EMKO TRANS-SYNCRO User manual

TRANS-SYNCRO
AUTO START LOAD SHARE UNIT
FOR GAS/DIESEL/GASOLINE GENERATORS
WITH J1939 ECUs
User Manual
EMKO ELEKTRON K A. .
Demirta Org. San. Bolg.
Karanfil Sk. No: 6 TR
16369 Bursa / TURKEY
Ý Þ
þ
Phone
Faks
Url
E-mail
: [phone]
: [phone]
:
:
[e-mail]
www.emkoelektronik.com.tr
[e-mail]
Introduction Manual. ENG TRANS-SYNCRO 02 V37 09/20

CONTENTS
2
1.Introduction.......................................................................................................................................
2.Installation.........................................................................................................................................
1.1 General Specifications..............................................................................................................
1.2 Warranty....................................................................................................................................
1.3 Maintenance .............................................................................................................................
Figure 2.2 Panel Cut-Out..........................................................................................................
2.4 Governor Connection.................................................................................................................
2.5 AVR Connection.........................................................................................................................
3.1 Front Panel Description.............................................................................................................
3.2 Changing And Saving Parameter Values .................................................................................
4.1 Operator Parameters.................................................................................................................
4.1.1 Generator.........................................................................................................................
4.2 Technician Parameters..............................................................................................................
4.2.1 System.............................................................................................................................
4.2.2 Generator.........................................................................................................................
4.2.3 Engine..............................................................................................................................
4.2.4 Inputs...............................................................................................................................
4.2.5 Outputs.............................................................................................................................
4.2.6 Timers..............................................................................................................................
4.2.7 Expansion Modules..........................................................................................................
4.2.8 Synchronization................................................................................................................
4.2.9 Logic Controller................................................................................................................
4.2.10 User Adjustment.............................................................................................................
2.1 Unit Configuration......................................................................................................................
2.2 Panel Mounting..........................................................................................................................
Figure 2.1 Front View................................................................................................................
2.3 Electrical Connection.................................................................................................................
3.Definition Of Front Panel And Accessing To The Parameters......................................................
4.Parameters........................................................................................................................................
5.Auto Adjust Feature For Governor And AVR..................................................................................
6.Logic Controller.................................................................................................................................
7.Specifications....................................................................................................................................
8.Other Informations............................................................................................................................
Page 4
Page 38
Page 6
Page 5
Page 38
Page 5
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Page 4
Page 4
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Page 51
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Page 5
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Page 25
Page 142
Page 63
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Page 89
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Page 144
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Page 155
Page 141

3
EU DECLARATION OF CONFORMITY
Manufacturer’s Name : EMKO ELEKTRONIK A.S.
Manufacturer’s Address : DOSAB, Karanfil Sk., No:6,
16369 Bursa, TURKEY
Product Name :
Type Number : TRANS-SYNCRO
Product Category : Electrical equipment for measurement, control and
laboratory use
This declaration is issued under the sole responsibility of the manufacturer.
The product(s) that are stated above are fully in conformity with the essential requirements of
Council Directives:
This declaration is based on the full compliance of the products with the following European
standards:
Synchronising & Load Sharing Unit
When and Where Issued Authorized Signature
2014 / 35 / EU The Low Voltage Directive
2014 / 30 / EU The Electromagnetic Compatibility Directive
EN 61000-6-4:2007 EMC Generic Emission Standard for Industrial Environments
EN 61000-6-2:2005 EMC Generic Immunity Standard for Industrial Environments
EN 61010-1:2010 Safety Requirements for electrical equipment for measurement, control
and laboratory use
EN 60947-6-1:2005/A1:2014 Low - voltage switchgear and controlgear - Part 6-1: Multiple
function equipment - Transfer switching equipment
02 March 2017 Name : Serpil YAKIN
BURSA-TURKEY Position : Quality Manager
nd

1.Introduction
1.1 General Specifications
4
1.2 Warranty
EMKO Elektronik warrants that the equipment delivered is free from defects in material and
workmanship. This warranty is provided for a period of two years. The warranty period starts from
the delivery date. This warranty is in force if duty and responsibilities which are determined in
warranty document and instruction manual performs by the customer completely.
1.3 Maintenance
Repairs should only be performed by trained and specialized personnel. Cut power to the device
before accessing internal parts.
Do not clean the case with hydrocarbon-based solvents (Petrol, Trichlorethylene etc.). Use of
these solvents can reduce the mechanical reliability of the device. Use a cloth dampened in ethyl
alcohol or water to clean the external plastic case.
TRANS-SYNCRO is a synchronising & load sharing unit for diesel, gas or gasoline generators.
The unit is an easy to use multi-generator loadshare system, designed to synchronise up to 32
generators including electronic and non-electronic engines.
- Sequential set start
- Manual voltage/frequency adjustment
- Direct/Reverse Governor andAVR control
- Volts, frequency and phase matching
The unit monitors J1939 ECU messages and provides remote start/stop control via J1939
protocol (supported some ECUs: Volvo EMS2, Volvo EDC4, Perkins, Scania, MAN MFR and
standard messages).
- Multi genset load sharing (up to 32 gensets)
- kW and kVAr load sharing
- Busbar voltages and frequency measurements
- Dead bus sensing
- Bus failure detection
- Load dependent automatic start/stop
- Equal aging of gensets
-Auto adjust feature for Governor andAVR
- Synchroscope display
- Logic Controller functionality for PLC
- Black or gray theme selection for 4.3 TFT LCD screen
The unit is extensively programmable through the front panel, with password protection on two
levels. Operational parameters can also be monitored and controlled from a PC via a built-in USB
communication port.
In the event that the engine fails to start on the first attempt, the attempt will be repeated a
programmed number of times or until successful.
The unit monitors generator operation and gives warning of any faults that are detected.
If a fault is detected, the unit shuts down the engine and shows the failure message on the LCD
display and activates the internal sounder.
General Specifications:
"

Ýçindekiler
A visual inspection of this product for possible damage occured during shipment is
recommended before installation. It is your responsibility to ensure that qualified mechanical
and electrical technicians install this product.
If there is danger of serious accident resulting from a failure or defect in this unit , power off
the system and seperate the electrical connection of the device from the system.
Keep the power off until all of the wiring is completed so that electric shock and trouble with
the unit can be prevented.
Before beginning installation of this product, please read the instruction
manual and warnings below carefully.
2.Installation
Ýçindekiler
2.1 Unit Configuration
Ýçindekiler
2.2 Panel Mounting
The unit is designed for panel mounting. Fixing is by two screw fixings.
Insert the unit in the panel cut-out from the front.
Insert the fixings in the slotted at the corners of the unit and tighten the fixing screws to secure
the unit against the panel.
1-
2-
During the equipment is putted in hole on the metal panel while mechanical
installation some metal burrs can cause injury on hands, you must be careful.
The unit can be programmed using the buttons and LCD display on the front panel or PC
Software.
5
!
!
Figure 2.1 Front View Figure 2.2 Panel Cut-Out
223mm
162mm
188.61mm
276.42mm
LOAD
ON
ü
LOG
PROG
ESC
MAN
AUTO TEST
ENGINE
RUNNING
RESET

2.3 Electrical Connection
6
TRANS-SYNCRO three phase connections schematic
c1-
The first and last units must be fitted with a 120 ohm resisýtor across H and L.
,
5- Current transformers secondary should be grounded. The CT of 5VA s recommended.
2-
3-
4-
i
Connect the unit as shown in the appropriate diagram. Be sure to connect the battery supply the right
way round
Screened cable must be used for connecting the communication The screen is grounded at one end
ONLY.
The CAN interface requires that a 120 Ohms terminator is fitted to each end of the communications
link. This termination resistor is fitted internally into the unit. So it is not required externally.
Screened cable must be used for connecting the CAN, ensuring that the screen is grounded at one end
ONLY.
Screened cable must be used for connecting the Magnetic Pickup, ensuring that the screen is
grounded at one end ONLY.
FUSE-1, FUSE-2, FUSE-3 : 2A. T
FUSE-4, FUSE-5, FUSE-6 : 2A. T
FUSE-7 : 10 A. T
FUSE-8 : 32 A. T
USB
PROGRAMMING
61
BATTERY -
BATTERY+ FUSE-7
1
62 63
EARTH
I
57565554535251
TRANSISTOR OUTPUT
MAX. 1 A
BATTERY+
Conf.Output-9
Conf.Output-8
Conf.Output-7
Conf.Output-6
Conf.Output-5
Conf.Output-4
Conf.Output-3
22
D+(W.L.)
Charge Alt.
23
Cabin Temp.
(Conf.Input-13)
24
Conf.Input-12
25
Conf.Input-11
26
Conf.Input-10
27
Conf.Input-9
28
Conf.Input-8
29
Conf.Input-7
30
Conf.Input-6
31
High Temperature
(Conf.Input-5)
32
Low Oil Pressure
(Conf.Input-4)
33
GCB feedback
(Conf.Input-3)
34
Remote Start
(Conf.Input-2)
35
BATTERY -
USB
HOST ETHERNET
RJ45
4
605958
Conf.Output-2 “Crank”
Conf.Output-1 “Fuel”
FUSE-8
TRANSISTOR OUTPUT
MAX. 15 A
46 47 48 49 50
Temperature Sender
Oil Pressure Sender
Sender Common
Configurable Analog Input-2
Level Sender or
Configurable Analog Input-1
3
5
14
L1
GENERATOR
BUS VOLTS
L2 L3 N
G
Generator
Contactor
Output
FUSE-1
FUSE-4
21 20 19 18
I
13 12 11
FUSE-2
FUSE-3
8A
4 3 8765
FUSE-5
FUSE-6
17
L1 L2 L3 N LOAD
36
H(+) L(-)
J1939 ECU
SCR
37 38 39
(+) (-)
MPU
SCR
40 41 64
H(+) L(-)
SCR
65 66 696867
A(+) B(-)
SCR
42 43 45
G+ G- A+ A-
GOVERNOR AVR
MULTI LINK
COMMUNICATION
(CAN OPEN)
RS485
COMMUNICATION
c
c c
c
2
c
44
Connect screen at generator only
Connect screen at generator only
Emergency Stop
(Conf.Input-1)
To Engine
Earth
MAX. 300V~
GEN. VOLTS
MAX. 300V~
GEN. CURRENT
Conf.
Output-10
8A
2 1
TO OTHER UNITS
ON THE BUS

2.4 Governor Connection
2.4.1 INTERFACING TO GOVERNORS & ENGINE ECUs
2.4.1.1 INTERFACING WITH TRANS-SYNCRO CONTROLLERS
2.4.2 SPECIFICATIONS
2.4.3 CONNECTION DETAILS
This section details the interface connections between the Trans-Syncro controllers and the most
popular Engine Speed governors used with diesel generating sets. If your particular type of
Governor is not covered within this section, please contact our technical support department for
advice.
The analogue Governor output provide an isolated, adjustable DC voltage level to connect into
the control inputs of many governors. This replaces the manually operated or motorised
potentiometers used in many synchronising and load sharing applications. The output is also
suitable for connection to the load sharing controller inputs of many popular Governors. This
enables the Trans-Syncro controller to adjust the Governor output to match the mains/bus and
hence get the supplies into synchronism. The module is especially suited for use in active power
sharing systems.
Item Value
Output type Optically isolated DC voltage level
Isolation Optically isolated to 1000V
Minimum output load 1000W
TRANS-SYNCRO
CONTROLLER
AVR
GOVERNOR
Governor Output
AVR Output 44 A+
45 A-
42 G+
43 G-
7

2.4.4 DETERMINING CONNECTIONS AND SETTINGS FOR GOVERNORS NOT LISTED IN
THIS PUBLICATION
The following guide is intend to assist the user to determine where to connect to governors
not listed in this document.
Additional it will assist you to find correctly setting for Governor output setting. Initial output
value and output range value.
This diagram shows the remote adjust potentiometer is usually connected to the governor.
The potentiometer adjust the voltage into the IN terminal between the voltage supplied at ‘-’
and ‘+’.
To find the ‘centre’ and ‘range’ voltages accepted by the device’s input, measure the DC
voltage of terminal ‘+’ in relation to terminal ‘-‘ as shown.
You measure 4V from ‘-‘ to ‘+’. Halving this voltage gives the centre voltage (2V). The range
voltage setting will have a maximum value of 2V above or below the centre voltage. To
determine the settings of initial value and range value (min. output and max. output) refer to
the tables 1,2,3,4.
The TRANS-SYNCRO controller connects only to the “-“ and “IN” terminals and provides the
varying DC voltage to simulate the turning of a potentiometer. The analogue output terminals
of the TRANS-SYNCRO controller are connected as follows.
Note that the “+” terminal of the governor/AVR is left unconnected.
Example:
VDC
Governor
IN
+
-
Governor
IN
+
-
Trans-Syncro
Analogue
Output (G+)
Trans-Syncro
Analogue
Output (G-)
8

Table-1:
Table-2:
Table-3:
Table-4:
Output range and initial output value
for min. out parameter %0 and max. out parameter %100
Output range and initial output value
for min. out parameter %20 and max. out parameter %40
Output range and initial output value
for min. out parameter %50 and max. out parameter %75
Output range and initial output value
for min. out parameter %70 and max. out parameter %80
Min Out Max Out Output Range
% 0 “-10 Vdc” % 100 “+10 Vdc”
Initial Out
-10 Vdc ...+10 Vdc % 0 “-10 Vdc”
% 10 “-8 Vdc”
% 20 “-6 Vdc”
% 30 “-4 Vdc”
% 40 “-2 Vdc”
% 50 “0 Vdc”
% 60 “2 Vdc”
% 70 “4 Vdc”
% 80 “6 Vdc”
% 90 “8 Vdc”
% 100 “10 Vdc”
Min Out Max Out Output Range
% 20 “-6 Vdc” % 40 “-2 Vdc”
Initial Out
-6 Vdc ...-2 Vdc % 0 “-6.0 Vdc”
% 10 “-5.6 Vdc”
% 20 “-5.2 Vdc”
% 30 “-4.8 Vdc”
% 40 “-4.4 Vdc”
% 50 “-4.0 Vdc”
% 60 “-3.6 Vdc”
% 70 “-3.2 Vdc”
% 80 “-2.8 Vdc”
% 90 “-2.4Vdc”
% 100 “-2.0 Vdc”
Min Out Max Out Output Range
% 70 “4 Vdc” % 80 “+6 Vdc”
Initial Out
4 Vdc ...+6 Vdc % 0 “4.0 Vdc”
% 10 “4.2 Vdc”
% 20 “4.4 Vdc”
% 30 “4.6 Vdc”
% 40 “4.8 Vdc”
% 50 “5 Vdc”
% 60 “5.2Vdc”
% 70 “5.4 Vdc”
% 80 “5.6 Vdc”
% 90 “5.8 Vdc”
% 100 “6.0 Vdc”
Min Out Max Out Output Range
% 50 “0 Vdc” % 75 “+5 Vdc”
Initial Out
0 Vdc ...+5 Vdc % 0 “0.0 Vdc”
% 10 “0.5 Vdc”
% 20 “1.0 Vdc”
% 30 “1.5 Vdc”
% 40 “2.0 Vdc”
% 50 “2.5 Vdc”
% 60 “3.0 Vdc”
% 70 “3.5 Vdc”
% 80 “4.0 Vdc”
% 90 “4.5 Vdc”
% 100 “5.0 Vdc”
9

2.4.4.1 SCALE AND OUTPUT INITIAL VALUE SETTINGS FOR GOVERNOR OUTPUT:
1-
2-
3-
4-
5-
6-
7-
8-
9-
10-
11-
12-
13-
Frequency Set Value Frequency
Actual Value Governor Output
Frequency Set Value
Governor Output Frequency Actual Value
Governor Output
Frequency Actual Value Frequency
Set Value Governor Output
Frequency Actual Value Governor Output
Frequency Actual Value
Frequency Set Value
Note:
Set to “09.01.001.Frequency Control” parameter as “ ”.
Set to “09.01.003.Minimum Output Value” parameter as “ ”, and set to
“09.01.004.Maximum Output Value” parameter as “ ”.
Set to “09.01.005.Initial Value” parameter as “ ”.
Set to “09.01.006.Output Direction” parameter as “ ” and run generator on Manual
mode.
The first thing to do is to determine the direction of the GOVERNOR. For this,
“09.01.005.Initial Value” parameter increases slightly, for example by making “ ”,
analyzing the changing frequency of the generator. Than, GOVERNOR is noted as “ ”
direction if there is increasing on the generator frequency, and it is noted as “ ”
direction if there is decreasing.
Ensure the running of the generator at “ ” frequency by changing “09.01.005.Initial
Value” parameter. When generator runs at “ ” frequency, percentage value of the
“09.01.005.Initial Value” parameter is noted as “ ” value.
Ensure the running of the generator at “ ” frequency again by changing
“09.01.005.Initial Value” parameter. When generator runs at “ ” frequency, percentage
value of the “09.01.005.Initial Value” parameter is noted as “ ” value and generator
stops.
Set to “09.01.001.Frequency Control” parameter as “ ”.
Set to “09.01.003.Minimum Output Value” as “ ” or “ ” which is smaller than
the percentage values are noted on steps 6th and 7th.
Set to “09.01.004.Maximum Output Value” as “ ” or “ ” which is bigger than
the percentage values are noted on steps 6th and 7th.
Set to “09.01.005. Initial Value” parameter as “ ”.
If GOVERNOR direction is find out as “ ” on the 5th step, set to “09.01.006.Output
Direction” parameter as “ ”, but if GOVERNOR direction is find out as “ ” on
the 5th step, set to “09.01.006.Output Direction” parameter as “ ”.
Run the generator on Manual mode again. Go to “GOVERNOR CONTROL” working
page. At that page, when “ ” is “ ”, is observed that “
” is “ ” and “ ” is approximately “ ”. Than, set to
“ ” as “ ” by increment/decrement buttons. It is observed
“ ” and “ ” are began to increasing. When
“ ” value reach to “ ” value by increasing, it is observed that
“ ” reach to “ ” by increasing too. After that, set to “
” as “ ” by increment/decrement buttons. It is observed “ ”
and “ ” are began to decreasing. When “ ” value
reach to “ ” value by decreasing, it is observed that “ ” reach to
“ ” by decreasing too. For the last time, set to “ ” as “ ”
again. That means, GOVERNOR setting made with success anymore.
It is recommended to fix the generator voltage to “ ” when setting the Governor.
Passive
0.0%
100.0%
60.0%
0-Positive
65.0%
48.0Hz
48.0Hz
52.0Hz
52.0Hz
Active
50.0Hz
50.0Hz 50.00%
52.0Hz
100.00%
52.0Hz
48.0Hz
0.00%
48.0Hz 50.0Hz
400Vac
Positive
Negative
Scale-1
Scale-2
Scale-1 Scale-2
Scale-1 Scale-2
50.0%
Positive
0-Positive Negative
1-Negative
10