Deif GC-1F User manual

INSTALLATION INSTRUCTIONS AND
REFERENCE HANDBOOK
Installation instructions
Functional description
Parameter list
Document no.: 4189340472L
Genset Controller, GC-1F

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This description includes the following versions:
GC-1F SW version 1.2x.x
GC-1F/2 SW version 2.x.x or later

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Table of contents
1. ABOUT THIS DOCUMENT....................................................................................................5
GENERAL PURPOSE ..................................................................................................................................... 5
INTENDED USERS......................................................................................................................................... 5
CONTENTS/OVERALL STRUCTURE .................................................................................................................. 5
2. WARNINGS AND LEGAL INFORMATION ...........................................................................7
LEGAL INFORMATION AND RESPONSIBILITY ...................................................................................................... 7
ELECTROSTATIC DISCHARGE AWARENESS ...................................................................................................... 7
SAFETY ISSUES ........................................................................................................................................... 7
FACTORY SETTINGS ..................................................................................................................................... 7
DEFINITIONS................................................................................................................................................ 7
UL APPLICATIONS ........................................................................................................................................ 8
3. GENERAL PRODUCT INFORMATION.................................................................................9
INTRODUCTION ............................................................................................................................................ 9
TYPE OF PRODUCT ....................................................................................................................................... 9
STANDARD FUNCTIONS ................................................................................................................................. 9
OPTIONS................................................................................................................................................... 10
4. INSTALLATION INSTRUCTIONS .......................................................................................11
MOUNTING ................................................................................................................................................ 11
TERMINALS ............................................................................................................................................... 13
WIRING .................................................................................................................................................... 17
BINARY INPUTS .......................................................................................................................................... 18
BREAKER SELECTION ................................................................................................................................. 19
CHARGER ALTERNATOR CONNECTIONS......................................................................................................... 20
CONNECTION OF THE 3-PHASE VOLTAGE AND CURRENT ................................................................................. 21
CONNECTION OF THE 1-PHASE VOLTAGE AND CURRENT ................................................................................. 21
CONNECTION OF THE SPLIT-PHASE VOLTAGE AND CURRENT............................................................................ 22
COMMUNICATION ....................................................................................................................................... 23
TECHNICAL INFORMATION............................................................................................................................ 28
5. PUSH-BUTTONS, LEDS AND DISPLAY............................................................................31
UNIT......................................................................................................................................................... 31
6. FUNCTIONAL DESCRIPTIONS ..........................................................................................34
ALARM FUNCTION....................................................................................................................................... 34
TIMER FUNCTION........................................................................................................................................ 34
MAINS VOLTAGE UNBALANCE DETECTION ...................................................................................................... 35
PHASE SEQUENCE ERROR........................................................................................................................... 35
UTILITY SOFTWARE INPUT CONFIGURATION ................................................................................................... 35
OUTPUT FUNCTIONS................................................................................................................................... 40
CONFIGURATION OF THE EXTERNAL I/O (OPTION H8) ..................................................................................... 43
ALARM INDICATION LEDS........................................................................................................................... 45
PARAMETER GROUPS ................................................................................................................................. 46
LANGUAGE SELECTION ............................................................................................................................... 46
FAIL CLASS ............................................................................................................................................... 48
SERVICE TIMERS........................................................................................................................................ 49
COMMAND TIMER ....................................................................................................................................... 50
CONFIGURABLE VIEWS IN THE DISPLAY ......................................................................................................... 52
EIC SPEED RAMP (REQUIRES OPTION H5) ................................................................................................... 55
VDO SENSORS.......................................................................................................................................... 56
BINARY INPUT WITH WIRE BREAK DETECTION................................................................................................. 60
FUEL PUMP LOGIC ...................................................................................................................................... 60
ANALOGUE INPUTS 0(4) TO 20 MA............................................................................................................... 62
GENERATOR BREAKER CONTROL ................................................................................................................. 66
TEST FUNCTION ......................................................................................................................................... 67

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OFF MODE ................................................................................................................................................ 68
M-LOGIC .................................................................................................................................................. 69
BUZZER .................................................................................................................................................... 70
UPGRADE OF FIRMWARE ............................................................................................................................. 71
GSM AND MODEM COMMUNICATION ............................................................................................................. 75
SMS ALARMS............................................................................................................................................ 76
PC UTILITY SOFTWARE CONNECTION VIA MODEM ........................................................................................... 77
PC UTILITY SOFTWARE COMMUNICATION SAFETY ........................................................................................... 78
AUTO ENGINE START .................................................................................................................................. 79
START SEQUENCES.................................................................................................................................... 80
STOP SEQUENCES ..................................................................................................................................... 85
7. PARAMETER LIST ..............................................................................................................87
PARAMETER GROUPS ................................................................................................................................. 87
SETUP...................................................................................................................................................... 87
PARAMETER OVERVIEW .............................................................................................................................. 89
FAIL CLASS ............................................................................................................................................... 92
ENGINE ALARM SETTINGS (PROTECTION) ...................................................................................................... 93
MULTI-INPUTS ......................................................................................................................................... 101
BINARY INPUTS WITH WIRE BREAK.............................................................................................................. 101
ANALOGUE INPUTS 0(4) TO 20 MA............................................................................................................. 102
VDO INPUTS ........................................................................................................................................... 103
RPM INPUT............................................................................................................................................. 104
HZ/V MONITORING SETTINGS..................................................................................................................... 111
COMMUNICATION SETUP ........................................................................................................................... 118
EXTERNAL I/O SETUP ............................................................................................................................... 122

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1. About this document
This chapter includes general user information about this handbook concerning the general
purpose, the intended users, the overall purpose and the overall contents and structure.
General purpose
This document is the Installation Instructions and Reference Handbook for DEIF’s Genset
Controller, the GC-1F. The document mainly includes installation instructions, presentation of
push-buttons, LEDs and display, functional descriptions and complete standard parameter lists.
The general purpose of the Installation Instructions and Reference Handbook is to provide the
information needed to install the unit correctly and to provide information about the functionality
of the unit and its applications. The handbook also offers the user the information he needs in
order to successfully set up the parameters needed in his specific application.
Intended users
The handbook is mainly intended for the person responsible for installing the unit and for the
person responsible for the unit setup. Naturally, others might also find useful information in the
handbook.
Contents/overall structure
The Installation Instructions and Reference Handbook is divided into chapters and in order to
make the structure of the document simple and easy to use, each chapter will begin from the top
of a new page. The following will outline the contents of each of the chapters.
About this document
This first chapter includes general information about this handbook as a document. It deals with
the general purpose and the intended users of the Installation Instructions and Reference
Handbook. Furthermore, it outlines the overall contents and structure of the document.
Warnings and legal information
The second chapter includes information about general legal issues and safety precautions
relevant in the handling of DEIF products. Furthermore, this chapter will introduce note and warning
symbols, which will be used throughout the handbook.
General product information
The third chapter will deal with the unit in general and its place in the DEIF product range.
Installation instructions
This chapter includes the information needed to perform correct installation of the unit, for
example mounting instructions, terminals, wiring, inputs, etc.
Push-buttons, LEDs and display
This chapter deals with push-button and LED functions. Furthermore, information about the
display including icon list is presented.
Please make sure to read this handbook before working with the Multi-line 2
controller and the genset to be controlled. Failure to do this could result in
human injury or damage to the equipment.

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Functional descriptions
This chapter includes functional descriptions for the unit’s standard functions. Screen dumps
and flow charts are used in order to simplify the information.
Parameter list
This chapter includes a complete standard parameter list for setup. Therefore, this chapter is to
be used for reference, when information about specific parameters is needed.

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2. Warnings and legal information
This chapter includes important information about general legal issues relevant in the handling of
DEIF products. Furthermore, some overall safety precautions will be introduced and recommend-
ed. Finally, the highlighted notes and warnings, which will be used throughout the document, are
presented.
Legal information and responsibility
DEIF takes no responsibility for installation or operation of the genset. If there is any doubt about
how to install or operate the generator set controlled by the unit, the company responsible for the
installation or the operation of the set must be contacted.
Electrostatic discharge awareness
Sufficient care must be taken to protect the terminals against static discharges during the
installation. Once the unit is installed and connected, these precautions are no longer necessary.
Safety issues
Installing the unit implies work with dangerous currents and voltages. Therefore, the installation
should only be carried out by authorised personnel who understand the risks involved in working
with live electrical equipment.
Factory settings
The unit is delivered with certain factory settings. Given the fact that these settings are based on
average values, they are not necessarily the correct settings for matching the individual engine.
Thus precautions must be taken to check the settings before running the engine.
Definitions
Throughout this document, a number of notes and warnings will be presented. To ensure that
these are noticed, they will be highlighted in order to separate them from the general text.
Notes
Warnings
The notes provide general information which will be helpful for the reader to
bear in mind.
The warnings indicate a potentially dangerous situation which could result in
death, personal injury or damaged equipment, if certain guidelines are not
followed.
Be aware of the hazardous live currents and voltages. Do not touch any AC
measurement inputs as this could lead to injury or death.
The units are not to be opened by unauthorised personnel. If opened anyway, the
warranty will be lost.

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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.

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3. General product information
This chapter includes overall product information about the unit in general and its place in the
DEIF product range.
Introduction
The concept of the GC-1F is to offer a simple and effective solution to genset builders, who
need a flexible yet cost-competitive protection and control unit for small and medium-sized
generators.
Type of product
The Generator Controller GC-1F is a microprocessor-based control unit containing all necessary
functions for protection and control of a power generator. Besides the control and protection of
the diesel engine it contains a full 3-phase AC voltage and current measuring circuit. The unit is
equipped with an LCD display presenting all values and alarms.
Standard functions
Engine control
Start preparation (preheating or prelubrication)
Start/stop sequences with selectable number of start attempts
Fuel solenoid selection (coil type)
Idle speed control
Local or remote start/stop
Stop sequence with cooling down
Command timers
Shut down override (fire pump)
Fuel logic
Running feedback detection selectable
oGenerator Hz/V
oCharger alternator input (W terminal)
oBinary input (D+)
oOil pressure
oRPM input
Engine monitoring
Three configurable inputs, all selectable between
oVDO or
o0(4) to 20 mA from active transducer or
oBinary with wire break
oSix binary inputs, configurable
RPM input, selectable
oMagnetic pickup
oNPN or PNP pickup
oTacho generator
oCharger alternator W terminal

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Generator monitoring
3-phase or single phase generator monitoring
oVoltage/current/frequency/power factor/power/reactive power
Mains monitoring
3-phase or single phase generator monitoring
oVoltage/frequency
Generator protection (ANSI)
Over-/under-voltage (27/59)
Over-/under-frequency (81)
Over-current (50/51)
Overload (32)
Reverse power (32)
Phase sequence error (47)
Mains protection (ANSI)*
Over-/under-voltage (27/59)
Over-/under-frequency (81)
*Only HW 1.05 and SW 2.2x.x
M-Logic
Simple logic configuration tool
Selectable input events
Selectable output commands
Display panel
128 × 64 pixel backlight STN
Alarm texts editable
All texts in multi-language
Clear text alarm messages
Clear text diagnostics for both hardwired inputs and CAN bus messages (J1939)
Log book holding 150 log entries
Real time clock for time and date
Options
The basic GC-1F genset controller unit can be equipped with an AMF and option needed to
provide a real emergency power system controller. Furthermore, CAN bus communication for
different engine types is available, and CAN bus for up to two AOPs is possible at the same
time. Also Modbus RS-485 is available as an option.
A full options list is included in the data sheet.

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4. Installation instructions
This chapter includes the information needed to perform correct installation of the unit, for
example mounting instructions, terminals, wiring, inputs, etc.
Mounting
The unit is designed for flush mounting by means of 4 fixing clamps (IP52), which are included
at delivery. To have the IP65 (12 fixing clamps), the unit must be ordered with option L. The two
fixing clamps on each side are mounted on the top and bottom of the GC-1F box.
Mounting of the unit
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
measurements:
H × W = 151.00 × 211.00 + 1.00 mm
H × W = 5.94" × 8.31" + 0.04"
Unit dimensions

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Tightening torques
Unit panel door mounting: 0.3 Nm (see diagram in "Unit dimensions ")
Plug connections (terminals): 0.5 Nm
AOP-1 and AOP-2 (see diagram below)
Panel door mounting: 0.7 Nm
Sub-D screw: 0.2 Nm
DC-DC converter terminals: 0.5 Nm

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Terminals
Unit rear view
The RJ11 connector for the PC connection interface box is placed on the side of
the unit.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 36 37 38
L1 N L2 NA L3 L1 N NA L2 NA L3
Mains voltage Gen Voltage
+ 0 1 2 3
R21 R22 R23
com
Power
supply Status
config
Multi func-
tional input
1 2 3 4 5 6
com com Input R24 R26
Binary inputs Emergency
stop
45 46
39 40 41 42 43 44
L1
Gen Current
L2 L3
49
50
51
52
53
54
55
56
57
58
59
Can L
GND
Can H
Can 1 J1939
Option H5
B(-)
GND
A(+)
Modbus
RS485
Option H2
Option H8/X4
Can 2
Can H
GND
Can L
47 48
Term. 3-4, status relay is only configurable in HW 1.05 and SW 2x.x.

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Terminal description
Term. Technical data Description
1 Power supply + Aux. supply
2 Power supply – GND
3-4 Status out/configurable. Contact ratings 1 A 24 V DC/
V AC Resistive
General status output for marine approvals**
Configurable only available from HW 1.05 and
sw 2.x.x
9 Common Common for term. 10 to 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 to 23 Common for relay 21, 22 and 23 and input for
emergency stop*
21 Relay output 21. Contact ratings 2 A 30 V DC/V AC
(UL/cUL Listed: 1 A Resistive)
Start prepare/configurable. Function NO
22 Relay output 22. Contact ratings 2 A 30 V DC/V AC
(UL/cUL Listed: 1 A Resistive)
Starter (crank)/configurable. Function NO
23 Relay output 23. Contact ratings 2 A 30 V DC/V AC
(UL/cUL Listed: 1 A Resistive)
Run coil/configurable. Function NO
24-25 Relay output 24. Contact ratings 8 A 30 V DC/V AC
(UL/cUL Listed: 6 A Resistive)
Horn/configurable. Function NO
26-27 Relay output 26. Contact ratings 8 A 30 V DC/V AC
(UL/cUL Listed: 6 A Resistive)
Alarm/configurable. Function NO
Multi-functional inputs
5 Common Common for term. 6 to 8
6 RMI1/0(4) to 20 mA/binary input Fuel level/configurable
7 RMI2/0(4) to 20 mA/binary input Oil pressure/configurable
8 RMI 3/0(4) to 20 mA/binary input Water temp./configurable
Tacho RPM input
16 RPM input (MPU) Magnetic pickup/tacho generator
17 RPM-GND Common for RPM input
18 RPM input (W/L) Magnetic pickup. PNP, NPN or charge alternator
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
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
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.

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44 Gen. current L3, s2 3-phase mains voltage inputs
28 Mains voltage L1
29 Mains voltage neutral
30 Mains voltage L2
31 Not used, must not be connected
32 Mains voltage L3
Breaker relays
45 Relay R45. Contact ratings 2 A 30 V DC/250 V AC
(UL/cUL Listed: Contact ratings 2 A 30 V DC/30 V AC) Generator circuit breaker/configurable, function
NO (normally open).
46 Relay R45 Optional relay for closing mains breaker (option B3)
47 Relay R47. Contact ratings 2 A 30 V DC/250 V AC
(UL/cUL Listed: Contact ratings 2 A 30 V DC/30 V AC) Mains circuit breaker/configurable, function NC
(normally closed). Option B3
48 Relay R47 Optional relay NO contact (option M19)
47 Relay R47. Contact ratings 2 A 30 V DC/250 V AC
(UL/cUL Listed: contact ratings 2 A 30 V DC/30 V AC) Mains circuit breaker/configurable, function NO
(normally open)
48 Relay R47
Optional Modbus RS-485 interface (option H2)
49 B (-)
Modbus RS-485 RTU or ASCII
50 GND
51 A (+)
Optional CAN bus port #1: Engine interface (option H5)
53 CAN-H
CAN J1939 engine communication
54 CAN-GND
55 CAN-L
Optional CAN bus port #2: AOP-2 (option X4)
57 CAN-H
CAN communication line to AOP-2
58 CAN-GND
59 CAN-L
Optional CAN bus port #2: External I/O interface (option H8)
57 CAN-H
CAN communication port to external I/O
58 CAN-GND
59 CAN-L
* If terminal 20 is used for emergency stop, please see wiring diagram below.
** 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 deenergise and the
switch will open. If the unit fails to start up at power-up, then the relay switch will remain open.
The relay output functions are configurable via the PC utility software and can be configured to
cover the following functions:
-Alarm/limit
-Engine run indication
-Horn
-Idle speed output
-Not used
-Prepare
-Run coil
-Starter
-Stop coil
-Engine heater
-Stop coil (not acc. in start seq.)
-Fuel pump

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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:
- VDO sensor input
- 0 to 20 mA input
- 4 to 20 mA input
- Binary input with wire break (switch function)
Tacho RPM input (MPU) can be configured to cover the following functions:
- Magnetic pickup (2-wire)
- NPN or PNP pickup*
* These RPM inputs require external equipment.
Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:
- Magnetic pickup (2-wire)
- W terminal on charger alternator
- NPN or PNP pickup*
* These RPM inputs require external components.
The generator voltage and current input can be configured to the following:
- Voltage 100 to 25000 V primary
- Current 5 to 9000 A primary

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Wiring
The illustrated configuration is the default factory setting. 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.
If a stop coil is used, the REX resistor can be connected to the starter relay
(crank).

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Binary inputs
All binary inputs are 12/24 V DC bi-directional optocoupler type. The typical wiring is illustrated
below:
12/24 V DC
The binary inputs use fixed signals. Only the mode shift input and the test input
(if the timer is used) use pulse signal.

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Breaker selection
The GC-1F can handle contactors and pulse breakers. Selection of breaker type is done under
output setting.
Pulse breaker: GB ON + GB OFF
GB pulse ON time: GB ON + GB OFF can be set in menu 6234
Continuous breaker: GB continues
Continuous breaker selection Pulse breaker selection
GC-1Fs ordered with option M19 will have relay 47 with NO contact.
Pulse breakers are only available in HW 1.05 and SW 2.x.x

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Charger alternator connections
The charger alternator can be used as running-feedback in 2 different ways:
1) Using the D+ terminal connected to terminal 12
2) Using the W terminal connected to the RPM input
Rex: Excitation resistor 12 V systems: 47 4 W
24 V systems: 100 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 voltage (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.
Usually only one of these possibilities is used.
If a stop coil is used, the REX resistor can be connected to the starter relay
(crank).