Kutai electronics GCU-100 User manual

KUTAI ELECTRONICS INDUSTRY CO., LTD.
TEL : [phone] FAX : [phone] Website : www.kutai.com.tw
Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 80664, Taiwan
GCU-100
Automatic Engine Control and
Protection Module Operators Manual

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2GCU-100
TABLE OF CONTENTS
Section Page
SECTOIN 1 : INTRODUCTION
1.1 Preliminary Comments And Safety Precautions.........................................................................................3
1.2 Overview.....................................................................................................................................................3
1.3 Product Overview........................................................................................................................................3
SECTOIN 2 : FRONT PANEL LAYOUT
2.1 Front Panel Layout......................................................................................................................................4
2.2 Rear Panel Layout......................................................................................................................................5
2.3 Panel Cut-Out .............................................................................................................................................5
2.4 Unit Dimensions..........................................................................................................................................6
2.5 Installation Reference.................................................................................................................................6
SECTOIN 3 : OPERATION
3.1 Summary.....................................................................................................................................................7
3.2 AUTO Mode................................................................................................................................................7
3.3 MANU Mode ...............................................................................................................................................7
3.4 OFF Mode...................................................................................................................................................7
SECTOIN 4 : SYSTEM SETTING & OPERATION
4.1 System Setting............................................................................................................................................8
4.2 Setting the Hour Meter................................................................................................................................8
4.3 Setting the Magnetic Pick-up (MPU)...........................................................................................................8
4.4 Setting the AC Voltage and Current Display ..............................................................................................9
4.5 Setting AC Voltage Protection ....................................................................................................................9
4.6 Engine Over-load Protection Setting ..........................................................................................................9
4.7 Panel Display Setting................................................................................................................................10
4.8 Manual Start & Stop Operation.................................................................................................................10
4.9 Setting the Programmable Inputs Alarm1 and Alarm2.............................................................................10
4.10 Service and Maintenance Reminders.......................................................................................................10
4.11 Engine Idle................................................................................................................................................10
4.12 Charge Alternator Excitation.....................................................................................................................11
4.13 Setting Communication Modules GCU-100 to PC (KCU-XX) ..................................................................11
4.14 CANBus J1939 Transducer KCU-04 (Optional) .......................................................................................11
4.15 Lamp Testing............................................................................................................................................11
4.16 System Setting Reference........................................................................................................................13
SECTOIN 5 : FAILURE WARNING DESCRIPTION
5.1 Failure Signal Reference ..........................................................................................................................15
5.2 Warning.....................................................................................................................................................15
5.3 Shutdown Mode........................................................................................................................................15
SECTOIN 6 : SPECIFICATION
SECTOIN 7 : TERMINAL & WIRING DESCRIPTION
7.1 Connection Detail......................................................................................................................................16
7.2 Three Phase System External Wiring Diagram........................................................................................17
7.3 Single Phase System External Wiring Diagram .......................................................................................17

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GCU-100 3
SECTION 1 : INTRODUCTION
1.1 Preliminary Comments and Safety Precautions
This manual contains information for operational
maintenance and wiring connections, Read it carefully.
1.2 Overview
GCU-100 works with most generators; it has both
universal graphical light signal warnings and 3 sets of 4
digit LED displays, which feature 3 phase voltage,
current, frequency, battery volt, and running hours.
The GCU-100 can be programmed from the front panel
without using a laptop or complicated instructions, and
all new settings are saved on an internal (EEPROM).
1.3 Product Overview
Simply select one of three push buttons on the front
panel to choose either automatic (AUTO), manual
(MANU) and (OFF) operations.
The GCU-100's main features are :
●Digital modular design
●3 sets of 4 easy to read large digits display
●Multiple restart capabilities
●Governor Idle timer used for engine warm-up
●Engine cool-down settings
●Service and maintenance reminders
●Complete generator monitoring and protection
LED Display :
●3-phase AC voltage
●3-phase AC current
●AC Hertz
●Timer countdown display
●DC (Battery) voltage reading
●Clear universal warning signal signals
●Easy to check system settings
The front panel can be preset to display fixed values or
to cycle the display, allowing the operator to read all
the generator values as they automatically cycle
through. In addition, if a failure occurs during operation,
the module displays a graphical warning or a failure
signal(s) on the front panel.
If you install an additional communications module, the
control can display an exact copy of the controls panel
on a remote computer screen using ether the Ethernet,
USB or RS48 communications.
Monitoring and Protection :
●Engine start failure
●Emergency stop
●High coolant temperature
●Low oil pressure
●Engine over speed
●Engine under speed
●AC over voltage
●AC under voltage
●Current load monitoring
●Low fuel level
●Battery charging alternator failure (D+)
●Battery over and under voltage
●Magnetic Pick-up (MPU) failure
●Engine service and maintenance reminders
The GCU-100 also has 2 extra user programmable
inputs.

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4GCU-100
SECTION 2 : FRONT PANEL LAYOUT
2.1 Front Panel Layout
ICON
DESCRIPTION
ATTENTION
Auto
Press to put the control in AUTO –Activated by using a remote start
Off
Press turn the control OFF
Manual
Press to do a MANUAL START from the front panel
Increase & Selection
When in programming mode, pushing this button Increases the set point.
In normal operational mode, press to select and display the next phase
voltage reading.
Program & Selection
Press and hold for 4 sec. to enter programming or to select the next line.
Normally used to change to the next phase when reading current.
Decrease & Selection
When in programming mode pushing this button decreases the set point.
In normal operation, press to sequentially display AC frequency, battery volt
or engine running hours.

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GCU-100 5
2.2 Rear panel layout
2.3 Panel Cut-Out (Measurement：mm)

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6GCU-100
2.4 Unit Dimensions (Measurement：mm)
2.5 Installation Reference
ALARM
GCU-100
Genset Controller
KUTAI
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs

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GCU-100 7
SECTION 3 : OPERATION
3.1 Summary
GCU-100 Operation :
1. AUTO : In AUTO Start Mode (Remote Start)
2. MANU : Manual Start Mode
3. OFF : Engine Stop / Reset
Select only one button at a time. The buttons have
double functions, depending if you are programming the
control or in normal operation.
3.2 AUTO Mode
In AUTO, the module governs the start and stop of the
gen-set. The flashing LED on the AUTO button
indicates the control is in AUTO and waiting for a start
signal, the moment this signal is received by grounding
terminals J1-17, the LED stops flashing, and the
generator initiates its auto start sequence.
This sequence starts by first Pre-heating the engine.
The control now displays the word “Pr.Ht” on the
“VOLTs” screen and the countdown on the “AMPs”
screen.
Next, the module begins to crank the engine, in the
same way displaying the word “Star” on the “VOLTs”
screen and the countdown on the “AMPs” screen. If the
engine does not start the module, it repeatedly returns
to Pre-Heat to execute another start sequence. If the
engine fails to start, the module then displays “FAIL”
on the screen, and simultaneously lights up the engine
start failure LED on the panel, activating the failure
warning alarm signal output terminal J1-4.
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
Pr-Heat Start Idle Cool-Down Stop
However, if the GCU-100 determines the gen-set
started and is operating correctly, the module
immediately stops the starter to prevent damage, if it
senses :
●Engine oil pressure is up (oil pressure switch
activated).
●AC voltage
●AC frequency 18 Hz and above
●MPU detects 20% the rated RPM
The GCU-100 also has engine IDLE, and once the
engine has started, and operating “IDLE” is displayed
on the “VOLTs” screen with its corresponding
countdown on the “AMPs” screen: You can disable
engine idle when programming.
Finally, the GCU-100 activates a 30 second grace
period to let all parameters build up and stabilize. If it
fails to do so in 30 seconds, the module stops the
engine displaying the failures and warnings.
When the remote start signal disappears, the module
goes into Engine Cool-down displaying “COOL” on the
“VOLTs” screen and its corresponding countdown
timer on the “AMPs” screen. However, if the remote
start signal is reactivated during engine Cool-down, the
module cancels the countdown, returns to normal
operation, and continues providing power.
After Cool-down times out, the module will implement
an engine stop, either energize to stop or energize to
start. When executing engine stop, “Stop” will be
displayed on the “VOLTs” display screen and
countdown timer on the “AMPs” display screen.
ATTENTION
When the generator is on engine Cool-down, the
GCU-100 remains in effect; and if, any failure
occurs, the module bypasses the countdown and
shuts down the generator immediately.
3.3 MANU Mode
In MANUAL, you can start and stop the gen-set
manually. If you press the OFF button, the gen-set will
make the normal programmed shutdown.
In AUTO and MANUAL the engine start and stop
program are almost identical but in MANUAL, engine
Cool-down is not used. Reference chapter 3.2.
3.4 OFF Mode
Press the OFF button to shut down the gen-set or also
for fault failure RESET. If the OFF button is pushed
during normal operation, the program omits engine
Cool-down execute engine shut down immediately.
If a major malfunction is detected during operation, the
module immediately shuts down the gen-set to prevent
further damage to the equipment or operating
personnel. The display shows all failures at the same
time on the front panel so maintenance service can
carry out necessary repairs. To reset the warning(s)
and failures, press the “OFF” button.

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8GCU-100
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
SECTION 4 : SYSTEM SETTING &
OPERATION
ATTENTION
Before proceeding to system setting, make sure
all wiring and batteries are connected.
4.1 System Setting
There are total of 53 programmable setting in the
GCU-100, you can program the module according to
different gen-set operation controls and protection
preferences by pressing the setting key / buttons on
the front panel. To start, press OFF and then press and
hold the program (pen) button for 4 seconds.
The display screen will now display “Prog” & “Vr1.0” for
4 seconds, “Vr1.0” is the program version. Next “Ln.01”
will appear on the display screen, representing the
program setting entry, (00) the system setting
parameter.
You can change the setting using the increase (up
arrow) and decrease (down arrow) button. Each time
your presses the (pen) button the system advances to
next entry, pressing the (OFF) button returns to the
previous entry.
After programming, the last entry or if the panel is left
inactive for 10 seconds, the screen displays the word
“End” and the system automatically records all new
entries and settings.
You can terminate system programming at anytime by
pressing the (PEN) button for 4 seconds until the word
“End” appears on the display. (For setting information,
see reference 4.13 system setting reference).
FUNC METER
AMPs METER
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLT METER
FUNC METER
AMPs METER
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLT METER
FUNC METER
AMPs METER
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLT METER
The GCU-100 comes pre-programmed with factory
settings. You can reset to factory setting at any time by
pressing the (UP and Down arrow) buttons together for
4 seconds until “Au.PO” appears on the screen.
4.2 Setting the Hour Meter
Removing the battery does not affect the hour meters
accumulative memory and does not reset itself even
with no power.
To reset the hour meter
go into program mode and
immediately before the
Prog Vr1.0 message
disappears from the screen
press the (OFF) button for 4
seconds until the screen
displays “Hour” the 1234 /
Value) in the screen
represents the total
accumulated operation
hours.
Press the UP and DOWN
buttons to change the hours.
By pressing and holding,
you can speed up the
process. When the setting
is completed, press the
(PEN) button for 4 seconds
until (SAVE) appears on the
screen.
If the buttons are left untouched for 10 seconds, the
operation terminates showing (END) on the screen and
the control turning OFF and any modification made to
the hour meter will not be recorded.
4.3 Setting the Magnetic Pick-up (MPU)
The MPU (Magnetic Pick-up) detects the engine
revolution according to the frequency measured on the
engine flywheel teeth. Most generators with electronics
speed controllers/governors have them installed.
MPU frequency range：100 Hz 10K Hz

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GCU-100 9
To set the MPU frequency, start the engine in
MANUAL and manually set the engine to 50 Hz or 60
Hz, then quickly press PEN, UP and DOWN arrow
simultaneously for 4 seconds until the word (SAVE)
appears on the display screen.
If the control sees a erroneous frequency reading from
the MPU that Is. below 100 or above 10K Hz, the
control deduces it as an MPU failure and will splay
(FAIL) on the screen and at the same time light up the
warning LED. Check the MPU for incorrect wiring or
bad connections, and after correcting the problem,
repeat the previous steps to finish setting up the MPU.
Any the previous frequency settings are unaffected.
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
ALARM
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
ALARM
Some electronics speed controllers “Governors” do not
share the MPU with other devices, so you may have to
install another (MPU) or use a dual coil MPU with the
GCU-100. When the control cannot read the frequency
correctly, the GCU-100 shuts down the engine and the
MPU failure icon lights up on the panel.
For MPU settings refer to programming, lines (2), (16),
(17), (18), (19), (21), (22), (23).
4.4 Setting the AC Voltage and Current Display
In normal operation, you can read full phase voltage
and current directly off the screen. This reading is
factory calibrated. However, if the gen-set encounters
capacitive or inductive loads, waveform distortion
causes minor voltage differences with a calibrated
voltmeter.
If you want an identical reading, you need to
re-calibrate the control AC voltage and current settings.
Once the new calibration is completed, the voltage
reading is identical to the display. The over, under
voltage and load current protection will use these new
values as the system’s reference voltage.
For AC voltage and current display, settings go to
system setting and programming lines (3), (4), (10),
(11).
4.5 Setting AC Voltage Protection
The module comes preprogrammed for AC over and
under voltage protection. However if defective AC
Voltage is detected, it activates a permissive timer to
give the generator time to recover. However if it does
not recover on time, the module activates the AC
voltage protection shutdown showing the abnormal
voltage on the display and lighting up the high or low
AC Voltage LED on the control panel. If the voltage
recovers within the permissive count down, the control
automatically omits the abnormality.
The GCU-100 has two types of protections; a simple
warning and a total engine shutdown.
●Engine Shutdown：perform an immediate engine
power failure, displaying the abnormal reading on
the screen, and lighting up the appropriate a LED
indicator.
●Generator Warning：display the abnormal reading on
the screen and lighting up the appropriate a
universal indicator without stopping the generator.
For AC voltage protection and settings refer to system
programming lines (5), (6), (7), (8), (9).
4.6 Engine Over-load Protection Setting
To prevent inappropriate load usage and causing
gen-set failure and damage, the module is equipped
with engine over-load protection function. User needs
to setup appropriate over load protection setting
according to the gen-set maximum output.
If the system detects engine overload, it automatically
starts engine over-load timer countdown. If rated load
usage does not recover within the countdown, the
system automatically executes engine over-load
protection and displays a failure signal on the panel
and at the same time provides corresponding failure
signal output. If rated load usage is resumed within the
countdown timer, then it automatically omits the
overload warning.

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10 GCU-100
The GCU-100 provides two kinds of warning and
protection mode for engine over-load protection.
●Engine stop mode：When engine over-loads, the
module will execute engine stop and display a
failure signal on the panel, at the same time it will
provide corresponding failure signal output.
●Warning mode：display failure signal on the panel,
while at the same time provide corresponding failure
signal output. User can use the signal output to
disconnect the load and let gen-set operate without
load to cool down.
For engine over-load protection related settings refer to
system setting reference entries (12), (13), (14), (15).
4.7 Panel Display Setting
There are two types of display settings, fixed and cycle
display. The default setting is cycle display when you
view each parameter for 2 seconds.
To monitor particular parameter, press the
corresponding button to freeze the desired parameter
and press again to return to cycle display.
●Press the up and down arrows to change between
different phases readings.
●Press the up and down arrows to change between
different phase current readings.
●Press decrease / selection button to interchange
between AC frequency, Battery voltage and
operation Timer.
FUNCTIONs
AMPs
31
L
12
L
23
L
3
2
L
1
L
L
V
VOLTs
4.8 Manual Start & Stop Operation
An important and practical item on this control is the
technician shutdown bypass setting on line 53. When
activated, a technician can perform adjustments and
correction on the generator without the control stopping
it constantly. Now you can simply start the generator
by pushing the MANUAL button and stopping it by
pushing the AUTO button. Finally pushing the OFF
button takes you back to normal operation and
protections.
Before going into bypass mode make sure the
GCU-100 is connected properly, in bypass mode the all
the AUTO / OFF / MANU LED will turn-on as a
reminder that the control is in bypass mode. In bypass
mode, the module will continue to provide all warning
LED signals but cancel engine shutdown.
ATTENTION
Under bypass Manual Start and Stop Operation,
all of the engines protections are cancelled. If a
major failure occurs during this operation, the
module will not execute and engine shutdown
and the user will need to activate engine
shutdown manually. Only use this setting for
initial configuration and calibration of the
generator and not for providing load for long
period to prevent possible damage to the gen-set.
4.9 Setting the Programmable Inputs Alarm1 and
Alarm2
This module has 2 extra alarm outputs that are user
programmable that can ether provide a warning or a
shutdown.
To set up the two alarms refer to programming lines
(45), (46), (47), (48), (49), (50).
4.10 Service and Maintenance Reminders
This controller can activate a generator service
reminder by lighting up a service LED in the shape of a
clock face on the front panel. Program the service timer
in 10-hour units. For example if 20 is entered then the
scheduled timer is set to 200 hrs intervals (20 *10 hrs =
200 hrs). Reset the timer after activation.
For service and maintenance reminders, go to system
setting, programming lines (51), (52).
4.11 Engine Idle
A generator normally goes to full load speed on startup;
this may shutdown a cold engine. To avoid this
problem, the GCU-100 has an engine idle warm-up
timer allowing the engine to warm-up before loading.
You can activate or deactivate this function depending
on the type of engine and governor in use. Or if the
engine already has a block heater.

___________________________________________________________________________________________
GCU-100 11
To set the engine idle warm-up timers go to system
programming line (33).
4.12 Charge Alternator Excitation
GCU-100 provides excitation to the battery charging
alternator D+ terminal during engine start and later
monitors the D+ terminal to check if the alternator is
working properly. If the alternator fails, the control turns
on the charge alternator failure LED.
For battery charging alternator excitation setting, go to
system programming lines (39), (40), (41).
4.13 Setting Communication Modules GCU-100 to
PC (KCU-XX)
You can monitor and control the gen-set and controller
from a remote PC using the optional USB / RS485 /
Ethernet remote communication modules.
WARNING
A remote start signal can activate the GCU-100
and the engines can start at anytime without
warning. Place a “Danger” warning sign next to
the generator, stating that this generator can start
at anytime!” also install a warning buzzer or a
flash light. Unexpected engine starts can result in
serious injury or death. When performing service
or maintenance, always disconnect the remote
start signal input.
If you have an Ethernet module installed on your
GCU-100 you can remotely monitor and operate the
ATS and generator using the IPhone and Android
mobile phones.Free App software currently available
for Apple iOS5.1 system or above and android
operating system. Free software can be downloaded
from App Store or Google Play by simply key in “Kutai”
and hit search.
Free software can be downloaded from App Store or
Google Play by simply key in “Kutai” and hit search.
KCU-01 –USB communication module
KCU-02 –RS-485 communications module
KCU-03 –Ethernet communications module
The corresponding program settings for GCU-100
installed with KCU-XX module includes item (54), (55),
(56) Programming item (54) is a must. When Item (54)
is set to "00", then the remote monitoring software is
restricted to read information only whereas remote
command is strictly forbidden.
If KCU-02 - RS485 communication module is installed,
additional program setting on lines (55) and (56) are
needed.
For more detail, information refers to the KCU-XX
manual.
NOTE
GCU-100 with KCU-02 module constitutes a
closed LAN network. Each controller address can
be set from 1 to 99 and not to be repeated. Same
transmission rate is a must !!
4.14 CANBus J1939 Transducer KCU-04
(Optional)
The KCU-04 module is used with CPU equipped
engines using the J1939 CAN Bus protocol. It is
connected to any one of the four slots on the back of
the GCU-100 controller.
For J1939 related settings refer to Setting Line (24).
Installing the KCU-04 provides the GCU with the
following information.
●Temperature reading in ˚C or ˚F
●Oil Pressure reading in Psi or Bar
●High temperature warning and shut-down alarm
●Low oil Pressure warning and shut-down alarm
●Over-speed warning and shut-down alarm
●Under-speed warning and shut-down alarm
●Low fuel level warning and shut-down alarm
When you connect the KCU-04 module the GCU
disables the High Temperature, Low Oil Pressure and
Low Fuel Level protections automatically and all
related programming lines are automatically eliminated.
You don’t need to install any of sensors, this
information now comes from the CAN Bus, and
protections relegated to the engine CPU. The GCU’s
job is to show warning, alarm and shutdown messages
using the universal icons on the front panel.
The GCU does not disable its own over speed and under
speed protection, Both of GCU and the engine CPU will
shut-down the generator for over speed.
4.15 Lamp Testing
The GCU-100 controller provided lamp test function for
user to check all the LEDs and displays on the front
panel.
To run lamp test, set the controller in OFF mode first.
Press the OFF button then all the LEDs and displays
will be illuminated immediately. When the OFF button
released the controller will return to normal operation.

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12 GCU-100

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GCU-100 13
4.16 System Setting Reference
ITEM
DESCRIPTION
SETTING
FACTORY
SETTING
1
Phase Selection (3Ø 3Wire, 1Ø 3Wire, 1Ø )
00 3Ø 3W
01 1Ø 3W
02 1Ø
00
2
Generator Frequency (60 or 50 Hz)
00 60 Hz 01 50 Hz
00
3
AC voltage display function setting
00 Fix display
01 Cycle Up
02 Cycle Down
00
4
AC voltage display calibration (if needed)
00 99 V
0V
5
Permissive AC voltage timer
00 99 sec
(00 Option Cancelled)
15
6
Under voltage protection setting (18 = to 180 volts)
08 47
18
(180V)
7
Under voltage protection Warning or Shutdown
00 Warning 01 Shutdown
01
8
Over voltage protection setting (25 = to 250 volts)
11 50
25
(250V)
9
AC over voltage protection Warning or Shutdown
00 Warning 01 Shutdown
01
10
AC current display function setting
00 Fix display
01 Cycle Up
02 Cycle Down
00
11
AC current display calibration (if needed)
00 99 A
0 A
12
Set (CT) Current Transformer size in “AMPs”
Example The default setting is (12) for use with
an1000A/5A Current Transformer
(If you not set the correct CT value you are going to get a
erroneous current readings)
1 50/5 2 100/5 3 150/5
4 200/5 5 250/5 6 300/5
7 400/5 8 500/5 9 600/5
10 750/5 11 800/5 12 1000/5
13 1200/5 14 1500/5 15 1600/5
16 2000/5 17 3000/5
12
13
Engine overload timer
00 99 sec
(00 no overload protection)
0
14
Engine Overload protection setting (The setting value is the
percentage ratio from the primary current of Current
Transformer) For example : CT=1000/5A and Overload
protection setting is 80%, then the over current activation
will be 1000A * 80% = 800A
30 99%
80%
15
Engine over-load protection Warning or Shutdown
00 Warning 01 Shutdown
01
16
Engine over-frequency setting
51 75 Hz
65 Hz
17
Permissive engine over-frequency timer setting
00 99 sec
(00 no under-speed protection)
05
18
Engine under-frequency setting
40 59 Hz
55 Hz
19
Engine Under-frequency permissive timer setting
00 99 sec
(00 no over-speed protection)
10
20
Engine under-speed protection Warning or Shutdown
00 Warning 01 Shutdown
01
21
Magnetic Pick-up (MPU) installation
00 NO 01 Yes
00
22
Magnetic Pick-up (MPU) used to set engine over speed
00 NO 01 Yes
00
23
Magnetic Pick-up (MPU) Failure Warning or Shutdown
00 Warning 01 Shutdown
00
24
Use the Oil pressure switch or get info from J1939
(KCU-04) transducer
00 NO 01 NC
02 J1939 + KCU-04
01
25
Low oil pressure permissive delay
02 99 sec
05

___________________________________________________________________________________________
14 GCU-100
ITEM
DESCRIPTION
SETTING
FACTORY
SETTING
26
Coolant Temperature sensor type NO (Normal Open) or
NC (Normal Close)
00 NO 01 NC
00
27
High Coolant Temperature permissive delay
02 99 sec
05
28
Engine pre-heat timer setting (Countdown)
02 99 sec
06
29
engine crack cycles
01 09
03
30
Starter cranking time setting
02 30 sec
06
31
Oil pressure switch used to stop engine cranking
00 No 01 Yes
01
32
Magnetic Pick-up (MPU) used to stop engine cranking
00 No 01 Yes
00
33
Engine in idle timer setting
00 99 sec
00
34
Control set to (Energize to STOP) Shutdown solenoid
Activation timer
02 99 sec
10
35
Set Engine fuel solenoid to either (Energize to STOP or
energize to START)
00 Energize to stop
01 Energize to start
00
36
Set Engine cool-down timer
00 60 min
00
37
Set Battery under voltage protection voltage
08 23 Vdc
08 Vdc
38
Set Battery over voltage protection voltage
13 35 Vdc
32 Vdc
39
Charge alternator permissive timer delay
00 99 sec
(00 Option Cancelled)
0
40
Charge alternator D+ terminal minimum voltage Setting
08 25 Vdc
08 Vdc
41
Charge alternator failure Warning or Shutdown
00 Warning 01 Shutdown
00
42
Fuel level Switch type NO (Normal Open) or NC (Normal
Close)
00 Not used
01 NO 02 NC
00
43
Low fuel level activation permissive timer delay
02 99 sec
10
44
Low fuel level warning or Shutdown
00 Warning 01 Shutdown
00
45
Set Alarm1 as NO (Normal Open) or NC (Normal Close)
type
00 No input signal
01 NO 02 NC
00
46
Alarm1 permissive timer delay
02 99 sec
10
47
Alarm1 Warning or Shutdown
00 Warning 01 Shutdown
00
48
Set Alarm2 as NO (Normal Open) or NC (Normal Close)
type
00 No input signal
01 NO 02 NC
00
49
Alarm 2 permissive timer delay
02 99 sec
10
50
Alarm2 Warning or Shutdown
00 Warning 01 Shutdown
00
51
Engine service and maintenance timer setting
Every value represents 10 hr (2 = 20 hrs)
00 25 (00 Option Cancelled)
00
52
Erase service and maintenance warning signal and reset
timer cycle
00 NO 01 Yes
00
53
Technician service mode - Shutdown override
00 Normal 01 override
00
54
Enable remote control by KCU-XX Module
00 NO 01 Yes
00
55
KCU-02 module address setting
00 None
01 99
00
56
KCU-02 Baud rate setting
01 115200 06 9600
02 57600 07 4800
03 38400 08 2400
04 19200 09 1200
05 14400
03

___________________________________________________________________________________________
GCU-100 15
SECTION 5 : FAILURE WARNING
DESCRIPTION
5.1 Failure Signal Reference
Icon Reference
WARNING
SIGNAL
DESCRIPTION
EXECUTION
Engine Start Failure
Shutdown
Emergency
Shutdown Activated
Shutdown
High Coolant
Temperature
Shutdown
Low Oil Pressure
Shutdown
Over-speed
Shutdown
Under-speed
Shutdown
or Warning
AC over voltage
Shutdown
or Warning
AC under voltage
Shutdown
or Warning
Gen-set Over-load
Shutdown
or Warning
Low Fuel Level
Shutdown
or Warning
Charge alternator
failure
Shutdown
or Warning
Low Battery Voltage
Warning
Warning
MPU Signal Failure
Shutdown
or Warning
Service &
Maintenance
Reminders
Warning
Spare Setting 1
Shutdown
or Warning
Spare Setting 2
Shutdown
or Warning
5.2 Warning
If a failure occurs and the condition does not pose
immediate danger to the operator or gen-set, the
control allows the generator to keep on running and
provide power and the failure warning LED light will
flash, and activate the warning signal output. Once the
failure is corrected and eliminated, the warning signal
will automatically reset itself and return to normal
operation.
5.3 Shutdown Mode
If a major failure occurs during operation that can
cause danger to personnel or equipments, the control
will execute an immediate engine shut down and
display the corresponding failure warning signals and
at the same time will activate the warning signal output
to alarm the maintenance personnel to service and fix
the problem. Once the failure is serviced and
eliminated, user can press 【OFF】button to reset the
failure warning and confirm if the failure is properly
eliminated.
SECTION 6 : SPECIFICATION
DESCRIPTION
SPECIFICATION
DC Supply
9 36 Vdc
Alternator Input Range
15 510 Vac (Ph-Ph)
Alternator Input
Frequency
50 / 60 Hz
MPU Signal Strength
+/- 2V to 70V Peak
MPU Input Frequency
100 10,000 Hz
Start Signal Output
8 Amp @ 12/24 Vdc
Fuel Solenoid Signal
Output
8 Amp @ 12/24 Vdc
Preheat Signal Output
8 Amp @ 12/24 Vdc
Accessory “ON” Output
8 Amp @ 12/24 Vdc
Idle Control Conductor
Capacity
8 Amp @ 12/24 Vdc
Warning Signal Output
8 Amp @ 12/24 Vdc
Overload Alarm Output
8 Amp @ 12/24 Vdc
Operating Temperature
-20 to 60 ˚C
Relative Humidity
Under 95 %
Power Consumption
Under 5W
Rated CT Capacity
Above 2.5VA
Secondary Rated current
5A
Weight
604 g +/- 2%

___________________________________________________________________________________________
16 GCU-100
SECTION 7 : TERMINAL & WIRING DESCRIPTION
7.1 Connection Detail
PIN No.
DESCRIPTION
ATTENTION
J1-1
Charge alternator D+ terminal input
Connect to charge alternator D+ terminals
J1-2
Battery negative ( V )
Connect to battery negative
J1-3
Battery positive ( V )
Connect to battery positive (12 / 24V)
J1-4
Failure signal output
Used to control external alarm buzzer
Supply (+V) (Max. rated output 8Amp)
J1-5
Idle speed control signal output
Connect to electronic governor for idle speed control
Supply (+V) (Max. rated output 8Amp)
J1-6
Starter motor signal output
Connect to starter motor
Supply (+V) (Max. rated output 8Amp)
J1-7
Fuel solenoid signal output
Connect to fuel solenoid or fuel valve control
Supply (+V) (Max. rated output 8Amp)
J1-8
Accessory on output
Connect to the panel lamp
(Max. rated output 8Amp)
J1-9
Overload alarm signal output
Used to trip the AC output breaker
Supply (+V) (Max. rated output 8Amp)
J1-10
Preheat signal output
Used to control the internal heater
Supply (+V) (Max. rated output 8Amp)
J1-11
Emergency stop signal output
Connect to panel emergency stop push button
J1-12
High Coolant Temperature signal
input
Connect to Coolant Temperature switch
J1-13
Low oil pressure signal input
to oil pressure switch or J1939 reader dry contact
J1-14
Low fuel signal input
connect to fuel level switch
J1-15
User defined signal input 2
Negative input when action
J1-16
User defined signal input 1
Negative input when action
J1-17
Remote start signal input
Connect to A.T.S or remote start terminal
J1-18
Spare terminal
J2-1
Spare terminal
J2-2
Spare terminal
J2-3
Spare terminal
J3-1
Magnetic Pick-up input
Connect to magnetic Pick-up to monitor engine speed
J3-2
Magnetic Pick-up input
Connect to magnetic Pick-up to monitor engine speed
J3-3
Spare terminal
J3-4
Spare terminal
J3-5
Spare terminal
J3-6
Spare terminal
J3-7
CT (COMM) terminal input
Connect to external CTs common position
J3-8
CT Secondary for (L1)
Connect to secondary phase R (L1) monitoring CT
J3-9
CT Secondary for (L2)
Connect to secondary phase S (L2) monitoring CT
J3-10
CT Secondary for (L3)
Connect to secondary phase T (L3) monitoring CT
J4-1
AC Input (L1)
Connect to AC input phase R
J4-2
AC Input (L2)
Connect to AC input phase S
J4-3
AC Input (L3)
Connect to AC input phase T

___________________________________________________________________________________________
GCU-100 17
7.2 Three Phase System External Wiring Diagram
7.3 Single Phase System External Wiring Diagram
J1-3J1-2J1-12 J1-13 J1-14 J1-17J1-15J1-11 J1-16
J3-1 J3-2
LOAD
J1-5 J1-4J1-6 J1-8J1-7 J1-9J1-10
J3-9 J4-2J4-3 J4-1J3-7J3-8 J3-10
BATTERY
Emergency Stop Oil Pressure SW Temperature SW prog.-2 Prog.-1
Fuel Level SW Remote Start
Accessory
Pre-Heat
+
Stop
Start
IDLE
Over-Load
Alarm
Comm. Alarm
BZ
"ON"
GCU-100 Controller
8A 8A 8A 8A 8A 8A 8A
Pick-up
Meganetic
MPU- MPU+
D+
Charge
Alternator
J1-1
J1-1
Alternator
Charge
D+
MPU+ MPU-
Meganetic
Pick-up
8A8A8A8A8A8A8A
GCU-100 Controller
"ON"
BZ
Comm. Alarm
Alarm
Over-Load
IDLE
Start
Stop
+
Pre-Heat
Accessory
Remote Start Fuel Level SW
Prog.-1 prog.-2 Temperature SW Oil Pressure SW Emergency Stop
BATTERY
J1-10 J1-9J1-7 J1-8J1-6 J1-4J1-5
J3-2J3-1
J1-16J1-11 J1-15 J1-17J1-14J1-13J1-12 J1-2 J1-3
LOAD
J3-9 J4-2J4-3 J4-1J3-7J3-8 J3-10