frequency enable 0, 1 (Disable, Enable)
Mains over frequency trip threshold 2-69
Mains over frequency return threshold 3-70
System Mains AC system 0, 1 (1Ph-2wire, 3Ph-4 Wire)
Engine Crank disconnect Start attempts 0-9

Disconnect on oil pressure 0, 1 (Disable, Enable)

Disconnect pressure threshold 0-50 bar
Pressure monitor before start 0, 1 (Disable, Enable)
Disconnect on oil pressure switch 0, 1 (Disable, Enable)
Pressure switch transient time 0-30S
Crank disconnect frequency 0-30Hz
Crank disconnect engine speed 0-900RPM
Speed Engine speed sense source 0, 1, 2 (MPU(Optional), Alternator
monitoring frequency, W-point)
Flywheel teeth 0-300
W-point frequency @ 1500RPM 0-500 Hz
Under speed shutdown enable 0, 1 (Disable, Enable)
Under speed threshold 0-3600RPM
Under speed delay 0-60s
Over speed threshold 1000-4000RPM
Over speed delay 0-20s
Battery Low battery volt action 0, 1, 2 (None, Warning, Shutdown)
monitoring
Low battery volt threshold 0-20V
Low battery volt delay 0-1800s
High battery volt action 0, 1, 2 (None, Warning, Shutdown)
High battery volt threshold 12-40V

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Level 0 Level 1 Level 2 Possible Value

High battery volt delay 0-1800s
Charge Charge alternator fail action 0, 1, 2 (None, Warning, Shutdown)
alternator
monitoring
Charge alternator fail threshold 0-12V
Charge alternator fail delay 0-60s
Preheat Preheat timer 2-900RPM
Temp limit enable 0, 1 (Disable, enable)
Temperature limit 25-60°C
Maintenance Oil filter Alarm action 0, 1 (None, Warning)
Engine hours 100-65000 hours
Air filter Alarm action 0, 1 (None, Warning)
Engine hours 100-65000 hours
Fuel filter Alarm action 0, 1 (None, Warning)
Engine hours 100-65000 hours
Electronic General Actuator speed 1-10
governor
(Optional)
Actuator direction 0, 1 (Anticlockwise, Clockwise)
Paralleling mode enable 0, 1(Disable, Enable)
RPM for 0 volt 500-4000
RPM for 5 volt 500-4000
Cranking steps 50-5000
Generator PID Target speed 500-4000 RPM
Parameters
Proportional gain 0-1000
Integral gain 0-2000
Derivative gain 0-1000
Friction set off 0-1000
Gain schedule trigger 0-1000
Loading factor 0-1000
Unloading factor 0-1000
Engine PID Target speed 500-4000 RPM
Parameters
Proportional gain 0-1000
Integral gain 0-2000
Derivative gain 0-1000
Friction set off 0-1000
Gain schedule trigger 0-1000

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Level 0 Level 1 Level 2 Possible Value

Loading factor 0-1000
Unloading factor 0-1000
Active Profile Active profile Active profile 0-10
(Optional)
Alternator configuration 0, 1 (1 Phase, 3 Phase)
Mains monitoring 0, 1 (On, Off)

10.1.2 Table 2 - Input Sources Selection

Value Source
0 None
1 User configured
2 Low fuel level switch
3 Oil pressure switch
4 High temp switch
5 Water level switch
6 Emergency stop
7 Remote start
8 Reserved parameter
9 Simulate “Start”
10 Simulate “Stop”
11 Simulate “Auto”
12 Close generator / open mains
13 Close mains / open generator
14 Simulate mains
15 Paralleling enable
16 Reserved parameter

10.1.3 Table 3 – Activation choices

Value Activation choices
0 Never
1 From start
2 From monitoring on
3 Always

10.1.4 Table 4 – LOP Sensor Calibration

Resistance(Ω) Pressure(Bar)
0-1000(R1-R10) 0-10(P1-P10)

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10.1.5 Table 5 – Eng_Temp Sensor Calibration

Resistance(Ω) Temperature° C
0-1000(R1-R10) 25-150(T1-T10)

10.1.6 Table 6 – Fuel_Level Sensor Calibration

Resistance(Ω) Level (%)
0-1000(R1-R10) 0-100(L1-L10)

10.1.7 Table 7 – Output Source Selection

Value Output source
0 Disable
1 Audible alarm
2 Battery over volts warning
3 Battery under volts warning
4 Charge alt shutdown
5 Charge alt warning
6 Close genset contactor
7 Close mains contactor
8 Mains failure
9 Common alarm
10 Common electrical trip
11 Common shutdown
12 Common warning
13 Cooling down
14 Digital input A
15 Digital input B
16 Digital input C
17 Digital input D
18 Digital input E
19 Digital input F(ANLG_IN LOP)
20 Digital input G (ANLG_IN ET)
21 Digital input H (ANLG_IN FLS)
22 Emergency stop
23 Stop solenoid
24 Fail to start
25 Fail to stop
26 Fuel relay
27 Generator available

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28 Generator over voltage shutdown

29 Generator under voltage shutdown
30 Generator over current
31 High coolant temperature
32 Low fuel level
33 Low oil pressure
34 Main high voltage
35 Mains low voltage
36 Oil pressure open circuit
37 Open generator contactor
38 Open mains contactor
39 Over frequency shutdown
40 Over speed shutdown
41 Start relay
42 Temperature sensor open circuit
43 Under frequency shutdown
44 Under speed shutdown
45 Oil filter maintenance due
46 Air filter maintenance due
47 Fuel filter maintenance due
48 Stop mode
49 Auto mode
50 Manual mode
51 GSM reset
52 Preheat output

10.1.8 Table 8 – Modbus baudrate Selection

Value Baudrate
0 1200
1 2400
2 4800
3 9600
4 19200
5 38400
6 57600
7 115200

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 SEDEMAC

11 Module Operation In Manual Control Mode

11.1 Starting The Engine

First Press STOP Key

Then, Press The START Key

11.2 Stopping The Engine To Crank The Engine.

While Engine Is Running,

Press STOP Key To Stop
Engine. To Stop Engine
Immediately Press STOP
Key Twice.

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11.3 Acknowledging The Alarms

Press The UP
Key To
Acknowledge
Alarms
And Warnings

Note: This is to acknowledge the “Audiable Alarm Output” if configured.

11.4 Clearing The Alarms

While On
Alarms Page,
Press
STOP Key
To
Clear The
Alarms
And Warnings

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11.5 Accessing Event Log

While In
Configuration
Mode,
Press And Hold
UP & DOWN
Key
To Enter
Into Event Log

12 Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Sr. Fault Possible Causes / Remedial Actions
No.
Normal Mode
1 Controller not powered ON. • Check that the battery voltage is within
operating voltage.
• Check DC power line fuse.
• Check continuity between battery +ve and
controller pin # 2.
• Check continuity between battery ground and
controller pin # 1.
2 Controller stuck on same page. • Reset the controller.
3 Controller fails to crank the engine when • Check “START” led is glowing.
commanded. • Check battery voltage
• Check the “START” output configuration.
• Check configured output is working correctly
by measuring the voltage at controller pin.
• Check the configuration of crank disconnect
methods.
• Check “Oil Switch” polarity is correct.
• Check Oil switch/sensor and wiring.
4 Emergency stop alarm when “Emergency Stop” • Check the “Emergency Stop” connection.
not pressed. • Check the “Emergency Stop” polarity in the
configuration.
5 Shutdown alarm/s. • Check the respective switch/sensor and
wiring.
• Check the configuration threshold.

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Sr. Fault Possible Causes / Remedial Actions

No.
6 Warning alarm/s. • Check the respective switch/sensor and
wiring.
• Check the configuration threshold.
7 Charge fail alarm. • Check the charge fail input connections.
• Check the current supplied by controller when
the pin is grounded through current meter.
(Should be equal to 220 - 270 mA.)
• Check charge alternator.
8 A) Controller shows genset “ON” while • Check the oil switch/sensor and wiring.
genset is at rest. • Check oil switch/sensor polarity in
B) “Fail to stop” alarm when genset is at rest. configuration.
• Check oil switch input configuration.
9 Controller issues “Start” command after power on. • Check “Start mode” configuration.
• Check crank output polarity.
• Check crank connections and wiring.
10 Engine runs but controller shows genset “OFF”. • Check MPU signal/voltage signal(R phase).
• Check “Oil pressure” sensor/switch and
wiring.
Measurement Issues
11 Controller displays incorrect PF value. • Check wiring of the respective phase and the
CT.
12 Controller displays incorrect voltage. • Check wiring of the respective phase.
13 Controller displays incorrect KW. • Check wiring of the respective phase and the
CT.
• Check CT ratio in the configuration.
14 Controller displays incorrect current. • Check wiring of the respective phase and the
CT.
• Check CT ratio in configuration.
15 Controller displays incorrect LOP/fuel/Temp sensor • Check respective sensor and its wiring.
value. • Check the calibration for the respective sensor
in configuration.
16 Controller displays incorrect RPM. • Check the MPU connection and configuration
(if enabled).
• Check R-phase and neutral wiring.
• Check frequency and voltage on R-phase.
Communication Issues
17 Unable to connect with computer/laptop through • Check the controller is in “Programming”
USB. mode.
• Check for correct and updated drivers are
installed in computer/laptop for controller.
• Check the cable.
• Check PC USB port.
18 Unable to connect with computer/laptop through • Check that correct and updated drivers are
CAN. installed in computer/laptop for controller and

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Sr. Fault Possible Causes / Remedial Actions

No.
CAN device.
• Check the cable/device.
• Check computer/laptop USB port.
19 Controller fails to start/stop genset after • Check the controller is in “Auto” mode.
commanded through SMS. • Check the controller is receiving the SMS(If
controller receives SMS it will send an
acknowledgement).
• Check the wiring of the communication port.
• Check the wiring of GSM module.
AUTO Mode Issues
20 Controller does not receives “Remote start” • Check the wiring of the remote start.
command. • Check the configuration for the remote start
input.
• Check that the controller is in “Auto” mode.
21 Controller does not receives “Remote stop” • Check the wiring of the remote stop.
command. • Check the configuration for the remote stop
input.
• Check controller is in “Auto” mode.
22 While in Auto mode, controller issues “Start” • Check the mains wiring.
command even if the mains present. • Check the configuration for mains monitoring.
E-Governor Issues
23 A) Controller not able to maintain the target • Check the actuator connections.
RPM. • Check mechanical linkage assembly.
B) Engine RPM is not stable • Check the configuration parameters for e-
governor.
• Check the PID control gains.
24 Engine cranks but does not start the engine. • Check that the actuator moves to full throttle
position when engine cranked.
• Check the actuator connections.
• Check mechanical linkage assembly.
• Check the configuration parameters for e-
governor.

Disclaimer: Due to continuous development, the details provided in this document are subject to change without any
prior notice.

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 SEDEMAC

SEDEMAC Mechatronics
C9-10, C Block, MIDC Bhosari,
Opp Faurecia Ltd, Pune 411026.

Support over email:

Email: support@sedemac.com

Support over phone:

+91-8551039888
+91-8551041888
+91-8551043888

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