Harsen GU641B User manual

Manual
GU641B
Genset Controller
HM1016ER1
Harsen
®

Manual HM1016ER1 The interpretation of the Symbol
Harsen
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I
The interpretation of the Symbol:
WARNING:
A WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death, serious personal injury or property damage.
CAUTION:
A CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in damage to equipment or property.
NOTE:
A NOTE provides other helpful information that does not fall under the
warning or caution categories.

Manual HM1016ER1 The interpretation of the Symbol
Harsen
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II
WARNING:
Read this entire manual pertaining to the work to be performed before
installing, operating, or servicing this controller. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause
personal injury and/or property damage.
The engine or other type of prime mover should be equipped with an over
speed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The over speed shutdown device must be totally independent of the prime
mover control system. An over temperature or low pressure shutdown device
may also be needed for safety, as appropriate.
CAUTION—BATTERY CHARGING
To prevent damage to a controller that uses an alternator or battery-charging
device, make sure the charging device is turned off before disconnecting the
battery from the system.
Controllers contain static-sensitive parts. Observe the following precautions
to prevent damage to these parts:
Do not disassemble the rear back of controller and touch the components or
conductors on a printed circuit board.

Manual HM1016ER1 History
Harsen
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III
History
No.
Rev. Date Editor Validation
Changes
1 HM1016ER1
2011.1.1 P.L New

Manual HM1016ER1 Contents
Harsen
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Contents
1. Description……………………………………………………………………………………………………
2. Outline Dimension Drawings and Controller Wiring…………………………………………………
3. Panel Operation………………………………………………………………………………………………
4. Control and Operation Instruction…………………………………………………………………………
5. Measure and Display Data…………………………………………………………………………………
6. Pre-alarm and Shutdown Alarm……………………………………………………………………………
7. Parameters Setting……………………………………………………………………………………………
8. Installation Guide……………………………………………………………………………………………
9. LCD displays and Menu System……………………………………………………………………………
10. Technical Specification………………………………………………………………………………………
1
2
6
7
16
17
21
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50
53

Manual HM1016ER1 Description
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1.Description
GU641B is a new generation Automatic Mains (Utility) Failure module for single Genset, which adopts
bran-new outline configuration, focus on the requirements of customers, and perfectly improves the
performance of controller. It fully meets the auto control requirements of different kinds of Genset for
user or special assembly factory.
The module also monitors and protects the engine, indicating operational status, fault conditions and
metering on the front panel LCD and LED.
True RMS measure of voltage and current.
2 analog inputs for kinds of optional built-in sensors, parameters also can be configured by user.
More outputs of configurable auxiliary control relays.
More configurable isolated digital inputs.
Buttons on control panel are used for selecting control modes, starting and stopping the operating
procedure, displaying data and modifying the parameters. LED indicators are used for indicating
the operation mode of controller and the running status of Genset, and LCD displays each
measuring parameter and status.
Flexible equipped with RS485, RS232 and USB, realizing remote monitor; or communicated with
PC, fully realizing functions of remote signaling, telemetering and remote control, can read and set
the running parameters of controller.
All connections of the controller are by secure plug and socket, for ease and convenience to connect,
move, maintainand replace the device.
This manual is only suitable for GU641B Automatic control module, user must carefully read
this manual first.

Manual HM1016ER1 Outline Dimension Drawings and Controller Wiring
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2.Outline Dimension Drawings and Controller Wiring
2.1 Following Details:
Module Dimensions W192mm×H144mm
Panel Cutout W174mm×H126mm
Thickness D56mm (without connection)

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2.2 Terminal Connections:
Pinno.
Function Description Signal Dim
1 GEN. V
L1-N
input 0-346Vac 1mm²
2 GEN. V
L2-N
input 0-346Vac 1mm²
3 GEN. V
L3-N
input 0-346Vac 1mm²
4 GEN. Neutral 1mm²
5 Not used
6 MAINS V
L1-N
input
0-346Vac 1mm²
7 MAINS V
L2-N
input 0-346Vac 1mm²
8 MAINS V
L3-N
input 0-346Vac 1mm²
9 MAINS Neutral 1mm²
10 I1 Gen current input (S1) 0-5A 2.5mm²
11 I2 Gen current input (S1) 0-5A 2.5mm²
12 I3 Gen current input (S1) 0-5A 2.5mm²
13 Common port for current inputs (S2)
0-5A 2.5mm²
14 LOP sensor <1KΩ2.5mm²
15 HET sensor <1KΩ2.5mm²
16 Common port for sensor 2.5mm²
17 Common port for relay outputs 2.5mm²
18 Fuel solenoid relay output N.O. contact, 16A/30Vdc 2.5mm²
19 Start (Crank) relay output N.O. contact, 16A/30Vdc 2.5mm²
20 Relay output 3 (GCB close/open) N.O. contact, 3A/30Vdc, configurable (1) 1mm²
21 Relay output 4 (MCB close/open) N.O. contact, 3A/30Vdc, configurable (2) 1mm²
22 Relay output 5 N.O. contact, 3A/30Vdc, configurable (3) 1mm²
23 Relay output 6 N.O. contact, 3A/30Vdc, configurable (4) 1mm²
24 charger excitation power output if not used, do not connect to negative 1mm²
25 Configurable digital input signal 1 low level is active 1mm²
26 Configurable digital input signal 2 low level is active 1mm²
27 Configurable digital input signal 3 low level is active 1mm²
28 Configurable digital input signal 4 low level is active 1mm²
29 Configurable digital input signal 5 low level is active 1mm²
30 Magnetic pick-up signal (+) 1-70Vac 2 cores
shielded
31 Common for configurable inputs and
magnetic pick-up signal(-)
32 Battery supply (+B) 2.5mm²
33 Battery supply {-B} 12V/24V (8-35Vdc continuous) 2.5mm²
34 Ground 2.5mm²
NOTE:
Relay output 3 and 4 are respectively configured as GCB and MCB
close/open relay when default setting, however both can be reconfigured
by user if required.

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2.3 Typical Wiring Diagram
A fuse with the rating of 1A shall be provided external to the equipment.

Manual HM1016ER1 Panel Operation
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3.Panel Operation
The operation panel consists of 3 sections: LCD display indicating measurement parameters, LED
indicator for common failure, and push buttons for Genset and selection of control modes.
LCD can display 3-row data in the same time. LCD also has a backlight so that the operator can clearly
read information day or night. After pressing any button the backlight will automatically turn off after a
preset time.
The LCD display and its control push buttons provide a friendly operational interface for the operator to
easily control the Genset, read information and parameter setting.
3.1 Control buttons and LED
Function Description Tag
Scroll Button
Scroll menu for parameters display / enter into or exit parameters
setting by pressing and holding this button for 2sec.
MUTE / Lamp Test Button
When failure occurs, alarm buzzer sounds. Pressing mute button will
mute the sound. LCD displays mute icon. Press it again will clean
mute function, buzzer continues to sound. Press and hold this button
for 2sec, all LEDs illuminate simultaneously.
AUTO Mode Button / LED / “+” Value Increase
The push button is used for selecting “auto mode”. When the controller
is running in AUTO mode, the LED above the button is illuminated.
The activation and deactivation of the “remote start signal input” and
“Mains Failure” controls the starting and stopping of the Genset.
When in parameters setting mode, this button is used to increase
value / scroll down menu.
MAN Mode Button / LED / “-” Value Decrease
The push button is used for selecting “manual mode”. When the
controller is running in MANUAL mode, the LED above the push button
is illuminated. The Start and Stop push buttons control the starting of
the Genset.
When in parameters setting mode, this button is used to decrease
value / scroll up menu.
TEST Mode Button / LED / “√
√√
√” Confirm Parameters Configure
The push button is used for selecting “test mode”. When controller is
running in TEST mode, the LED above the push button is illuminated,
the controller starts the generator simulating Mains failure and the
activation of “remote start signal”.
When in parameters setting mode, this button is used to enter into
submenu / confirm modification.

Manual HM1016ER1 Panel Operation
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START Button / LED / Return
The push button is used for manually start the Genset. When controller
is running in MANUAL mode, press this button to start the generator.
When in parameters setting mode, this button is used to return.
STOP / RESET Button / “→
→→
→” Move Setting
The Push button is used for manually stops the Genset. No matter
what mode the controller is running, press and hold this button for
2sec to stop the generator, the mode of the controller will be default to
“MAN” mode automatically from “AUTO” or “TEST” mode and the
generator will be shut down after cool down period, during the cool
down period if you press and hold this button for 2sec again, the
generator will be shut down immediately.
If failure occurs, press this button, the shutdown alarm lockout can be
cleared.
When in parameters setting mode, this button is used to move to next
parameters setting position.
C/O Button
There are 2 C/O buttons respectively beside the Mains and Gen icons.
They are used to close/open the switches of Mains and Gen when
controller is running in MANUAL mode.
Shutdown Alarm (FAILURE) LED
The LED will illuminate permanently when shutdown alarm occurs.
Pre-alarm (WARNING) LED
The LED will illuminate permanently when pre-alarm occurs.
GEN. Normal LED
Gen. normal LED will illuminate after both voltage and frequency of the
Gen. reach loading voltage and frequency.
GCB/MCB Closed LED
LED will illuminate when GCB/MCB is closed and power supplied by
Gen / Mains, LED will flash when GCB / MCB failure occurs.
MAINS Normal LED
Mains normal LED will illuminate after both voltage and frequency of
the Mains reach the preset value range.

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4.Control and Operation Instruction
The controller has 3 modes:AUTO, MANUAL and TEST.
4.1 Operation Modes Setting:
Operation Description
Press and hold the “AUTO” button for 2sec, the LED above the button
is illuminated; the controller is running in “AUTO” mode.
Press and hold the “MAN” button for 2sec, the LED above the button is
illuminated; the controller is running in “MAN” mode.
Press and hold the “TEST” button for 2sec, the LED above the button
is illuminated; the controller is running in “TEST” mode.
NOTE: Only 1 mode can be selected from above 3 modes.
4.2 AUTO Control Sequence:
The controller is running in “AUTO” mode.
When Mains (Utility) is normal, Mains is on load:
When Mains is normal, both voltage and frequency of Mains are within the range of preset value, the
Mains Normal LED illuminates, the timer for Mains ON delay is activated, when it times out, the MCB
close/open relay closes, the transfer switch switches on Mains, the Mains Aux. Switch’s contact feeds
back the signal to a configurable input on our controller. The MCB closed LED illuminates.
WARNING:
The Mains Normal LED illuminated means that both voltage and
frequency of Mains are within the range of preset values; Mains Normal
LED flashing means either voltage or frequency of Mains are over the
range of preset values; Mains Normal LED does not illuminate means that
the Mains voltage is lower than the measuring range.
Do not assume the Mains is not available if Mains Normal LED does not
illuminate.
Mains fail to load:
If MCB close/open relay is closed, the timer for MCB closing is activated, when it times out, if the
controller does not receive the feed back signal from the Mains Aux. Switch’s contact, then Mains fail to
load is activated.

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NOTE:
Above control procedure, assumes that one of configurable inputs has
been configured as Mains Aux. Switch Closed and connects the
switch’s N.O. Aux. contact to this port. If you do not configure an input as
Mains Aux. Switch Closed, then the MCB closed LED illuminates is only
an indication that the MCB close/open relay should have been closed,
under this condition, the alarm for Mains fail to load is inactive, and the
along function of start Genset is also inactive.
Generator Auto Start Sequence:
Controller implements following procedure when Mains voltage failure occurs (it means that the
controller detecting either the voltage or the frequency of Mains is over the range of preset values and
delay confirmed), or Mains fail to load, or remote start signal is active and Mains failure;
NOTE:
To achieve remote start, one of configurable inputs must be defined as
remote start signal.
The Start delay timer is activated, when it times out, the Preheat relay output is energised (if preheat
function selected), the timer starts. When it times out, the fuel relay output is energised, and operates
the fuel solenoid of the engine. After 300ms delay, the start relay output is energised, the start motor
engages and begins to crank. When the engine speed reaches the crank cutout RPM, the start relay
output is de-energised and the safety-on delay starts. When the safety-on times out, if the controller
detects that the parameters of the Genset such as voltage, frequency, oil pressure, coolant temperature
are normal, and no other failure is detected this indicates the Genset has successfully started and
running normally. The LCD displays the Genset Measurement Parameters.
When Generator is running normally, Gen. Normal LED illuminates, the timer for GEN. ON delay is
activated, when it times out, GCB close/open relay closes, the transfer switch switches on Gen. The
Gen Aux. Switch’s contact feeds back a signal to a configurable input on the controller. GCB closed
LED illuminates.
NOTE:
If Mains fails to load, the start sequence is initiated without the start-delay
timer.
When Mains voltage failure and remote signal is active, the start-delay
timer is activated, if remote start signal is inactive or Mains voltage
resumes to normal during this period, the start delay timer terminates
immediately, the controller terminates the starting procedure, and then
recovers to the original standby status.
During cranking or idle period, if the remote start signal is inactive or
Mains voltage resumes to normal, the controller stops the start procedure,
then recovers to the original standby status.
Under any conditions, GEN. ON delay only can be started after Safety-on
Delay times out.

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NOTE:
The start motor will power off while cranking if there are one of the
following conditions occur:
A. The AC generator’s frequency reaches the preset value (configurable
cranking cutout value);
B. The AC Engine speed reaches crank cutout value;
C. Generator’s voltage reaches the crank cutout value (optional);
D. Charger voltage reaches crank cutout value (optional);
E. Cutout P-delay time’s up (optional);
F. Cranking time’s up.
Controller can not implement crank procedure in one of following
conditions:
A. The AC generator’s frequency reaches the preset value (configurable
cranking cutout value);
B. The AC Engine speed reaches crank cutout value;
C. Generator’s voltage reaches the crank cutout value (optional);
D. LOP switch is opened or oil pressure is higher than crank cutout
value (optional).
CAUTION:
If magnetic pickup is not used, to avoid damage to the start motor please
make sure the generator’s voltage is higher than the measurable value of
controller while cranking, since the crank cutout signal is sensed from the
generator voltage and frequency.
NOTE:
Above control procedure, assumes that one of configurable inputs has
been configured as Gen Aux. Switch Closed and connects the switch’s
N.O. Aux. contact signal to this port. If you do not configure an input as
Gen Aux. Switch Closed, then the GCB closed LED illuminates is only
an indication that the GCB close/open relay should have been closed.
If you have selected idle function, the idle relay will be closed at the same time as the crank relay is
closed, the idle timer will begin counting down after successful crank, when it times out, the idle relay
opens, other procedure is the same as above.
NOTE:
Controller will not detect under voltage, under frequency, under speed, and
charge failure during idle period.
Repeat Crank: During the crank period, if the engine can not ignite controller will not output start signal
during crank rest. Once crank rest timer times out the start relay energises once again and will attempt to
start engine again. The above procedure will be repeated until engine successfully ignites or reaches
the preset number of crank attempt.
If any shutdownalarm occurs during crank, controller will stop crankingimmediately, and the Gensetonly canbe
restarted after clearingthefailureandreset.
Start Failure: When the procedure above repeats again and again and reaches the preset number of
crank attempt, the crank relay output is then de-engised. The failure LED illuminates and the LCD
displays Fail to Start.

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CAUTION:
If Fail to Start occurs, operator must check the whole Genset system to
find out failure reason, only after clearing the failure can press “STOP /
RESET” button to relieve fault lock out status, and restart the Genset .
Mains return and generator shutdown sequence:
When Mains resumes to normal, Mains Normal LED illuminates, the Mains ON delay timer is activated,
GCB close/open relay is de-energised after it times out, MCB Close/open relay is energised, transfer
switch switches on Mains, the Mains Aux. Switch’s contact feeds back the signal to a configurable input
on our controller, MCB closed LED illuminates.
At the same time as the MCB close/open relay is energised, the timer for cool down is activated, when it
times out, the fuel relay de-energises, generator stops and recovers to its standby status.
NOTE:
If you do not configure an input as Mains Aux. Switch Closed, then the
MCB closed LED illuminates but is only an indication that the MCB
close/open relay should have been closed.
Stop Failure: When cool down times out, the fuel relay opens and the timer for Stop delay begins. If the
controller detects that the voltage of the generator or oil pressure or the speed of engine is greater than
the cutout values or LOP switch is open, when it times out, the failure LED illuminates and the LCD
displays Fail to stop.
NOTE:
After stop failure, the controller will not energise the crank relay output if
the failure has not been removed and the controller reset.
Generator auto start conditions:
When the controller is in “AUTO” mode, it will auto start under the following 3 conditions:
Mails voltage failure
Remote start signal is active
MCB failure
If you do not define one of the configurable inputs as Remote Start Signal, when the Mains fails, the
controller will automatically initiate the start sequence.
If one of the configurable inputs has been defined as Remote Start Signal, when remote start signal is
active and Mains fails, the controller will initiate start sequence. However if there is a Mains failure but
remote start input is not active the controller will not initiate start sequence, but the Mains close/open relay
will open.
If Genset has started since Mains fail to load, when failure is removed and controller unlocked by pressing reset button, GCB
close/open relay opens, MCB close/open relay closes, transfer switch switches the load to Mains.

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NOTE:
If no configurable input was defined as Main Aux. Switch closed, the
alarm for Mains fail to load is inactive.
4.3 MAN control Sequence:
The controller is running in “MANUAL” mode.
Mains is normal, Mains is on load:
When Mains is normal means that both voltage and frequency of Mains are within the range of preset
value, the Mains Normal LED illuminates, the MCB close/open relay will not close automatically.
Press the “C/O” button of Mains to close the Mains switch manually, then Mains is on load, the Mains Aux.
Switch’s contact feeds back the signal to a configurable input on our controller, MCB closed LED
illuminates. Press the “C/O” button of Mains again to open the Mains switch manually, the Mains is off
load, the MCB closed LED is turned off at the same time.
If you press the “C/O” button of Mains when Gen is on load, the GCB close/open relay will be opened first,
then Gen is off load, the MCB close/open relay closes later, Mains is on load.
NOTE:
When the controller is running in “MANUAL” mode, Mains must be
normal, or the “C/O” button of Mains will be disabled.
Generator starting sequence:
Pressing “START” button the fuel relay energises, and operates the fuel solenoid of engine, After
300ms delay, the start relay output is energised, the start motor engages and begins to crank, when the
engine speed reaches the crank cutout RPM, the start relay output is de-energised and the safety-on
delay starts. When the safety-on times out, if the controller detects that the parameters of the Genset
such as voltage, frequency, oil pressure, coolant temperature are normal, and no other failure is
detected this indicates the Genset has successfully started and running normally. The LCD displays the
Genset Measurement Parameters.
After both voltage and frequency of generator respectively reached the loading value, the Gen. Normal
LED illuminates, the GCB close/open relay will not be closed automatically.
Press the “C/O” button of Gen to close the Gen switch manually, Gen is on load, the Gen Aux. Switch’s
contact feeds back the signal to a configurable input on our controller, GCB closed LED illuminates.
Press the “C/O” button of Gen again to open the Gen switch manually, Gen is off load, the GCB closed
LED is turned off at the same time.
If you press the “C/O” button of Gen when Mains is on load, the MCB close/open relay will be opened first,
then Mains is off load, the GCB close/open relay closes later, Gen is on load.

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NOTE:
When the controller is running in “MANUAL” mode, the Gen must be
normal, or the “C/O” button of Gen will be disabled.
GCB and MCB close/open relays are electrically interlocked, they can’t be
closed at the same time.
Generator stopping sequence:
Press “STOP” button, GCB close/open relay opens, the generator is without load, the cool down timer
starts, when it times out, the fuel relay is de-energised, then the fuel solenoid opens immediately,
generator stops and goes to standby status.
If press “STOP” button again during cool down period, generator stops immediately without cool down time.
4.4 TEST Control Sequence:
When the Controller is running in “TEST” mode means it simulates Mains failure automatically. There are
two kinds of “TEST” modes, one is “Test with load”, another is “Test without load”, and they can be
selected through parameter setting.
Test with load: GCB close/open relay will be closed after the generator is started successfully and
running normally, then Gen will be on load.
Test without load: GCB close/open relay will not be closed after the generator is started successfullyand
running normally, the Mains remain on load.
4.5 The start and stop Sequence of engine whose fuel solenoid is N. O. type:
There are two kinds of fuel solenoids for an engine, one is N.C. type, the valve of this solenoid is closed
when the engine is in standby and it can be opened by switching on power; another is N.O. type, the
valve of this solenoid is opened when engine is in standby and it can be closed by switching on power. All
control sequences above are for N.C. type.
Start control sequence for N.O. type:
During the starting sequence the fuel relay of controller will not energise, fuel solenoid is off power, fuel
solenoid is normally open so no signal required for fuel solenoid to activate.
Stop control sequence for N.O. type:
During the controller’s stop sequence, the fuel relay energises, fuel solenoid is on power, the fuel solenoid
closes the fuel valve and the engine begins to stop. After a delay (same as Stop delay) fuel relay de-
energises, disconnecting the supply from the fuel solenoid.
Other control sequences are same as engine whose fuel solenoid is N. C. type.

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4.6 Idle function:
For idle function configure one of the configurable outputs as idle.
Refer to the flow chart 4.9 for start and stop for idle control flows.
NOTE:
Controller will not detect under voltage, under frequency, under speed, and
charge failure during idle period.
4.7 Preheat function:
For Preheat function, configure one of the configurable outputs as Preheat, The controller has 4
selectable preheat control modes as below:
Mode 1 — during preheat time, preheat relay output energises.
Mode 2 — during preheat time, preheat relay output energises until the successful ignition.
Mode 3 — during preheat time, preheat relay output energises until safety-on delay times out.
Mode 4 — one of the configurable inputs is defined as Preheat, preheat relay output energises when this
configurable input is active, and de-energises when configurableinput is inactive.
For preheat mode 1 to 3, please refer to the flow chart 4. 9 for start and stop for Preheat control flows.
For preheat mode 4, preheat function is active immediately when the controller is switched on power.
During crank period, the Preheat relayoutput will not energise in any of above modes.
LCD displays icon of preheat operating status when preheat relay output energises:

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4.8 The function of forcing start
Reason to add this function to the controller is that when the engine under abnormal conditions, e.g. the
battery voltage is too low or ambient temperature is too low, or generator only outputs voltage at a high
speed when magnetic pick-up is not used, the Genset cannot be started successfully when it
implements the build-up cranking process of controller. There are 2 methods to solve these conditions
in the controller:
First method: when controller is running in “MANUAL” mode, normally the crank time will not exceed the
pre-set value, but you can press “START” button and hold without changing the related parameters until
it has started, the crank time depends on the holding time on the button. Safety-on timer begins after it
has successfully started. The other processes and protections are the same as for a normal start.
Second method: when controller is running in “MANUAL” mode, configure the “EX. Crank permit” as
“1”, shown as schematic below, a PB switch is externally mounted to control cranking. Close PB switch,
engine cranks, when the speed reaches 150RPM or generator voltage output is not less than AC 20V if
magnetic pick-up is not used, then controller functions are triggered, the fuel relay output is energised,
safety-on timer begins after the speed reaches crank cutout value, the other processes and protections
are the same as normal start. If the speed falls below 150RPM within safety-on time, controller will be
reset and return to standby status.
CAUTION:
We normally don’t recommend using the second method to solve this
condition.
Pay attention to the installation of PB switch to avoid cranking when the Genset
isrunning.

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4.9 Flow chart for start and stop
T1－start delay
T2－crank time
T3－pre-heat time
T4－safety-on delay
T5－idle time
T6－Stop delay
NOTE:
If T4 is longer than T5, oil pressure protection is ignored during T5.
If T4 is shorter than T5, oil pressure protection becomes effective after T4
in T5.