Deif GCU 100 User manual

DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
INSTALLATION INSTRUCTIONS
Genset Controller Unit, GCU 100
● Mounting
● Terminal overview
● Wiring
● Communication wiring
● Unit dimensions and cut-out
Document no.: 4189340799D
SW version:

1. General information
1.1. Warnings, legal information and safety..................................................................................................3
1.1.1. Warnings and notes ......................................................................................................................3
1.1.2. Legal information and disclaimer ..................................................................................................3
1.1.3. Safety issues ................................................................................................................................3
1.1.4. Electrostatic discharge awareness ...............................................................................................3
1.1.5. Factory settings ............................................................................................................................4
1.1.6. UL applications..............................................................................................................................4
1.2. About the installation instructions...........................................................................................................4
1.2.1. General purpose ...........................................................................................................................4
1.2.2. Intended users ..............................................................................................................................4
1.2.3. Contents and overall structure ......................................................................................................4
2. Mounting
2.1. GCU 100 mounting.................................................................................................................................5
2.1.1. Mounting of the unit.......................................................................................................................5
2.1.2. Unit dimensions and panel cutout..................................................................................................5
2.1.3. Tightening torques.........................................................................................................................6
3. Terminals
3.1. Terminal overview and description.........................................................................................................8
3.1.1. Terminal overview .........................................................................................................................8
3.1.2. Terminal Description......................................................................................................................8
4. Wiring
4.1. Wiring diagram.....................................................................................................................................12
4.2. DC connections....................................................................................................................................13
4.3. Digital inputs.........................................................................................................................................14
4.4. Charger alternator connections............................................................................................................14
4.5. GCU wiring diagrams for voltage and current......................................................................................16
4.5.1. GCU 113......................................................................................................................................16
4.5.2. GCU 112......................................................................................................................................20
4.5.3. GCU 111 .....................................................................................................................................24
5. Communication
5.1. Wiring instructions................................................................................................................................28
5.2. CANbus engince communication.........................................................................................................29
5.2.1. Connection with 2-wire shielded cable (recommended)..............................................................29
5.2.2. Connection with 3-wire shielded cable........................................................................................30
5.3. Additional Operator Panel, AOP-2.......................................................................................................31
GCU 100 installation instructions
4189340799 UK
DEIF A/S Page 2 of 31

1. General information
1.1 Warnings, legal information and safety
1.1.1 Warnings and notes
Throughout this document, a number of warnings and notes with helpful user information will be presented.
To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-
al text.
Warnings
Warnings indicate a potentially dangerous situation, which could result in death, personal in-
jury or damaged equipment, if certain guidelines are not followed.
Notes
Notes provide general information, which will be helpful for the reader to bear in mind.
1.1.2 Legal information and disclaimer
DEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about how
to install or operate the engine/generator controlled by the Multi-line 2 unit, the company responsible for the
installation or the operation of the set must be contacted.
The Multi-line 2 unit is not to be opened by unauthorised personnel. If opened anyway, the war-
ranty will be lost.
Disclaimer
DEIF A/S reserves the right to change any of the contents of this document without prior notice.
The English version of this document always contains the most recent and up-to-date information about the
product. DEIF does not take responsibility for the accuracy of translations, and translations might not be up-
dated at the same time as the English document. If there is a discrepancy, the English version prevails.
1.1.3 Safety issues
Installing and operating the Multi-line 2 unit may imply work with dangerous currents and voltages. Therefore,
the installation should only be carried out by authorised personnel who understand the risks involved in work-
ing with live electrical equipment.
Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-
puts as this could lead to injury or death.
1.1.4 Electrostatic discharge awareness
Sufficient care must be taken to protect the terminal against static discharges during the installation. Once the
unit is installed and connected, these precautions are no longer necessary.
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General information
DEIF A/S Page 3 of 31

1.1.5 Factory settings
The Multi-line 2 unit is delivered from factory with certain factory settings. These are based on average values
and are not necessarily the correct settings for matching the engine/generator set in question. Precautions
must be taken to check the settings before running the engine/generator set.
1.1.6 UL applications
These flat surface panel-mounted controllers are intended to be used in Listed Generator Assemblies, where
the suitability of the combination has been determined by Underwriters Laboratories.
1.2 About the installation instructions
1.2.1 General purpose
These Installation Instructions mainly include general product and hardware information, mounting instruc-
tions, terminal strip descriptions, I/O lists and wiring descriptions.
The general purpose of this document is to give the user important information to be used in the installation of
the unit.
Please make sure to read this document before starting to work with the Multi-line 2 unit and
the gen-set to be controlled. Failure to do this could result in human injury or damage to the
equipment.
1.2.2 Intended users
These Installation Instructions are mainly intended for the person responsible for the design and installation.
In most cases, this would be a panel builder designer. Naturally, other users might also find useful information
in the document.
1.2.3 Contents and overall structure
This document is divided into chapters, and in order to make the structure simple and easy to use, each
chapter will begin from the top of a new page.
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4189340799 UK
General information
DEIF A/S Page 4 of 31

2. Mounting
2.1 GCU 100 mounting
2.1.1 Mounting of the unit
Included in the package is 12 fixing clamps.
The unit is designed for flush mounting for both IP52 and IP65 mounting. For IP52, four fixing clamps are to
be used; two at the top and two at the bottom.
For IP65, all 12 clamps must be mounted to comply with the rating.
2.1.2 Unit dimensions and panel cutout
The unit is designed for mounting in the panel front.
In order to ensure optimum mounting, the panel door must be cut out according to the following measure-
ments:
H × W = 151.00 × 211.00 + 1.00 mm
H × W = 5.94" × 8.31" + 0.04"
Dimensions are in mm (inches) and valid for GCU 111/112/113.
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Mounting
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160.0 (6.30)
220.0 (8.66)
151.0 (5.94)
211.0 (8.30)
61.0 (2.40)
54.0 (2.13)
0.15-0.20 Nm
2.1.3 Tightening torques
Unit panel door mounting: 0.15-0.20 Nm, 1.4-1.8 lb-in (see diagram in "Unit dimensions and panel cut-
out")
Plug connections (terminals): 0.5 Nm, 4.4 lb-in
AOP-1 and AOP-2 (see diagram below)
Panel door mounting: 0.7 Nm, 6.2 lb-in
Sub-D screw: 0.2 Nm, 1.8 lb-in
DC-DC converter terminals: 0.5 Nm, 4.4 lb-in
GCU 100 installation instructions
4189340799 UK
Mounting
DEIF A/S Page 6 of 31

220.0 (8.661)
115.0 (4.528)
Display
20.0 (0.787)
0.7 Nm
Screw M3
Bossard BN5687
or similar
0.2 Nm
9P Female
Sub 0
connector
Max. 10 mm
Min. 6 mm
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Mounting
DEIF A/S Page 7 of 31

3. Terminals
3.1 Terminal overview and description
3.1.1 Terminal overview
Unit rear view
6 7 83 4 51 2
+ -
Power
supply Multi-functional inputs
Com
RS485
Modbus
49
50
51
B(-)
GND
A(+)
CAN B
57
58
59
H
Com
L
CAN A
53
54
55
H
Com
L
56
52
Generator voltage
33 34 35 36 37 38
L1 N L2 L3
9 10 11 12 13 14 15 16 1817
Digital inputs
Com
19 20 21 23 24 2522 26 27
Com
Busbar voltage
28 29 30 31 32
L1 N L2 L3
45 46 47 48
L1 L2 L3
Generator current
39 40 41 42 43 44
MPU Com W
RPM inputs
Service
port
Emer.
Stop
Status
S1 S2 S1 S2 S1 S2
The RJ11 connector for the PC connection interface box is placed on the side of the unit.
3.1.2 Terminal Description
For the relay outputs, the following terms will be used:
NO means Normally Open.
NC means Normally Closed.
Com. means common terminal for the individual relay.
GCU 100 installation instructions
4189340799 UK
Terminals
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Terminal Technical data Description
1 Power supply + 6…36V DC (UL/cUL Listed: 7.5…32.7V DC)
2 Power supply – 0V DC
3-4 Status out/configurable. Contact ratings 1 A
24V DC/V AC Resistive
See note*
9 Common Common for term. 10…15
10 Digital input Start enable/configurable
11 Digital input Remote start/stop/configurable
12 Digital input Charge alternator D+ (running)/configurable
13 Digital input Configurable
14 Digital input Coolant temperature/configurable
15 Digital input Oil pressure/configurable
19 Common Common for emergency stop term. 20
20 Emergency stop and common for 21…23 Common for relay 21, 22 and 23 and input for
emergency stop**
21 Relay output 21. Contact ratings 2 A 30V
DC/V AC (UL/cUL Listed: 1 A Resistive)
Start prepare/configurable. Function NO
22 Relay output 22. Contact ratings 2 A 30V
DC/V AC (UL/cUL Listed: 1 A Resistive)
Starter (crank)/configurable. Function NO
23 Relay output 23. Contact ratings 2 A 30V
DC/V AC (UL/cUL Listed: 1 A Resistive)
Run coil/configurable. Function NO
24-25 Relay output 24. Contact ratings 8 A 30V
DC/V AC (UL/cUL Listed: 6 A Resistive)
Horn/configurable. Function NO
26-27 Relay output 26. Contact ratings 8 A 30V
DC/V AC (UL/cUL Listed: 6 A Resistive)
Alarm/configurable. Function NO
Multi-functional inputs
5 Common Common for term. 6…8
6 RMI 1/4...20 mA/digital input Fuel level/configurable
7 RMI 2/4...20 mA/digital input Oil pressure/configurable
8 RMI 3/4...20 mA/digital input Water temp./configurable
Tacho RPM input
16 RPM input (MPU) Magnetic pick-up tacho generator
17 RPM-GND Common for RPM input
18 RPM input (W/L) Magnetic pick-up. PNP, NPN or charge alterna-
tor W terminal
3-phase generator voltage input
33 Gen. voltage L1 Generator voltage and frequency
34 Gen. neutral
35 Not used, must not be connected
36 Gen. voltage L2
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4189340799 UK
Terminals
DEIF A/S Page 9 of 31

Terminal Technical data Description
37 Not used, must not be connected
38 Gen. voltage L3
3-phase generator current input
39 Gen. current L1, s1 Generator current
40 Gen. current L1, s2
41 Gen. current L2, s1
42 Gen. current L2, s2
43 Gen. current L3, s1
44 Gen. current L3, s2
3-phase busbar voltage inputs
28 Busbar voltage L1 Busbar voltage
29 Busbar voltage neutral
30 Busbar voltage L2
31 Not used, must not be connected
32 Busbar voltage L3
Breaker relays
45 Relay R45. Contact ratings 2 A 30V DC/
250V AC
(UL/cUL Listed: Contact ratings 2 A 30V DC/
30V AC)
Configurable, function NO (normally open)
46 Relay R45
47 Relay R47. Contact ratings 2 A 30V DC/
250V AC
(UL/cUL Listed: Contact ratings 2 A 30V DC/
30V AC)
Configurable, function NO (normally open)
48 Relay R47
Modbus RS485 interface
49 B (-)
Modbus RS485 RTU or ASCII50 Data GND
51 A (+)
CANbus port A: Engine interface
53 CAN-H
CAN J1939 engine communication
54 Data GND
55 CAN-L
Optional CANbus port B: AOP-2 interface
57 CAN-H
CAN communication line to AOP-258 Data GND
59 CAN-L
GCU 100 installation instructions
4189340799 UK
Terminals
DEIF A/S Page 10 of 31

* The status relay is the uP watchdog output. This relay is normally energised, and the switch is closed after
power-up. If the uP fails or the power is lost, the relay will de-energise and the switch will open. If the unit fails
to start up at power-up, then the relay switch will remain open.
** If terminal 20 is used for emergency stop, please see wiring diagram below.
The relay output functions are configurable via the PC utility software and can be configured to cover the fol-
lowing functions:
● Alarm/limit
● Engine run indication
● Horn
● Idle speed output
● Not used
● Prepare
● Run coil
● Starter
● Stop coil
● Engine heater
● Fuel pump
It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with double
systems.
The multi-functional inputs can be configured to cover the following functions:
● RMI sensor input
● 4…20 mA input
● Binary input with wire break (switch function)
Tacho RPM input (MPU) can be configured to cover the following functions:
● Magnetic pick-up (2-wire)
● NPN or PNP pick-up*
* These RPM inputs require external equipment.
Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:
● Magnetic pick-up (2-wire)
● W terminal on charger alternator
● NPN or PNP pick-up*
* These RPM inputs require external components.
The generator voltage and current input can be configured to the following:
● Voltage 100…25000 V primary
● Current 5…9000 A primary
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4189340799 UK
Terminals
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4. Wiring
4.1 Wiring diagram
27
26
25
12
Controller
Oli pressure
1
2
R24
R23
RJ11
plug
R22
R21
24
23
22
21
20
19
4
3
15
14
13
11
10
9
Coolant temp.
Overspeed
Remote start
Start enable
Programming
tool
Battery
- +
Emer. STOP
Status
Start prep.
Starter
RUN coil
- + F
Alarm horn
Alarm
Running
1N4007
Rex
D+D-
Charging
alternator
R26
Term. 12 can be used as alarm input if not
used for charger generator terminal D+
Rex: 12 V systems: 47 Ω 4 W
24 V systems: 100 Ω 6 W
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
The illustrated configuration is an example of settings. The use of the relays can be chosen
freely.
It is important to protect the unit against damage caused by high voltages. Therefore, the fuse
must not be more than 2 A slow-blow.
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 12 of 31

4.2 DC connections
57
58
59
Com
CAN L
CAN H
External I/O and AOP 2
GND
A (+)
B (-)
Modbus
49
50
51
8
7
6
RMI
RMI
RMI
Multi-functional inputs,
RMI sensors
5
Multi-functional inputs,
Analogue 4-20 mA
8
7
6
2
1
3
Multi-functional inputs,
Binary input
5
8
7
6
2
1
3
5
- +
- +
- +
R
R
R
53
54
55
Controller
Com
CAN L
CAN H
Engine communication
Tacho input
Magnetic pickup/
Tacho generator
16
17
Tacho input
NPN/PNP pickup
18
17
Tacho input
W input from charger
alternator
18
17
out
+24V DC B+ W
B-
Controller Controller
Controller Controller Controller
Controller Controller Controller
Connection example 4-20 mA
Active transducer
Passive transducer
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4189340799 UK
Wiring
DEIF A/S Page 13 of 31

4.3 Digital inputs
All digital inputs are 12/24V DC bi-directional optocoupler type. The typical wiring is illustrated below:
The digital inputs use fixed signals. Only the mode shift input and the test input (if the timer is
used) use pulse signal.
4.4 Charger alternator connections
The charger alternator can be used as running-feedback in two different ways:
1. Using the D+ terminal connected to terminal 12
2. Using the W terminal connected to the RPM input
Usually only one of these possibilities is used.
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 14 of 31

U
Charger
alternator
9
V W
Stator
Brush
Brush
Exciter
coil (rotor)
Excitation
controller
B+ D+ W
1N4007
Rex
2524 12 18 17
Running
feedback
- +
Battery
Run coil RPM
input
Rex: Excitation resistor 12 V systems: 47 Ω 4 W
24 V systems: 100 Ω 6 W
At standstill, the battery + is connected to terminal 9 (common), and a current flows to terminal 12 and via the
D+ input on the alternator to ground (battery -). When the starter is engaged (cranking), the battery will supply
the D+ through the REX resistor, helping the alternator to excite. When the alternator starts to produce volt-
age (excitation OK), the speed of the alternator will be above running speed, and the voltage on term. 12 will
rise to a value higher than the battery voltage and then interrupt the current flow through REX and activate
the running feedback input. Engine is running.
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 15 of 31

4.5 GCU wiring diagrams for voltage and current
4.5.1 GCU 113
3-phase
BUSBAR
L1 L2 L3N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s1
s2
s2
GENERATOR
BUSBAR
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
GB
TB
s1
s2
Consumers
GCU 113
GB ON
command
TB ON
command
GB OFF
command
TB OFF
command
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 16 of 31

2-phase L1L2
BUSBAR
L1 L2N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s2
GENERATOR
BUSBAR
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
GB
TB
s1
s2
Consumers
GCU 113
GB ON
command
TB ON
command
GB OFF
command
TB OFF
command
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 17 of 31

2-phase L1L3
BUSBAR
L1 L3N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s2
GENERATOR
BUSBAR
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
GB
TB
s1
s2
Consumers
GCU 113
GB ON
command
TB ON
command
GB OFF
command
TB OFF
command
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 18 of 31

1-phase
BUSBAR
L1N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
GENERATOR
BUSBAR
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
GB
TB
s1
s2
Consumers
GCU 113
GB ON
command
TB ON
command
GB OFF
command
TB OFF
command
GCU 100 installation instructions
4189340799 UK
Wiring
DEIF A/S Page 19 of 31

4.5.2 GCU 112
3-phase
BUSBAR
L1 L2 L3N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s1
s2
s2
GENERATOR
BUSBAR
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
GB
s1
s2
GCU 112
GB ON
command
GB OFF
command
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Wiring
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