YUGANDHAR SYSTEMS

GENSET CONTROLLER

FEATURES:

Compact, Reliable, Flexible and intelligent AMF controller based on advance

micro-controller
controller technology.
Most suitable for remote applications.
Effective Auto, Manual, Test and Bypass modes.
Settings of 26 variable parameters provided.
Built in alarm annunciator for emergency faults.
Built in display of Engine R.P.M., Alternator Frequency and Engine Run Hour,
and Battery Voltage, which eliminates the need of separate meters.
All settings and Hour Counter are stored in internal EEPROM.
Built in watch dog timer makes the system fail safe.
Six keys facilitate mode changing, manual operation, fault acknowledge,
fault reset, changing display parameter, as well as setting of different
parameters.
Twenty One LEDs are provided to indicate the status of mains, genset, load,
load
faults,
s, displayed parameter and modes.
modes
Description:
The Genset controller is an useful and intelligent control system for gensets. It
can start the engine automatically, supervise the performance and stop the engine on
detection of errors. It is very easy to interface to the engine and control panel ingredients.
The controller has a built-in alarm annunciator and the effective user interface via 4
digit display, 21 LEDs and 6 Keys. All the necessary parameters like time delays, start
attempt, stop solenoid type etc, can be set during the installation.

FRONT PANEL DESCRIPTION:

Refer the Genset controller front panel drawing, There is a 4 digit display, 21 LEDs with
the corresponding labels and 6 membrane type keys for different operations.
Functions of Display, keys and leds is listed below.

A. KEYS :
KEY FUNCTION
START Starts the engine in manual or test mode.
STOP / RST Stops the engine manually, Resets the fault, Loads the default value in SET mode.
ACK Acknowledge the fault, shuts off the hooter.
MODE Changes the operating mode to the next available mode.
UP ARROW Parameter display scroll up, Value increment in SET mode.
DOWN ARROW Parameter display scroll down, Value decrement in SET mode.

B. LEDS:
LED SWITCHED ON IF…
MAINS ON Mains is ON sensed via LVM in the control panel.
MAINS LOAD On command for Mains Contactor is given by the controller.
GENSET ON Genset is sucessfully started by the controller.
GENSET LOAD On command for Genset Contactor is given by the controller.
FAULT Fault is detected by the controller and when the common fault relay is on.
START FAIL Genset failed to start in the programmed no. of attempts
STOP FAIL Genset failed to stop in the stop cycle.
LOW OIL PRESSURE Low Lub. Oil Pressure Fault
HIGH TEMPERATURE High head Temperature Fault
LOW FUEL LEVEL Low Fuel Level Fault
HALF FUEL Half Fuel Level Warning.
OVERLOAD Electrical Overload Fault
OVERSPEED Engine Overspeed Fault
E.STOP Emergency Stop Fault.
BATT. V Displayed parameter is Battery Voltage
R.P.M. Displayed parameter is engine R.P.M.
Hz. Displayed parameter is Frequency in Hertz.
HOURS Displayed parameter is Engine Hours ( Range 000.0 to 6553.5 Hrs.)
AUTO Auto Mode
MAN Manual Mode
TEST Test Mode - Invoked thorugh keyboard as well as Auto Test Mode.
BYPASS Bypass Mode - When Bypass input is active,
 Following is the list of the different messages displayed .

CONTROLLER INPUTS AND OUTPUTS :

The controller controls the engine via the inputs and outputs. Following is the list of
inputs and outputs, their nature and function. (Refer back panel and relay board drg.)
DIRECT INPUTS :
NAME FUNCTION ORIGIN NATURE
B+ 6 to 35 VDC Batt.positive. Battery Aux. Supply
B- Battery negative Battery Aux. Supply
N Alternature supply Neutral 230 VAC Single PH. supply on when
PH Alternature supply Phase Alternetor output engine is running
INPUTS THROUGH FLAT CABLE FROM RELAY BOARD:
NAME FUNCTION ORIGIN NATURE
LFL Low Fuel Level Fuel Tank - LFL switch NC When Low fuel Level
HFL Half Fuel Level Fuel Tank - HFL switchNC When Half fuel Level
HCT High Temperature Engine - HCT Switch NC When High Temp.
MO Mains ON Mains LVM NC When Mains Fail
LOP Low Oil Pressure Engine - LOP Switch NC When Press. Is Low
OLD Overload Overload Relay NC When Overload
BPS Bypass Input Bypass Switch NC When Bypass active
ESTP Emergency Stop E.Stop Switch NC When E.Stop pressed

OUTPUTS :
RELAY NAME USED TO CONTACT TYPE
START Energise the Starter NO Group I
STOP Energise the Fuel Solenoid NO Group I
FAULT Common fault ( Hooter ) NO Group I
MAINS CONTACTOR Switch on Mains Contactor NO contact
GENSET CONTACTOR Switch on Genset Contactor NO contact
PFC RELAY 1 Remote sensing - telemetry NO contact
PFC RELAY 2 Remote sensing - telemetry NO contact
PFC RELAY 3 Remote sensing - telemetry NO contact
PFC RELAY 4 Remote sensing - telemetry NO contact
The Start, Stop and Fault relays are grouped with pole common (COM pin).
All the relays outputs are potential free contacts ( 2Amp @230 VAC)
PARAMETER SETTING :

Most of the required parameters are settable in Genset Controller. Following is the list of
settable parameters.

0 B la ck Tim e U n it 0: S e c 1: M in u te s S e le ctio n 0.000

1 B la ck Tim e 1 255 A s p e r P a ra 0 1.005
2 S ta rt A tte m p ts 1 9 - 2.003
3 C ra n k P e rio d 2 9 Se c 3.003
4 C ra n k P a u s e 2 59 Se c 4.003
5 M o n ito r D e la y 1 99 Se c 5.010
6 M a in s V e rif y D e la y 1 99 Se c 6.005
7 C o o l D o w n P e rio d 0 255 Se c 7.010
8 S to p C y cle P e rio d 10 30 Se c 8.020
9 W a rn in g A l a rm D u ra tio n 1 255 Se c 9.020
10 F a u lt A lra m D u ra tio n 1 99 M in . 10.05
11 O v e r F re q u e n cy Lim it 50 60 H z. 11.55
12 D e cra n k in g F re q u e n cy 25 40 H z. 12.30
13 F u e l S o le n o id Ty p e 1 2 Ty p e 13.01
14 C h e ck LO P S w itch w h ile S ta rt/ S to p 0 1 Ty p e 14.00
15 LF L E rro r Ty p e 0 1 S e le ctio n 15.01
16 H F L Erro r T y p e 0 1 S e le ctio n 16.00
17 B a tte ry Lo w V o lta g e 0 24 V o lts 17.09
18 P F C R e la y 1 - E rro r N u m b e r 1 10 S e le ctio n 18.01
19 P F C R e la y 2 - E rro r N u m b e r 1 10 S e le ctio n 19.02
20 P F C R e la y 3 - E rro r N u m b e r 1 10 S e le ctio n 20.03
21 P F C R e la y 4 - E rro r N u m b e r 1 10 S e le ctio n 21.04
22 T e s t D u ra tio n 1 99 M in . 22.03
23 A u to Te s t T e s tin g 0 99 Days 23.00
24 F a u lt V e rif ica tio n Tim e 1 9 Se c 24.03
25 Lo a d C h a n g e o v e r D e la y 1 9 Se c 25.02
26 R u n Tim e 1 10 H o u rs 26.10
27 R e s t T im e 0 10 H o u rs 27.00
28 P u ll co il e n a b le 0 1 S e le ctio n 28.00
PARAMETER DESCRIPTION :

0. Blackout Time Units : Units for parameter 1 ( Blackout Time), 0: Sec, 1: Min.

1. Blackout Time : Time delay between mains fail sensed and genset start up is
Attempted, It has variable unit as per parameter 0. Blackout Timer is an intelligent
timer. It keeps the track of last mains fail and new mains fail to adjusts its timing.

2. Start Attempts : No. of times the genset is attempted to start successfully before
declaring the start failure error.

3. Crank Period : Maximum time duration for which the starter pulse is applied to
the engine.

4. Crank Pause : Time duration between two successive start pulses in case the engine
does not start with the earlier pulse.

5. Monitor Delay : The time duration for which the engine is allowed to settle down
after started. No faults are checked during this period

6. Mains Verify delay : Total time for which the mains is verified for its healthy
condition after it resumes (when genset is on).

7. Cool Down Period : The time for which the engine is kept running without load
before stopping. ( invalid if engine is stopped due to fault).

8. Stop Cycle Period : Time duration for which the fuel solenoid is energized or
de-energized to stop the engine.

9. Warning Alarm Duration : Time duration for which the fault relay is kept on after
sensing the warning type of errors.

10. Fault Alarm Duration : Time duration for which the fault relay is kept on after
sensing the shut down type of errors, after stopping the engine. The fault relay can
also be switched off by pressing ACK key, during the fault alarm duration.

11. Over Frequency Limit : Setting for over frequency fault in Hz.

12. De-cranking Frequency : Frequency at which the starter is disabled while start up.

13. Fuel Solenoid Type : Type 1. Energize to stop

Type 2. Energize to run.
14. Check LLOP switch while start / stop :
Setting 0 – Checks LLOP for NC before starting, else POPn error.
De-cranking on LLOP switch NO as well as de-cranking freq.
Checks LLOP switch for NC after stop cycle, else declares
Stop Failure error.
Setting 1 - Ignores status of LLOP switch while start/stop.

15. LFL Error Type : 0 – Indication with warning alarm ( no shut down ).
1 - Shut down engine on LFL

16. HFL Error Type : 0 – Only indication, no warning alarm.

1 – Indication with warning Alarm.

17. Battery Low Voltage : Setting for Battery Low Voltage warning error.

18. PFC Relay1 Error No. : Assign potential free contact relay 1 to any of the errors
no. 1 to 10 ( refer error no. table )

19. PFC Relay2 Error No. : Assign potential free contact relay 2 to any of the errors
no. 1 to 10 ( refer error no. table )

20. PFC Relay3 Error No. : Assign potential free contact relay 3 to any of the errors
no. 1 to 10 ( refer error no. table )

21. PFC Relay4 Error No. : Assign potential free contact relay 4 to any of the errors
no. 1 to 10 ( refer error no. table )

22. Test Duration : Total time for which the engine is kept running in test mode.

23. Auto Test after : No. of days after last started, the test mode should
automatically execute.
24. Fault Verification Time : Time duration for which the fault is verified before
processing it.
25. Load Changeover Delay : Time lag between contactor changeover.

26. Run Time : Maximum Duration in Hours the Set should run continuously.

27. Rest Time : Maximum Duriation in Hours the Set should be kept Off, in case the
engine has been used for full set Run time.
0 means – No Rest Time. (Continuous Run)
.

28. Pull Coil Enable : pull coil enable / disable using this parameter..
0= disable, 1=Enable.
Error No. Table :

ERROR NAME ERROR NO.

START FAIL ERROR 1
STOP FAIL ERROR 2
LLOP ERROR 3
HCT ERROR 4
LFL ERROR 5
HFL ERROR 6
OVERLOAD ERROR 7
OVERSPEED ERROR 8
EMERGENCY STOP ERROR 9
BATTERY LOW ERROR 10
NOT IN AUTO MODE 11
EXCITATION OUTPUT 12
COMMON FAULT 13

SETTING PROCEDURE :
To enter the set mode of the controller, Mains present Press Stop Key.Key Keep the keys
pressed till controller displays “ 0.000” or “ 0.001”.. Now release the keys.
key The controller
has entered the set mode. The keyboard is now redefined for its functions as shown
below.

Refer the parameter table. The first parameter to set is “Blackout Time Units”. As soon
as the controller enters the set mode, the first parameter
parameter is displayed as “0.”, followed by
the earlier preset value say 0 as “000” so the complete display is “0.0000”.
Use PARA UP, PARA DN keys to scroll between the parameters. One can change the
value of setting by using the VAL UP, VAL DN keys. Also RST key loads the default
minimum value. Please note that the value can not cross the predefined limits. For eg.
The start attempts can only be, within 1 to 9.Once the value for the selected parameter is
changed it has to be saved using PARA UP or PARA DN keys, when the value is saved
and next parameter is displayed.
If due to any reason if the settings are corrupt or if the controller is not set the default
values are assigned to the parameters. The default values are “min.” values given in the
parameter table.

BACK PANEL VEIW :

RELAY BOARD :
SPECIFICATION :

Operating Voltage : 6 to 35 VDC Battery Input.

Inputs : 1. Potential free inputs.
a. LOP, HCT from Engine, LFL,HFL from fuel tank and OVERLOAD,
EMR. STOP, BYPASS from Control Panel.
b. Mains voltage healthy signals (MAINS ON) from LVM.
2. Single phase (230VAC) Alternator output for RPM sensing.
Outputs : (Relay board have voltage specific varieties)
a. Starter, fuel, fault outputs : 12 / 24VDC (2 Amp max.)
b. Relay 1,2,3,4 - Potential free contacts : 230VAC, 2 Amp max.
c. Mains and genset contactor relays : Potential free contacts.
230VAC , 2Amp max.
Ambient Conditions :
Operating Temp. range : 0 to 60 deg. C.
Storage Temp. range : -20 to 60 deg. C.
Box Dimensions : 96(H) X 144 (W) X 60 (D)mm. (With connector projection)
Panel mounting.
Panel Cutout : 92(H) X 138(W) mm.
Relay Board : 119 X 97 mm. Mounting holes pitch (H) 110 mm, (V) 87mm.

Gen-set Controller Wiring Diagram

Note :---
If pull And hold coil required ,
Stop relay use as hold coil and PFC1 relay use as pull coil.