Monicon GTR-205 User manual

GTR-205
Generator Controller
Manual
Web Site：http://www.monicon.com.tw
E-mail：[email protected]w

GTR 205 Manual BETA
File version: V20501E 2
1. Introduction
GTR-205 is a full digital Gen-set controller equipped with all basic functions and LCD panel
that include error message display; fault input detection, analog signal measurement and generator
status. When the error occurred, GTR-205 shuts down the engine; real-time diagnosis can be
known easily by reading LCD panel information. Furthermore, parameters can be adjusted from
front panel in accordance with any special requirement. Operating DC power range is from 8 to 38
volts, and low power consumption in standby mode which suitable for small battery charger.
2. Feature
Analog Display includes: Coolant temperature, Oil pressure, Running hour, Frequency and
DC volt, 3 phases AC voltage, and 3 phasesAC current, 3 phases grounded AC voltage,
utility 3 phases voltage
Monitor and display fault information include: Over speed (RPM), Low Frequency, High
Frequency, High Coolant Temperature, Low Oil pressure, Over Crank, Low Fuel Level,
Low Coolant Level, Low Battery, Sensor Open and Sensor Short, 24 errors recorder, Start
fail recorder, Sum of starts recorder.
System Operation Buttoms: Off, Auto, Manual, Pre-Heat, Stop, Run / Idle.
Programmable front panel.
Super wide operating DC power range from 8 to 38 volts.
Equipped with high security terminal connector that provide easy plug-in and removal.
Ultra low power consumption 100 mA @ 12V; 50 mA @ 24V.
Two colors back light make it easier to distinct system status.
9 output power Relays not only provide several functions but also endure heavy power
capacity
3. Specification
Operational DC power input
8 ~ 38 V (DC)
Power consumption
Max. 2 W, 100 mA @ 12 V; 50 mA @ 24 V
Measured Frequency
Minimum detect volts: 10 V (AC)
Range: 0 ~ 80 Hz
Accuracy: 0.2%
DC volt meter
Range: 10 ~ 31 V
Accuracy: 0.5%
AC volt meter
Range: 15 ~ 512 V
Accuracy: 0.5%
AC current meter
Range: Convert via CT ratio
Accuracy: 0.5%
Output capacity
6A / 30 V
Operating temperature
-30 ~℃70 ℃
Storage temperature
-40℃~ 100 ℃

GTR 205 Manual BETA
File version: V20501E 3
Dimension
216 mm × 144 mm × 89mm
Panel cutout
210 mm × 138 mm
Weight
745 g
4. Panel description
4.1 Front view
Fig. 1

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File version: V20501E 4
4.2 LED light indication
4.2.1. Mains available LED：On when the mains is within limits and able to take load. Off
when the mains happens unbalance in voltage or frequency.
4.2.2. Generator available LED：On when the generator is within limits and able to take load.
Off when the generator happens unbalance in voltage or frequency.
4.2.3. Close Mains LED：On when contact G35 and G36 short. Off when contact G35 and
G36 disconnect. The LED light doesn’t matter with system schedule.
4.2.4. Close Generator LED：On when contact G43 and G44 short. Off when contact G43 and
G44 disconnect. The LED light doesn’t matter with system schedule.
4.2.5. Test with load LED：On when enforce generator to test with load. Push button
once time, LED light will on and then twice LED light will off.
4.3 LCD display figures
＊＊（Explanation of LCD display, please check 4.6 Buttons）
LCD Display Line 1
LCD Display Line 2
LCD Display Line 3
Operation Model
Mains available
LED
Close Mains
LED
Generator
available LED
Close Generator
LED
Test with load
LED
System Status

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File version: V20501E 5
4.4 LCD Icon Explanation
Icon Explanation Icon Explanation
Emergency stop AC value
High coolant temperature DC value
Idle Mode Unit of voltage
Low frequency Running hours
Low battery voltage Unit of frequency
Low fuel level Unit of Celsius
Low oil pressure Unit of pressure
Low coolant level Gen-set system
System not in auto Auto Mode
Over Crank Sensor is opened
Over frequency Sensor is shorted
Pre-heat Configuration save
Running Configuration up limit
Stop Mode Configuration bottom limit
Manual status Parameter number
Over speed High Voltage
Sensor alarm/Error occurred Low Voltage
AC short IN 1 Action
AC overload IN 2 Action
Fig. 2
4.5 LCD Information
4.5.1 Battery DC voltage value
4.5.2 AC frequency value
4.5.3 Coolant temperature value
4.5.4 Oil pressure value
4.5.5 Running hours
4.5.6 RPM value
4.5.7 Gen-set L1-L2 Phase Voltage value
4.5.8 Gen-set L2-L3 Phase Voltage value
4.5.9 Gen-set L3-L1 Phase Voltage value
4.5.10 Gen-set L1 Phase Current value
4.5.11 Gen-set L2 Phase Current value
4.5.12 Gen-set L3 Phase Current value
4.5.13 Gen-set L1-N Phase Voltage value

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File version: V20501E 6
4.5.14 Gen-set L2-N Phase Voltage value
4.5.15 Gen-set L3-N Phase Voltage value
4.5.16 Utility L1-L2 Phase Voltage value
4.5.17 Utility L2-L3 Phase Voltage value
4.5.18 Utility L3-L1 Phase Voltage value
4.5.19 Utility frequency
4.5.20 Error record
4.5.21 Start fail record
4.5.22 Sum of starts record
4.6 Buttons explanation
a. Under the code entry model, can be the button of digit in
thousands.
b. Under the parameter setting model, can switch to next
parameter setting page.
a. Under the code entry model, can be the button of digit in
hundreds.
b. Under the parameter setting model, can switch to previous
parameter setting page.
a. Under the code entry model, can be the button of digit in
tens.
b. Under the parameter setting model, the button can increase the setting value. .
a. Under the code entry model, can be the button of digit in ones.
b. Under the parameter setting model, the button can reduce the setting value.
Fig.2
Buttons explanation

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File version: V20501E 7
a. Button of In/ Out parameter setting
a. Button of confirm
LCD display line 1 : L1-L2 gen-set voltage L2-L3 gen-set voltage L3-L1
gen-set voltage L1-N gen-set voltage L2-N gen-set voltage L3-N gen-set
voltage L1-L2 utility voltage L2-L3 utility voltage L3-L1 utility voltage
L1-L2 gen-set voltage ……
LCD display line 2 : L1 gen-set currentL2 gen-set currentL3 gen-set current
Engine RPM L1 Gen-set current ……
LCD display line 3 : Coolant temperature、Run hours、Oil pressure Coolant
temperature、Battery voltage、Oil pressure Coolant temperature、Run hours、
Oil pressure Coolant temperature、Battery voltage、Oil pressure ……
4.7 Code entry model
Only under the “OFF” model can enter the Parameter setting model.
Press the button can enter the code entry model. And then press the button under
the code of “0000” will show you the information of sum of start record and errors record.
Press the button can enter the code entry model. And then press the button under
the code of “0528” can enter the parameter setting model.
A. The sum of starts & Errors record.
=>
（Figure 3）（Figure 4）
Press the button can enter the code entry model. At that time LCD will display code
“0000＂and then press the button will show you the information of sum of starts
record and errors record. As the figure 4, LCD will show “Continuous fail, 5 times”, “The sum
of starts, 24 times”, “The eighth error record is low frequency “. Press button can
check the previous error record and press or can check the next error record.
Continuous fail, 5 times.
Error record :
Low frequency
The eighth
error record.
The sum of starts, 24 times.

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B. Parameter setting
=> =>
（Figure 5）（Figure 6）（Figure 7）
Press the button can enter the code entry model.，The way to press code “0528” is
pressing the button 5 times and pressing the button 2 times and then pressing the
button 8 times. Then LCD screen will show as figure 6 in that time. Then you can enter
the parameter setting model after press the button . If you want to switch to the second or
third parameter setting, keep press the button once or twice time until which parameter
setting you need shows up.
C. Parameter setting switch. Part I
=> =>
（Figure 8）（Figure 9）（Figure 10）
For example : Figure 8, Parameter 1, System presumption : 10 secs.
If you want to change the system presumption to 8 secs. Please press the button 2 times
(As figure 9). And then press the button once time, the LCD screen will show “SAVE”
one second on the place of “PARA”. When the word “SAVE” show up meaning the parameter
setting has been changed successfully. At that time you can see the LCD screen change form
figure 9 to fugure 10 and one second later, the screen change to figure 9 again.
If you want to change the system presumption to 12 secs. Please press the button 2
times, and following the same steps as above mentioned.
If you want to cancel the parameter setting, press the button can help you to return the
first page. Or you can press the button or to next or previous parameter setting
Code＂0528＂ Gen-set
Paramete
r : Stop
Parameter 1
System presumption : 10 seconds

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File version: V20501E 9
D. Parameter setting switch. Part II
（Figure 11）（Figure 12）
For example : Parameter 1, System presumption range : 5~40 secs.
If the setting value you need are lower than the system acceptable range (5 secs), the LCD
panel will show you to alarm the error as figure 11.
If the setting value you need are higher than the system acceptable range (40 secs), the LCD
panel will show you to alarm the error as figure 12.
5. Operation instruction
5.1. Correct wiring the same as our wiring diagram.
5.2. When the controller connect to the DC power, the LCD panel will light. And please check the
icons of LCD panel carefully.
5.3. When start the controller, system will stay in “OFF＂model and information page will stay
in the screen of L1 voltage, Current and Run hours.
5.4. Explanation of Buttons
Manual Auto Off Clear TestwithLoad Idle
5.5. Manual : Press the button 2 seconds under the model of “AUTO” or “OFF”. LCD
will show icon to present the situation of pre-heat. At that time, engine will start
immediately after pre-heat. If engine starts fail, the system will return to the model of “OFF”.
When the parameter setting value of pre-heat is 0 second, the per-heat will not be executed
and will start the engine immediate after press the button.

GTR 205 Manual BETA
File version: V20501E 10
5.6. AUTO：Press the button will lead you into“AUTO＂model and detect the utility
automatically then the system will decide to start the engine or not. At that time, LCD will
show the icon to present the situation of pre-heat and start the engine after the pre-heat.
If the engine start failed, the system will return to the model of “Pre-heat” and prepare to start
the engine again. If the parameter setting value of stop duration is 10 secs, the engine will
crank 10 secs to start the engine and then rest 10 secs to crank again. If after 3 cycles of
cracking and the engine still fail to start, the LCD screen will show the icon and act the
alarm. The system will return to “AUTO” model when the utility recovery again.
5.7. OFF：Press the button during the running engine will stop the engine and show the
icon on LCD screen. After 10 secs later (system presumption value of stop duration),
system will stop the engine and clear the icon on the screen. If the idle function has
been set, the screen will show the icon on the screen and dispear until the next time
that engine’s frequency up to the system presumption value.
5.8. Clear：When the errors happened, system will stop the engine and show the error messages on
the LCD screen. If you want clear the error messages, keep press the button to help
you to close the sounded buzzer and then LCD red light.
5.9. Test with Load：Press the button will lead the engine into the model of test with load.
At that time, the light upon the button will on and start to test the engine with load. Press the
button again will release the test model and return the system to the power supply by
utility. But generator will stop automatically until the times up cooling duration.
5.10. Nominal speed｜Idle：Press the button when the generator operating under the
nominal speed, the LCD screen will show the icon and lead the generator into the idle
function. On the contrast, press the button when generator operating under the idle
function will lead the generator return to nominal speed operation.
6. Parameter setting
6.1 Stop duration
Range: 5～40 sec
Default: 10 sec
Description: Engine stopping time, this affects the duration of the stop output period.
6.2 Pre-heat duration
Range: 0～10 sec
Default: 0 sec
Description: The time to pre-heat before start engine.
6.3 Crank attempts
Range: 1～9 attempts
Default: 3 attempts
Description: When cranking attempts is equal or greater than this setting, system indicates
over crank failure.

GTR 205 Manual BETA
File version: V20501E 11
6.4 Cooling duration
Range: 0～1250 sec (Setting value : 0~250, Cooling time=Setting value X 2.5sec)
Default: 0 sec
Description: When system is accepted normal stop command, generator will be in the
cooling mode and engine running until the time of this setting is reached.
6.5 IdleTime
Range: 0～1250 sec (Setting value : 0~250, Idle running time=Setting value X 2.5secs)
Default: 0 sec
Description: After engine start success, the system goes into idle mode. The setting is the
idle time.
6.6 Low battery voltage
Range: 9～32 V
Default: 20 V
Description: When battery voltage is lower than this setting value, system will show low
battery voltage error and shuts the engine down..
6.7 High frequency setting
Range: 48～70 Hz
Default: 66 Hz
Description: When frequency is greater than this setting value, system will show high
frequency error and shuts the engine down.
6.8 Function enable 1
Range: 0～255
Default: 255
Description: Select function according your specification.
Over
Frequency EMS L.O.P H.W.T L.W.L L.F.L Over speed
Low
frequency
Weight
Ex. 128 64 32 16 8 4 2 1 Result
Default
 255
List 1
⌦In table “” means [Enable], “” means [Disable].
⌦The setting can be calculated by adding all related bit multiplies its weighted value.
⌦For example: The setting is
128 * 1 + 64 * 1 + 32 * 1 + 16 * 1 + 8 * 1 + 4 * 1 + 2 * 1 + 1 * 0 = 255
6.9 Low frequency setting
Range: 42～61 Hz
Default: 54 Hz
Description: When generator frequency is lower than this setting value, system will show
low frequency error and shut down the engine.

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File version: V20501E 12
6.10 Input switch type
Range: 0～31
Default: 29
Description: Select switch type for the fault input switch.
Reserve Reserve Reserve L.F.L switch L.W.L switch H.W.T
switch EMS. switch L.O.P.
switch
Weighted
Ex. 128 64 32 16 8 4 2 1
Result
Default
127
List2
⌦In table “1” means input switch is [normal open type], “0” means input switch is [normal close type].
⌦The setting can be calculated by adding all related bit multiplies its weighted value.
⌦For example: The setting of the L.F.L switch (N.C.) and EMS switch (N.C.) is
16 * 0 + 8 * 1 + 4 * 1 + 2 * 0 + 1 * 1 = 13
6.11 Oil pressure switch delay
Range: 0.4～6 sec (Setting value : 2~30, Delay time=Setting value X 0.2sec)
Default: 1.2 sec (6 X 1.2 = 1.2)
Description: When oil pressure switch is activated and the active period is longer than this
setting, the controller will release the starter motor, if the system’s setting “Release motor
by O.P. switch” is enabled. This setting is nothing to do with low oil pressure delay.
6.12 Coolant temperature sender brand selection
Range: 0～2
Default: 1
Description: User can select which brand is used for measuring coolant temperature.
(0: SUSUKI, 1: SCD, 2: VDO)
6.13 Lubricant pressure sender brand selection
Range: 0～3
Default: 1
Description: User can select which brand is used for measuring lubricant pressure.
(0: SUSUKI, 1: SCD, 2: VDO 10 BAR, 3: VDO 5 BAR)
6.14 Current Transformer Ratio setting
Range: 50/5~6000/5
Default: 500/5
Description: User can accord system capacity to select suitable CT and setup the CT ratio.
50/5, 75/5, 100/5, 2: 150/5, 200/5, 250/5, 300/5, 400/5, 500/5, 600/5, 800/5, 1000/5, 1200/5,
1500/5, 1600/5, 2000/5, 2500/5, 3000/5, 3200/5, 4000/5, 5000/5, 6000/5
6.15 Low voltage setting
Range:186～440
Default:346
Description : When generator’s voltage is lower than this setting value, system will show
low voltage error and shut down the engine.

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File version: V20501E 13
6.16 High voltage setting
Range:220～484
Default:414
Description : When generator’s voltage is higher than this setting value, system will show
high voltage error and shut down the engine.
6.17 AC short setting
Range:100～500
Default:450
Description : When generator’s AC current higher than this setting value, system will show
AC short error and shut down the engine.
6.18 AC overload setting
Range:40～500
Default:400
Description : When generator’s AC current over than this setting value, system will show
AC overload error and shut down the engine.
6.19 High water temperature default
Range:75～120
Default:100
Description : When generator’s coolant temperature over than this setting value, system
will show high water temperature error and shut down the engine.
6.20 Low oil pressure default
Range:5～65
Default:15
Description : When generator’s oil pressure lower than this setting value, system will show
low oil pressure error and shut down the engine.
6.21 Enable functions 2
Range：0～255
Default：15
O.P release
motor Not in
Auto. LOP alarm HWT alarm Over
current Short Circuit Low voltage High voltage
Weighted
128 64 32 16 8 4 2 1
Result
Default 15
List 3
⌦In table “” means [Enable], “” means [Disable].
⌦The setting can be calculated by adding all related bit multiplies its weighted value.
⌦For example：8 + 4 + 2 + 1 = 15

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File version: V20501E 14
6.22 Display option
Range：0～15
Default：12
Reserve Reserve Reserve Reserve Pick up/
Charger Alt. RPM- real/convert. PSI/BAR ℃/℉
Reserve Reserve Reserve Reserve Charger Alt. Real RPM PSI ℃
Reserve Reserve Reserve Reserve Pick up Frequency
convert BAR ℉
Weighted
128 64 32 16 8 4 2 1
Result
Default
12
List 4
⌦In table “” means [Enable], “” means [Disable].
⌦The setting can be calculated by adding all related bit multiplies its weighted value.
⌦For example：8 + 4 = 12 ( Display : Pick up/ Frequency convert to RPM/ PSI/ ℃)
6.23 Speed release motor
Range：150～900
Default：480
Description : When generator’s running speed higher than this setting value, system will
enforce to stop the start motor.
6.24 Over speed
Range：980～2100 (RPM)
Default：1980 (RPM)
Description : When generator’s running speed higher than this setting value, system will
show low over speed error and shut down the engine.
6.25 Trip-Stop Option
Range：0～255
Default：0
Over Load AC Short Low
Voltage High Voltage Low Fuel IN2 IN1 Low
Frequency
Weighted
Sample 128 64 32 16 8 4 2 1
Result
Default 0
List 5
⌦In table “” means [Trip], “” means [Stop].
6.26 Fuel before start
Range：0～1
Default：0
6.27 Relay0
Range：0～29
Default：0 (The sum of errors output)
Description : Please study Relay List

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File version: V20501E 15
6.28 Relay 1
Range：0～29
Default：3 (Preheat output )
Description : Please study Relay List
6.29 Relay 2
Range：0～29
Default：12(Auto module)
Description : Please study Relay List
6.30 Relay 3
Range：0～29
Default：1 (System error)
Description : Please study Relay List
6.31 Relay 4
Range：0～29
Default：2 (Gen-set power supply to load)
Description : Please study Relay List
6.32 Relay 5
Range：0～29
Default：29 (Utility power supply to load)
Description : Please study Relay List
6.33 Parameter setting code 1
Range：01～99
Default：28
Description : Change the parameter setting code (0528).
6.34 Parameter setting code 2
Range：00～99
Default：05
Description : Change the parameter setting code (0528).
6.35 Utility over voltage
Range:220～484
Default:414
Description : When utility’s voltage
higher than this setting value, system will show utility over voltage error and start the
engine.
6.36 Utility low voltage
Range:186～440
Default:346
Description : When utility’s voltage lower than this setting value, system will show utility
low voltage error and start the engine.
6.37 PARA 37 Utility high frequency
Range：48～70 Hz
Default：66 Hz
Description : When utility’s frequency higher than this setting value, system will show
utility high frequency error and start the engine.
0.The sum of errors output /1.System error /2.Gen-set
power supply to load /3.Preheat output /4.Fuel before
start /5.Idle output /6.Over speed (RPM) / 7.High
frequency /8.Low frequency /9. Low oil pressure act
/10.High water temperature act /11.Not inAuto /12.Auto
module /13.Manual module /14.Over crank /15.AC high
voltage /16.AC Low voltage /17.Over current act
/18.AC short /19.Low battery voltage /20.Input 1 act
/21.Input 2 act /22.Low fuel level act /23.Low water
level act /24.Emergency stop /25.Sensor error alarm
/26.Gen-sets power supply to load (normal) /27.Gen-sets
power supply normal /28.Utility power supply normal
/29.Utility power supply to load.
List 5
Relay List

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File version: V20501E 16
6.38 PARA 38 Utility low frequency
Range：42～61 Hz
Default：54 Hz
Description : When utility’s frequency lower than this setting value, system will show
utility low frequency error and start the engine.
6.39 PARA 39 Utility unbalance
Range：5～30
Default：5
Description : When utility’s 3 phase voltage over than this setting value, system will show
utility low frequency error and start the engine.
6.40 PARA 40 TDES – Time Delay Emergency Start
Range：1～60 sec
Default：5 sec
Description : Setting for prevent engine start immediately from temporary utility power
unstable.
6.41 PARA 41 TDNE– Time Delay Normal to Emergency
Range：1～60 sec
Default：3 sec
Description : Setting to prolong the period from utility power supply switch to emergency
power supply to secure the stability of emergency power supply.
6.42 PARA 42 TDEN– Time Delay Emergency to Normal
Range：1～60 sec
Default：3 sec
Description : Setting to prolong the period from emergency power supply switch to utility
power supply. This setting value can prevent the unnecessary switch from unstable utility
power supply.

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File version: V20501E 17
7. System parameters
7.1 Emergency stop delay: 0.4 sec/ action: stop
7.2 Over frequency delay: 2 sec/ action: stop
7.3 High coolant temperature delay: 1 sec/ action: stop
7.4 Low oil pressure delay: 1 sec / action: stop
7.5 Low coolant level delay: 4 sec/ action: stop
7.6 Low frequency: 6 sec/ action: stop
7.7 Low fuel level delay: 4 sec/ action: alarm
7.8 Low Battery Voltage: 5 sec/ action: alarm
7.9 Circuit breaker closed delay: 7.5 sec/ action: stop
(After Gen-set normally runs about 7.5second, the G43 contact and G44 contact will form a
closed output circuit about 1 second then open the closed output circuit.)
7.10 Frequency release motor: 16 Hz/ action: stop
7.11 Cranking time: 10 sec/ action: stop
7.12 Protection pending time: 10 sec/ action: stop
(After Gen-set start successfully about 10 second, in this time period the controller
bypasses the faulty signal, except the emergency stop and the over speed.)

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8. Back view Description
8.1 Back view
Fig. 13

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8.2 Pin definition
Pin Description Pin Description
1 Battery plus pole 32 L2 Phase Utility power input
2 Battery negative pole 33 L3 Phase Utility power input
3 Starter output 34 N Phase Utility power input
4 Fuel valve output 35 Utility LOAD 1
5 Stop output 36 Utility LOAD 2
6 Alarm output 37 Utility close relay contact 1
7 Aux. output 0 38 Utility close relay contact 2
8 Aux. output 1 41 Gen-set close relay contact 1
12 Aux. input 2 42 Gen-set close relay contact 2
13 Low coolant level switch input 43 LOAD 1
14 Emergency stop switch input 44 LOAD 2
15 Low fuel level switch input 45 Aux. output 2
16 Low oil pressure switch input 46 Aux. output 2 (Normal Open)
17 High coolant temperature switch input 47 Aux. output 2 (Common Pin)
18 ATS remote control input contact 1 48 Aux. output 2 (Normal Close)
19 ATS remote control input contact 2 51 L3 Phase Current Input (L)
23 Frequency input contact 1 52 L3 Phase Current Input (K)
24 Frequency input contact 2 53 L2 Phase Current Input (L)
25 Spare 54 L2 Phase Current Input (K)
26 Coolant sensor input 55 L1 Phase Current Input (L)
27 Oil pressure sensor input 56 L1 Phase Current Input (K)
28 Speed input contact 1 57 N Phase Power Input
29 Speed input contact 2 58 L3 Phase Power Input
30 Aux. input 1 59 L2 Phase Power Input
31 L1 Phase Utility power input 60 L1 Phase Power Input
List6
8.3 VR Function
VRs are adjustment for matching tolerance between external and internal measuring meter
readout. All values can be shown on LCD panel and the accuracy of the setting values are
within 0.5%.
8.3.1 VR1：AC Voltage adjust - fine tuning
8.3.2 VR2：AC Current adjust - fine tuning
8.3.3 VR3：Water temperature value - fine tuning
8.3.4 VR4：Oil pressure value - fine tuning
8.3.5 VR5：Speed value adjust (fine tuning)
8.3.6 VR6：Speed value adjust (Coarse)

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File version: V20501E 20
9. Dimension
Fig. 14 Back view
Fig. 15 Side view
Fig. 16 Top view