SEDEMAC GC1100 User manual

MANUAL FOR
GC1100:
GENSET
CONTROLLER
Product Manual Version #0.00
ABSTRACT
This manual is intended as
an information guide for
operating SEDEMAC's GC1100
genset controller.
Doc #SED-MAN-GC1100-002
Date: 20-Apr-2018

Copyright
All rights reserved. No part of this publication may be reproduced, distributed or transmitted
by any means (including photocopying or storing in any medium by electronic means or other)
without the prior written permission of the copyright holder. Any reference to trademarked
product names used within this publication is owned by their respective companies.
SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document
without prior notice. For permission requests and applications to reproduce any part of this
publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned
contact details.
SEDEMAC Mechatronics Pvt. Ltd.
C9-10, C Block, MIDC Bhosari
Pune 411026, INDIA
Web Support:
Email: [e-mail]
Website: www.sedemac.com
Telephonic Support:
[phone]
[phone]
[phone]
[phone]
[phone]

GC1100 SEDEMAC
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Safety Instructions
General Instructions
✓This document includes important instructions that should be followed during installation and
maintenance of the generator Set controller.
✓For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an
authorized service personnel. Follow all applicable state and local electrical codes.
✓Efficient and safe operation of the controller can be acquired only if the equipment is correctly
operated, configured and maintained. Many accidents arise due to ignorance or illiteracy towards the
elemental rules of safety and precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions
to the operator, service personnel or the equipment.
•Highlights an essential element of a procedure to ensure correctness
•Indicates a procedure or practice, which could result in damage or
destruction of equipment, if not strictly observed
•Indicates a procedure or practice, which could result in injuring
personnel or loss of life, if not followed correctly
Electrical Safety
✓Electric shock can cause severe personal injury or death.
✓Ensure the generator set must be grounded before performing any installation or service.
✓Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock.
Prevent contact with terminals, bare wires, connections, etc., while the generator and related equip-
ment are running. Do not tamper with interlocks.
✓To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wir-
ings must be appropriate to which they will be subjected to.
In Operation Safety
✓Before installing genset controller, ensure that all power voltage supplies are positively turned off at
their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental
start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.
Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical
shock.
✓Remove electric power supply before removing controller or touching other electrical parts.
✓Use extreme caution when working on electrical components. High voltage can cause injury or death.
✓Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
✓Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
✓Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or
feet are wet. It may result in severe electrical shock.

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✓Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock
or burning.
✓In case of an accident caused by electric shock, immediately shut down the electrical power source. If
this is not possible, try to release the victim from the live conductor. Avoid direct contact with the
victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live
conductor. If the victim is unconscious, apply first aid and get immediate medical help.

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List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer their
respective description. This list does not contain units of measure.
Acronym
Description
AC
Alternating Current
ACK
Acknowledge
ALT
Alternator
AMF
Auto Mains Failure
AUX
Auxiliary
BTS
Base Transceiver Station
CHG
Charging
CKT
Circuit
CT
Current Transformer
DC
Direct Current
DG
Diesel Generator
DIG IN
Digital Input
ENG TEMP
Engine Temperature
ETS
Engine Temperature Sensor
FLS
Fuel Level Sensor
GCU
Genset Control Unit
Genset
Generator Set
GND
Ground
HMI
Human Machine Interface
HSD
High Side Driver
HWT
High Water Temperature
LCD
Liquid Crystal Display
LED
Light Emitting Diode
LLOP
Low Lube Oil Pressure
LOP
Lube Oil Pressure
LVL
Level
MCP
Manual Control Panel
MPU
Magnetic Pickup Unit
OV
Over Voltage
PID
Proportional Integral Derivative
PWM
Pulse Width Modulation
RMS
Root Mean Square
RPM
Revolutions Per Minute
R-Y-B
Red-Yellow-Blue
SCP
Sensor Common Point
SMD
State Machine Diagram
TEMP
Temperature
USB
Universal Serial Bus
UV
Under Voltage

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Table of Contents
1Introduction..........................................................................................................................1
Key Highlights of the Product..........................................................................................1
Product Features.............................................................................................................1
Specifications ......................................................................................................................3
Terminals.........................................................................................................................3
Power Supply Specifications...........................................................................................4
Generator Voltages and Frequency Measurements........................................................4
Load Current Measurements...........................................................................................5
Mains Voltage and Frequency Measurements ................................................................5
Digital Inputs ...................................................................................................................6
Analog Resistive Sensor Inputs ......................................................................................6
Analog Current Input .......................................................................................................7
Magnetic Pick Up Input ...................................................................................................7
Digital Outputs .............................................................................................................7
D+ CHG ALT ................................................................................................................8
Sensor Common Point.................................................................................................8
Deep Sleep Mode Feature...........................................................................................8
Communication Ports .........................................................................................................9
Installation..........................................................................................................................10
Dimensions ...................................................................................................................10
Mounting on panel.........................................................................................................10
Terminal Description......................................................................................................12
Typical Wiring Diagram .................................................................................................14
Module Display ..................................................................................................................16
Monitoring Mode ...........................................................................................................16
Description of Control keys..............................................................................................19
Functions of Control keys..............................................................................................19
Configuration Mode...........................................................................................................20
List of Configurable Parameters....................................................................................21
Digital Input Sources Selection .....................................................................................30
Digital Output Source Selection ....................................................................................31
Module Operation ..............................................................................................................33
Auto Mode.....................................................................................................................33
Manual Mode ................................................................................................................37
Alarms ................................................................................................................................38
Troubleshooting.................................................................................................................41
Introduction to Communication Protocol........................................................................43

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RS485 MODBUS Based Protocol......................................................................................43
Connection Details.....................................................................................................43
Precautions................................................................................................................44
Function Code Used ..................................................................................................44
Register Map .............................................................................................................46
Protocol for CAN-Based Communication........................................................................51
Connection Details.....................................................................................................51
Structure of Communication ......................................................................................51
Packet Structure ........................................................................................................58
Notes .........................................................................................................................................59

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List of Figures
Figure 1: GC1100 genset controller's front fascia.........................................................................2
Figure 2: Connectors of 10.16 mm pitch ......................................................................................3
Figure 3: Connectors of 5.08 mm pitch ........................................................................................3
Figure 4: Connectors of 3.5 mm pitch ..........................................................................................3
Figure 5: SCP connection ............................................................................................................6
Figure 6: Dimensions of the GC1100 genset controller ..............................................................10
Figure 7: Fixing clip and screw supplied along with controller....................................................11
Figure 8: Controller mounting on the panel using the fixing clips ...............................................11
Figure 9: GC1100 genset controller from backside ....................................................................12
Figure 10: GC1100 genset controller power circuit (used in the Auto Mains Failure Mode) .......14
Figure 11: GC1100 genset controller control circuit (used in the Auto Mains Failure mode) ......15
Figure 12: Control keys function.................................................................................................19
Figure 13: Configuration mode screen .......................................................................................20
Figure 14: Configuration mode authentication page screen .......................................................20
Figure 15: Saving setting screen................................................................................................20
Figure 16: SMD for AMF mode...................................................................................................34
Figure 17: SMD for auto exercise mode.....................................................................................35
Figure 18: SMD for cyclic mode .................................................................................................36
Figure 19: SMD for manual mode ..............................................................................................37
Figure 20: RS485 MODBUS connection with the help of two core shielded twisted pair cable..43

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List of Tables
Table 1: Features list ....................................................................................................................1
Table 2: 10.16 mm pitch connector details ...................................................................................3
Table 3: 5.08 mm pitch connectors details ...................................................................................3
Table 4: 3.5 mm pitch connector details .......................................................................................4
Table 5: Power supply specifications............................................................................................4
Table 6: Generator voltage and frequency measurements...........................................................4
Table 7: Load current measurements ...........................................................................................5
Table 8: Mains voltage and frequency measurements .................................................................5
Table 9: Digital inputs ...................................................................................................................6
Table 10: Analog resistive sensor inputs ......................................................................................6
Table 11: Analog voltage/current input..........................................................................................7
Table 12: Magnetic pickup input ...................................................................................................7
Table 13: Digital outputs ...............................................................................................................7
Table 14: D+ CHG ALT.................................................................................................................8
Table 15: Sensor common point...................................................................................................8
Table 16: Communication ports....................................................................................................9
Table 17: Details of GC1100 terminals .......................................................................................12
Table 18: Screens of engine status and operating mode............................................................16
Table 19: Control keys in different modes ..................................................................................19
Table 20: Configurable parameters ............................................................................................21
Table 21: Digital input sources selection ....................................................................................30
Table 22: Engine temperature sensor calibration .......................................................................31
Table 23: Fuel level sensor calibration .......................................................................................31
Table 24: LOP sensor calibration................................................................................................31
Table 25: LOP sensor (4-20mA) calibration................................................................................31
Table 26: Digital output source selection ....................................................................................31
Table 27: Alarm actions ..............................................................................................................38
Table 28: Alarms and their causes .............................................................................................38
Table 29: Common faults and their remedial actions..................................................................41
Table 30: RS485 MODBUS communication configuration setting ..............................................43
Table 31: Details of function codes.............................................................................................44
Table 32: Command from MODBUS master for Function 4........................................................44

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Table 33: Normal response from genset controller slave for Function 4.....................................44
Table 34: Command from MODBUS master for Function 16......................................................45
Table 35: Normal response from genset controller slave for Function 16...................................45
Table 36: Command from MODBUS master for Function 3........................................................45
Table 37: Normal response from genset controller slave for Function 3.....................................46
Table 38: Register map for input registers..................................................................................46
Table 39: Register map for holding registers ..............................................................................50
Table 40: Interpretation of alarm status results...........................................................................50
Table 41: Structure of communication ........................................................................................51
Table 42: Structure of broadcasted message .............................................................................57
Table 43: Structure of command message .................................................................................57
Table 44: Structure of command message received over CAN ..................................................58

GC1100 SEDEMAC
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1 Introduction
This document elucidates information necessary for operating SEDEMAC's GC1100 genset controller. It
empowers the user with the necessary information for using GC1100 genset controller in an application
that involves communication of the genset controller with an external system similar as a server or a
remote data communication system.
SEDEMAC's GC1100 boasts its modern technology with robust features of genset controller with user-
friendly HMI and full graphics LCD. GC1100 controller is bundled with highly versatile software &
extensive I/O's and thereby support a wide variety of industry standard features in diesel/gasoline
engine gensets. GC1100 controller's smart software offers flexibility to configure each individual input
and output for a specific function or application.
GC1100 controller can be configured through SEDEMAC's laptop / desktop utility, named as
SEDEMAC's Smart Config. All parameters can also be configured using the keypad of the genset
controller.
1.1 Key Highlights of the Product
•Genset controller with configurable 5 digital inputs, 4 analog inputs – 3 resistive type and 1
current type (Can also be used as digital inputs if configured) and 6 digital outputs
•Auto, Manual and Remote start / stop modes for 1-ph & 3-ph gensets
•RPM sensing using frequency and MPU
•Supports auto exercise and cyclic modes
•Real time clock-based event logs
•PC connectivity via USB port, RS485, CAN
•Configurable fuel theft alarm
•Backlit and full graphics display with power saving feature
1.2 Product Features
Following table gives a brief overview of various product features of the GC1100
Table 1: Features list
Features
Specs for GC1100
Digital Switch Input
5
Analog Resistive Inputs
3
Analog Current Input
1
Mains V-Input (AMF)
Y
DG Alt V-Input, D+ CHG ALT I/O
Y
DG Alt I-Input
Y
Eng. Speed Input via MPU
Y
Digital HSD (0.75A)
6
Real Time Clock for event logs, exerciser
Y
USB I/O port for laptop access
Y
EEPROM for extended event logs OR regional
languages
Y
CAN I/O
Y
RS-485 I/O for MODBUS
Y

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DC Battery Supply Voltage (with -32V reverse
protection)
8 to 32V
Operating Temperature Range (deg C)
-20 to 65
Ingress Protection with Optional Gasket
IP65
Sensor Common Input with ±2V Sensing Range
Y
Warning auto clear enable / disable
Y
Fuel reference selection input
Y
On the fly mode change when engine is
healthy/engine off
Y
Figure 1: GC1100 genset controller's front fascia

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Specifications
2.1 Terminals
GC1100 controller host three types of terminal blocks as shown in Figure 2, Figure 3 and Figure 4 given
below:
10.16 mm pitch connector suitable for 2 sq. mm wire
Figure 2: Connectors of 10.16 mm pitch
Table 2: 10.16 mm pitch connector details
Connect
or type
Male (On
controller) *
SM Part
Number
Female (Mating)*
SM Part
Number
Quantity
(Nos)
4-Pin
5474274
SM0003195
5453499
SM0001163
2
*Phoenix (Phoenix Contact (I) Pvt. Ltd.)
5.08 mm pitch connectors suitable for 2 sq. mm wire
Figure 3: Connectors of 5.08 mm pitch
Table 3: 5.08 mm pitch connectors details
Connector
type
Male (On
controller) *
SM Part
Number
Female (Mating)*
SM Part
Number
Quantity
(Nos)
2-Pin
5447353
SM0000281
5441980
SM0001164
1
*Phoenix (Phoenix Contact (I) Pvt. Ltd.)
3.5 mm pitch connector suitable for 0.5 – 1.5 sq. mm wire
Figure 4: Connectors of 3.5 mm pitch

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Table 4: 3.5 mm pitch connector details
Connector
type
Male (On
controller) *
SM Part
Number
Female
(Mating)*
SM Part
Number
Quantity
(Nos)
4-Pin
5441294
SM0000278
5441430
SM0003731
2
6-Pin
5441317
SM0003346
5449283
SM0003732
1
8-Pin
5441320
SM0003348
5441456
SM0003733
1
10-Pin
5443962
SM0003349
5449306
SM0003734
1
* Phoenix (Phoenix Contact (I) Pvt. Ltd.)
2.2 Power Supply Specifications
Following table gives a brief overview of power supply specifications
Table 5: Power supply specifications
Controller's terminal number
1, 2 (Ground and Battery positive respectively)
Supply voltage range
8 to 32 V-DC (Suitable for 12/24 V-DC system)
Cranking drop out period
50 mS
Maximum reverse voltage
-32 V-DC
Battery voltage measurement
accuracy
±1 % full scale
Battery voltage measurement
resolution
0.1 V
Maximum current
~ 0.2 A @ 12 V-DC (Excluding all current loads for the high side
driver’s output and Rotary Actuator's output)
Standby current
80 mA @ 12 V-DC
Deep sleep current
20 mA @ 12 V-DC
2.3 Generator Voltages and Frequency Measurements
Following table gives a brief overview of generator voltage and frequency measurements
Table 6: Generator voltage and frequency measurements
Controller's terminal number
27, 28, 29, 30 (N, B, Y, R respectively)
Measurement type
True RMS
Phase to Neutral voltage
20 to 350 V-AC RMS
Phase to Phase voltage
20 to 606 V-AC RMS
Voltage accuracy
±1% of full scale for Ph to N
±1.5% of full scale for Ph to Ph
Voltage resolution
1 V-AC RMS for Phase to Neutral
2 V-AC RMS for Phase to Phase
Frequency range
5 to 75 Hz
Frequency accuracy
Accuracy: 0.25% of full scale
Resolution: 0.1 Hz

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For single genset application, it is mandatory to connect the genset phase and
neutral cables to the genset controller's phase R and Neutral terminals respectively
2.4 Load Current Measurements
Following table gives a brief overview of load current measurements
Table 7: Load current measurements
Controller's terminal number
35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for
phase R)
Measurement type
True RMS
Maximum CT secondary
current rating
5 A
Burden
0.25 VA
Accuracy
±1.4 % of full scale nominal (5 A)
Follow the recommended phase sequence while connecting the Current
Transformer (CT)
2.5 Mains Voltage and Frequency Measurements
Following table gives a brief overview of Mains voltage and frequency measurements
Table 8: Mains voltage and frequency measurements
Controller's terminal number
31, 32, 33, 34 (N, B, Y, R respectively)
Measurement type
True RMS
Phase to Neutral voltage
20 to 350 V- AC RMS
Phase to Phase voltage
20 to 606 V-AC RMS
Voltage accuracy
±2 % of full scale for Phase to Neutral
±2.5 % of full scale for Phase to Phase
Voltage resolution
1 V-AC RMS for Phase to Neutral
2 V-AC RMS for Phase to Phase
Frequency range
3 to 75 Hz
Frequency accuracy
Accuracy: 0.25% of full scale
Resolution: 0.1 Hz
For single phase application, it is mandatory to connect the mains phase and neutral
cables to the genset controller's phase R and Neutral terminals respectively.

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2.6 Digital Inputs
Following table gives a brief overview of digital inputs
Table 9: Digital inputs
Controller's terminal number
10, 11, 12, 21, 22
Number of inputs
5
Type
Negative sensing (connect switch to ground.)
Open circuit voltage
(VBATT – 1) V-DC
Software configurable options
Low Lub Oil Pressure (LLOP) Switch, High Engine Temperature
switch and many more. Please refer Table 21
2.7 Analog Resistive Sensor Inputs
Following table gives a brief overview of analog resistive sensor inputs
Table 10: Analog resistive sensor inputs
Controller's terminal number
24, 25, 26 (Eng_temp, Fuel_Level sensor, LOP respectively)
Number of inputs
3
Type
Ratio-metric sensing
Range
0 to 1000 Ω
Open circuit detection
Above 5.5 KΩ
Accuracy
±2 % of FSD up to 1000 Ω
Connection method
One should connect the sensor output terminals between the
genset controller terminal and the battery ground terminal.
Figure 5: SCP connection

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2.8 Analog Current Input
Following table gives a brief overview of analog current input
Table 11: Analog voltage/current input
Controller's terminal number
23
Type
current sensing
Range
4 to 20 mA
Accuracy
±1.25% of full scale
Resolution
0.1mA
2.9 Magnetic Pick Up Input
Following table gives a brief overview of magnetic pickup input
Table 12: Magnetic pickup input
Controller's terminal number
42
Type
Single ended
Frequency range
10 to 10000 Hz
Input voltage range
200 mV to 45 V-AC RMS
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine
speed sensing. The output of MPU is a sine-wave signal.
2.10 Digital Outputs
Following table gives a brief overview of digital outputs
Table 13: Digital outputs
Controller's terminal number
3, 4, 5, 6, 8, 9
Number of outputs
6
Type
High side driver
Maximum current
0.75 A
Software configurable options
Start relay, Fuel relay and many more. Refer Table 26
Do not connect “STARTER MOTOR” and “STOP SOLENOID” directly to the
controller's output terminals
Genset & mains contactor latching relays should be compiled against 4kVA surge as
per IEC-61000-4-5 standard.

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2.11 D+ CHG ALT
Following table gives a brief overview of D+ CHG ALT
Table 14: D+ CHG ALT
Controller's terminal number
7
Voltage range
0 to VBATT ; VBATT = 8 to 30 V-DC
Excitation
PWM (Current limited to 250 mA Or Average Power should be
below 3 watts)
Accuracy
±1% of full scale
The D+ CHG ALT is combine input and output terminal. When the genset starts, the terminal
provides controlled power output to excite the charging alternator. Once the charging alternator is
excited and starts providing voltage to battery, this terminal is used as input to sense the output
voltage of the charging alternator. In case of the charging alternator failure the GCU acts as per the
pre-configuration settings.
2.12 Sensor Common Point
Following table gives a brief overview of sensor common point
Table 15: Sensor common point
GCU connector terminal number
41
Range
±2V
Accuracy
±2% of full scale
Resolution
0.1 V
Important Note: The sensor common point (SCP) terminal (Pin # 41) of the
controller should be directly connected to an electrically sound point on the engine
body. This point on the engine body should serve as a common reference point for
all analog sensors such as those for measuring lube oil pressure, engine
temperature and fuel level. The electrical cable used for the connection should not
be shared with any other electrical connection. Such a wiring practice is strongly
recommended to ensure that there is negligible potential difference, if any, between
the engine body and the controller's SCP terminal, and predictable and accurate
analog sensor measurements are always available in a wide variety of field
conditions.
2.13 Deep Sleep Mode Feature
Deep Sleep Mode is a useful feature to prolong the battery life.
In this mode, normal functions of the controller are suspended, and controller is placed into its lowest
power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode.
When the controller wakes up, normal operations are resumed automatically.
The controller goes in Deep Sleep Mode when there is no user interaction for the pre-set Deep Sleep
Mode Delay.
•This mode is disabled in AMF mode.
•In Manual mode, press and hold “START”/“STOP” key for minimum one sec to come out of
Deep Sleep mode.

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Communication Ports
Following table gives a brief overview of communication ports
Table 16: Communication ports
USB
USB 2.0 Type B used for connection to PC running SEDEMAC Smart
config.
RS485 Serial Port
Half Duplex
Max Baud Rate 115200
Data connection 2 wire
Termination resistor of 120Ω is provided between output pin A & B
Common-mode operating range and bus-pin fault protection upto ±70V
Maximum distance of line is 1200m
Controller's terminal
number for RS485
15, 16
CAN
Baud rate used is 250 kbps
Packet size used is 8 bytes
Termination resistor of 120Ω is provided
Controller's terminal
number for CAN
13, 14

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Installation
4.1 Dimensions
Figure 6: Dimensions of the GC1100 genset controller
Recommended mounting panel cut-out dimensions: 118 mm X 93 mm.
4.2 Mounting on panel
To mount the controller into the panel, use the fixing clips provided along with the controller.
Follow the given steps: