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H-100 Control Panel

Operations Manual

ii H-100 Control Panel Operations Manual

WARNING!

California Proposition 65

Engine exhaust and some of its constituents are known to the state of California to cause cancer,

birth defects, and other reproductive harm.

WARNING!

California Proposition 65

This product contains or emits chemicals known to the state of California to cause cancer,

birth defects, and other reproductive harm.

Table of Contents

H-100 Control Panel Operations Manual iii

Section 1Safety

1.1 Introduction ..........................................................................................................................1

1.2 Safety Rules ..........................................................................................................................1

1.3 General Hazards ...................................................................................................................2

1.4 Electrical Hazards ................................................................................................................3

1.5 Fire Hazards ..........................................................................................................................3

1.6 Explosion Hazards ...............................................................................................................3

Section 2 General Information

2.1 Introduction ..........................................................................................................................5

2.2 Features ................................................................................................................................ 5

2.3 Panel Setup ...........................................................................................................................5

2.3.1 Changing the Controller Configuration .........................................................................................5

2.3.2 Customization ...............................................................................................................................6

2.4 The Measurement “Engine” ................................................................................................6

2.4.1 Analog Channels ..........................................................................................................................6

2.4.2 Analog Maths ................................................................................................................................7

2.4.3 Analog Alarms ..............................................................................................................................8

2.4.3.1 Types.................................................................................................................................... 8

2.4.3.2 Setpoints............................................................................................................................... 8

2.4.3.3 Delay Time............................................................................................................................ 8

2.4.3.4 Hysteresis............................................................................................................................. 8

2.4.3.5 Shutdown.............................................................................................................................. 8

2.4.3.6 Dialout................................................................................................................................... 8

2.4.3.7 Active When.......................................................................................................................... 8

2.4.3.8 Sensor Failure Check ........................................................................................................... 8

2.4.3.9 Shutdown on Sensor Failure................................................................................................. 8

2.4.4 Other Analog Options ...................................................................................................................9

2.4.4.1 Event Log.............................................................................................................................. 9

2.4.4.2 Analog Outputs..................................................................................................................... 9

2.4.5 Analog Sensor Ratings .................................................................................................................9

2.5 Output Functions .................................................................................................................9

2.5.1 Spare Analog Channels ................................................................................................................9

2.6 Engine Management ............................................................................................................9

2.6.1 Generator Parameters ................................................................................................................10

2.6.2 Engine Settings ...........................................................................................................................10

2.7 Voltage Regulator (Option) ...............................................................................................11

2.8 Governor (Speed Regulator) ............................................................................................. 12

2.9 Starting and Stopping Sequence Diagrams ....................................................................14

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iv H-100 Control Panel Operations Manual

2.10 Trending ............................................................................................................................14

2.10.1 Remote Trending ......................................................................................................................14

2.10.2 Local Trending ..........................................................................................................................15

2.10.3 Genlink Local Trending Setup ..................................................................................................15

2.10.3.1 No Trigger......................................................................................................................... 15

2.10.3.2 Pre-Trigger........................................................................................................................ 15

2.10.3.3 Post-Trigger...................................................................................................................... 15

2.10.3.4 Pre- and Post-Trigger ....................................................................................................... 15

2.11 The ILC ..............................................................................................................................15

2.12 The Front Panel Display ...................................................................................................16

2.12.1 Left Display ...............................................................................................................................16

2.12.2 Right Display Pages .................................................................................................................16

2.12.3 Left Display Pages ....................................................................................................................17

2.12.4 Right Display Pages .................................................................................................................20

2.12.5 Alarms ......................................................................................................................................20

2.13 Engine ................................................................................................................................22

2.14 Status .................................................................................................................................24

2.15 Service ...............................................................................................................................26

2.16 Generator ..........................................................................................................................27

2.17 Diagnostics .......................................................................................................................29

2.18 Exercise/HTS .....................................................................................................................31

2.19 Home ..................................................................................................................................34

2.20 The Control Panel .............................................................................................................34

2.21 The Alarm Log ..................................................................................................................34

2.22 The Event Log ...................................................................................................................35

2.23 Maintenance Settings .......................................................................................................35

2.24 Air/Fuel Ratio Control (Option) .......................................................................................35

2.25 I2T Current Monitoring (Option) ......................................................................................35

2.26 Internal Exercise Function ...............................................................................................36

2.27 QuietTest® Setup Using Genlink ....................................................................................36

2.28 Normal Exercise Setup Using Genlink ...........................................................................38

2.29 QuietTest® Setup Using Front Panel ..............................................................................40

2.30 Normal Exercise Setup Using Front Panel .....................................................................44

2.31 Set Date and Time ............................................................................................................49

2.31.1 Date and Time Setup Using Genlink ........................................................................................49

2.31.2 Date and Time Setup Using Front Panel ..................................................................................50

2.32 Adjust Display Contrast ...................................................................................................50

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H-100 Control Panel Operations Manual v

2.33 Enable HTS Commercial Transfer Switch ...................................................................... 52

2.33.1 HTS Setup Using Genlink .........................................................................................................52

2.33.2 HTS Setup Using Front Panel ..................................................................................................52

2.34 Communications ..............................................................................................................54

2.35 Remote Annunciator Connection (Option) .................................................................... 55

2.36 GenLink-DCP ....................................................................................................................55

2.36.1 GenLink Relay Control ..............................................................................................................55

2.36.2 Set Engine Hours ......................................................................................................................55

2.36.3 Absolute Maximum Ratings ......................................................................................................55

2.36.4 Environmental Ratings ..............................................................................................................55

2.37 2A and 10A Battery Chargers ......................................................................................... 55

2.37.1 2A, 12VDC Battery Charger .....................................................................................................57

2.37.2 10A, 12VDC Battery Charger ...................................................................................................57

Section 3 Analog Functions

3.1 User Configurable Analog Inputs ..................................................................................... 59

Section 4 I/O and Connector Information

4.1 Analog Inputs .....................................................................................................................63

4.2 Digital Outputs ...................................................................................................................64

4.3 Digital Inputs ......................................................................................................................64

4.4 Digital Output Functions ...................................................................................................65

4.5 Connector Pin Descriptions ..............................................................................................69

Section 5 Internal Alarms/Warnings

5.1 Alarm Displays and Descriptions .....................................................................................71

Section 6 Emissions Interface and Operation

6.1 OBD and Modbus Register Numbers ...............................................................................73

Section 7 Ground Fault Indication

7.1 Introduction ........................................................................................................................75

7.2 Definitions ...........................................................................................................................75

7.3 Requirements .....................................................................................................................75

7.4 Associated Documents .....................................................................................................75

7.5 Functional Description ......................................................................................................75

7.5.1 Enabling Ground Fault Indication Feature ..................................................................................75

7.5.2 Initial Parameter Values ..............................................................................................................76

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vi H-100 Control Panel Operations Manual

7.5.3 Data Sampling and Logic Execution Rates ................................................................................76

7.5.4 DOF Control if Enabled ..............................................................................................................76

7.5.5 AI Control if Enabled ...................................................................................................................76

7.6 GENLINK GFI Configuration Screen .................................................................................76

7.6.1 GFI enable ..................................................................................................................................77

7.6.2 GFI Screen's System Generated Fields .....................................................................................77

7.6.2.1 Generator Rated Current (RMS Amps)............................................................................... 77

7.6.2.2 Generator Average Current (RMS Amps)........................................................................... 77

7.6.2.3 Generator Gnd + Neutral Current (RMS Amps).................................................................. 77

7.6.3 GFI Field Editable Parameters ...................................................................................................77

7.6.3.1 Gnd + Neutral Current Threshold (RMS Amps).................................................................. 77

7.6.3.2 Gnd + Neutral Current Hysteresis (RMS Amps)................................................................. 77

7.6.3.3 Gnd + Neutral Fault Delay(s).............................................................................................. 77

7.6.3.4 Analog Input Channel Assignment (chan_ID)..................................................................... 77

7.6.3.5 Digital Output Function Assignment (chan_ID)................................................................... 77

7.6.4 Apply Button ...............................................................................................................................78

7.6.5 Print Button .................................................................................................................................78

7.6.6 Close Button ...............................................................................................................................78

7.6.7 GENLINK GFI Configuration Help Screen Information ...............................................................78

7.7 Basic Setup Instructions ...................................................................................................79

7.7.1 GFI Configuration Default Setup ................................................................................................79

7.7.2 GFI DOF Default Setup ..............................................................................................................79

H-100 Control Panel Operations Manual 1

Section 1Safety

1.1 — Introduction

Read this manual thoroughly. If any portion is not understood, contact the nearest Authorized Service Dealer for

clarification. The manufacturer also requires having an Authorized Service Dealer oversee the installation of any

standby generator set. Trained/qualified service technicians familiar with the control systems and available options

have full access to drawings, publications, and other information required for a successful installation.

1.2 — Safety Rules

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION, and

NOTE boxes are used to alert personnel to special instructions about a particular operation that may be hazardous if

performed incorrectly or carelessly. Observe them carefully. They indicate:

Indicates a hazardous situation or action that, if not avoided, will result in death or serious

injury.

Indicates a hazardous situation or action that, if not avoided, could result in death or seri-

ous injury.

Indicates a hazardous situation or action that, if not avoided, could result in minor or mod-

erate injury.

NOTE: Notes provide additional information important to a procedure or component.

These safety warnings cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance

with the special instructions while performing the action or service are essential to preventing accidents.

Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of informa-

tion each indicates:

This symbol points out important safety information that, if not followed, could

endanger personnel and/or property.

This symbol represents the potential for an Explosion Hazard.

This symbol represents the potential for a Fire Hazard.

This symbol represents the potential for an Electrical Shock Hazard.

SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be

followed during installation of the generator set and batteries. The manufacturer suggests

that these safety rules be copied and posted in potential hazard areas. Safety should

be stressed to all installers, operators, potential operators, and service and repair

technicians for this equipment.

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Safety

2 H-100 Control Panel Operations Manual

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this

manual, and on tags and decals affixed to the unit, are not all-inclusive. If using a procedure, work method, or operating

technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the pro-

cedure, work method, or operating technique used does not render the generator unsafe.

• Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance, or

being careless can cause possible injury or death. Permit only responsible and capable persons to install, oper-

ate, and maintain this equipment.

• Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.

• If this generator is used to power electrical load circuits normally powered by a utility power source, install a

transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution sys-

tem when the generator is operating. Failure to isolate an electrical system by such means will result in damage

to the generator and also may result in injury or death to utility power workers due to backfeed of electrical

energy.

Generators produce potentially lethal voltages. Ensure all steps are taken to make the genera-

tor safe before operation or service.

1.3 — General Hazards

• For safety reasons, the manufacturer recommends that this equipment be installed, serviced, and repaired by an

Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with

all applicable codes, standards, and regulations.

• Ensure that the generator is installed, operated, and serviced in accordance with the manufacturer’s instructions

and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance.

• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. If breathed in sufficient concentra-

tions, carbon monoxide can cause unconsciousness or even death. For this reason, adequate ventilation must

be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator

to an area where people, animals, etc. will not be harmed.

• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Never remove any

drive belt or fan guard while the unit is operating. Ensure that all guards, covers, and protective devices removed

during maintenance or service are reinstalled.

• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to

ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation pro-

visions, as this can affect safe operation of the generator.

• Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or men-

tally fatigued.

• Inspect the generator regularly, and promptly repair or replace any worn or damaged components using only fac-

tory approved parts and procedures.

• Before performing any maintenance on the generator, always disconnect the battery cables to prevent accidental

startup. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG, or (–) first, then remove the

POSITIVE, POS, or (+) cable. When reconnecting the cables, connect the POSITIVE cable first, the NEGATIVE

cable last.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may

result in exhaust, fuel, oil or coolant leaks.

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Safety

H-100 Control Panel Operations Manual 3

1.4 — Electrical Hazards

• All generators produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers

extremely high and dangerous voltages to the transfer switch as well as the generator when it is in operation.

Avoid contact with bare wires, terminals and other connections. Ensure all covers, guards, and barriers are in

place, and that they are properly secured and/or locked before operation. If work must be done around an oper-

ating unit, stand on an insulated, dry surface to reduce potential shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment,

lay down a dry wooden platform and cover with insulated mats before beginning.

• Verify that the generator is properly grounded.

• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical

current (ampacity) to which it will be subjected.

• Before installing or servicing equipment, verify that all power voltage supplies are positively turned off at their

sources. Failure to do so can result in hazardous and possibly fatal electrical shock.

• Connecting this unit to an electrical system normally supplied by an electric utility is by means of a transfer switch

so as to isolate the generator electric system from the electric utility distribution system when the generator is

operating. Failure to isolate the two electric system power sources from each other by such means will result in

damage to the generator and may also result in injury or death to utility power workers due to backfeed of electri-

cal energy.

• Generators installed with an automatic transfer switch will crank and start automatically when NORMAL (UTIL-

ITY) source voltage is removed or is below an acceptable preset level. To prevent automatic startup and possible

injury, disable the automatic start circuit (battery cables, etc.) before working on or around the unit. Place a “DO

NOT OPERATE” tag on the generator control panel and on the transfer switch.

• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not

possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use

a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is

unconscious, apply first aid and get immediate medical help.

• Do not wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,

or may get caught in moving parts resulting in injury.

1.5 — Fire Hazards

• Keep a fire extinguisher near the generator at all times. Keep the extinguisher properly charged and be familiar

with its use. Direct any questions to the local fire department.

NOTE: DO NOT use any carbon tetra-chloride type fire extinguishers. These fire extinguishers emit toxic fumes

and the liquid can damage wiring insulation.

1.6 — Explosion Hazards

• Properly ventilate the room or building housing the generator to prevent buildup of explosive gas.

• Do not smoke around the generator. Immediately wipe up any fuel or oil spills. Ensure that no combustible mate-

rials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result.

Keep the area surrounding the generator clean and free of debris.

• All types of fuels are potentially FLAMMABLE and/or EXPLOSIVE and must be handled with care. Inspect the

fuel system frequently and correct any leaks immediately. Be sure fuel supply lines are properly installed, purged,

and leak tested before placing the generator set into service.

Safety

4 H-100 Control Panel Operations Manual

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H-100 Control Panel Operations Manual 5

Section 2 General Information

2.1 — Introduction

The H-100 Control Panel is an electronic control box that functions as an advanced standby generator controller. Its

technology is based on the flagship PM-DCP system with all its flexibility included. A familiar user interface in the form

of GenLink®-DCP is used to program, monitor and change the parameters in the unit. The interface appears the same

as it does for the PM-DCP.

Specialized programs are built into the H-100 Control Panel to allow customers to configure spare I/O to their own

needs. For example, built in Integrated Logic Controller (ILC) logic can eliminate the need for ancillary external control-

lers. Everything can be user customized from measurements to alarms to special functionality.

Why do we do this? Having one set of control firmware buys us the economy of scale which can be passed on to the

customer. It also has great technical advantages. The H-100 Control Panel and all PM-DCP products are built around a

common “core” of firmware. This provides EVERY product with the same technical tools. For example, both the H-100

Control Panel and PM-DCP products can call out for assistance via a modem, every product can provide trending data

for its measured parameters, any measured value can be setup to create alarms or warnings, each product has a built

in ILC, etc. H-100 Control Panel is very flexible.

2.2 — Features

• Local/remote connection to a PC for GenLink®-DCP communication.

• Interface with up to four HTS Commercial Transfer Switches.

• Interface with up to two Remote Annunciator Panels.

• New Generation GenLink.

• Built-in Frequency and Voltage controller.

• External modem option with dialout capability upon alarm.

• Communication via standard CAN bus and Modbus protocols.

• Programmable I/O channel properties.

• Programmable alarm/warnings.

• Alarm and event logging with time stamping.

• Parameter logging and trending both to file and graphical.

• Built-in diagnostics.

• Internal ILC for combinatorial logic functions including analog inputs.

• Spare customer programmable Analog input capacity.

• Spare customer programmable Digital I/O capacity.

• Firmware can be updated via Telephone line.

2.3 — Panel Setup

2.3.1— Changing the Controller Configuration

The H-100 Control Panel controller is setup in the factory to match the product it is shipped with and generally no

changes are required. For spares purposes the controller can be re-configured in the field using the GenLink software

tool and a PC.

If you need to change the function of the panel, the best way to get a basic setup for a product is to use GenLink to

download a “product file”. This will setup all the basic parameters and just leave customization and calibration to be

done. Product files are available on the web site for downloading cross referenced to product serial numbers/generic

product types. The manufacturer does not recommend changing the settings individually for a product as this is labori-

ous and prone to human error. Some of the settings require detailed knowledge of things like governor settings which

are not easily discernable.

General Information

6 H-100 Control Panel Operations Manual

Some configurations are changeable from the H-100 Control Panel touch pad and displays. These configurations will

be described later and include:

• Setting Display Contrast

• Setting System Time and Date

• Setting Up/Enabling Internal Exercise

• Enabling Interface with HTS Commercial Transfer Switch

2.3.2— Customization

The controller is designed to be very flexible and allow great levels of customization via the GenLink tool. Once you

have customized your controller, you should save the settings for backup. This can be done during the customization

process, or at any time subsequent to customization by uploading the settings from the controller to GenLink and then

saving them. The digital outputs can be set to turn on from any one of a list of functions or they can be used as part of

the built-in ILC. The digital inputs can be moved, inverted, renamed, made alarms, used in the ILC, logged/not logged,

etc. Refer to the section “MEASUREMENT ENGINE” for details. Analog inputs are dealt with in the same section.

There are some parameters which are specific to the product, such as an engine controller or transfer switch. These

are all customizable via GenLink. Refer to the relevant section for details.

2.4 — The Measurement “Engine”

The measurement “engine” is the key feature of the system. All the inputs to the controller are processed by this mod-

ule. Each physical input is measured and the result processed by an individual set of rules that are set via a PC and

GenLink. Normally, a product is delivered with the inputs and outputs pre-configured and nothing needs to be done,

however the manufacturer has provided complete flexibility to each measurement (except where product safety is con-

cerned). The inputs are divided into analog and digital channels.

2.4.1— Analog Channels

There are 23 analog channels of which 14 have fixed functions. The remaining 9 channels are split between product

specific inputs (such as oil temperature), and customer spares. The exact split depends on the product. Table 1 shows

the channel allocation.

Some of the 14 fixed channels are “derived” readings in that they are calculated from the other readings. For example,

power is calculated from both voltage and current. These are not real hardware channels, but they result in an analog

reading that can be treated as a “fixed channel” just like any other.

CPU

Channel No.

Channel Title Update Rate

Derived

Value

7 User Configurable #1 (Usually Oil Temp) 3.84 ms No

8 User Configurable #2 (Usually Coolant Temp) 3.84 ms No

9 User Configurable #3 (Usually Oil Pressure) 3.84 ms No

10 User Configurable #4 (Usually Coolant Level) 3.84 ms No

11 User Configurable #5 (Usually Fuel level) 3.84 ms No

12 User Configurable #6 (Usually Spare) 3.84 ms No

13 User Configurable #7 (Usually Throttle Position) 3.84 ms No

14 Special Oxygen Sensor 192 µs No

15 Special Battery charge Sensor 3.84 ms No

16 Battery Voltage/PSU Voltages 3.84 ms No

1 Generator Phase A RMS Current Phase A ZERO CROSSING No

2 Generator Phase B RMS Current Phase B ZERO CROSSING No

3 Generator Phase C RMS Current Phase C ZERO CROSSING No

General Information

H-100 Control Panel Operations Manual 7

2.4.2— Analog Maths

Each of the 23 channels is processed by a set of measuring rules using constants that are set via GenLink. Usually

these constants can be changed by the customer. In the following illustration, the measurement is represented by M

and the GenLink constants are in italics. The measurement is processed in the following order and the result is then

stored for customer display or use.

M = M * Calibration Factor

This is used to calibrate out any reading inaccuracies where calibration factor is a number such that 1024 is equivalent

to 1, so it’s really M * calibration factor/ 1024. GenLink will hide this computation so you can enter floating point num-

bers such as 1.1 or 0.987 etc.

THEN

M = M processed by function “x”

Where the function “x” can be:

The function “x” may use any of the coefficients 1, 2, or 3, and in some cases will use calibration factor as a 4th coeffi-

cient (in that case use scaling factor for calibration). The coefficients are used to allow adjustment of the basic functions

to cater to future or alternate sensors. They perform different tasks in different functions, see Section 3 Analog Func-

tions for further details. Note that if calibration factor is used as a coefficient, it will be shown (and entered) by GenLink

as (actual coefficient/1024).

For example, if the coefficient is -378, it will be displayed as

-0.36914.

THEN

M =M * Scaling Factor:

Where scaling factor is a number such that 1024 is equivalent to 1, so it’s really M * scaling factor/1024. GenLink will

hide this computation so you can enter floating point numbers such as 2.1 or 0.987 etc.

- Generator Average Current Every Phase ZERO CROSSING Yes

4 Generator Phase A RMS Voltage Phase A ZERO CROSSING No

5 Generator Phase B RMS Voltage Phase B ZERO CROSSING No

6 Generator Phase C RMS Voltage Phase C ZERO CROSSING No

- Generator average voltage Every Phase ZERO CROSSING Yes

- Total Generator Power KW Every Phase ZERO CROSSING Yes

- Total Generator Power Factor Every Phase ZERO CROSSING Yes

- Generator Frequency Every Phase ZERO CROSSING Yes

- RPM #1 4-8 ms Variable No

- Air/Fuel Ratio Control % Duty Cycle 100ms No

1. THERMISTOR 5. UNALTERED 9. POLY_1ST_N1

2. CURRENT 6. POLY_3RD 10. POLY_1ST_N2

3. LINEAR 7. POLY_2ND 11. CAL_SCALE

4. PRESSURE 8. POLY_1ST 12. CFM_SENSOR

CPU

Channel No.

Channel Title Update Rate

Derived

Value

General Information

8 H-100 Control Panel Operations Manual

2.4.3— Analog Alarms

Each of the 23 channels is processed by a set of alarm rules using constants that are set via GenLink. Usually these

constants can be changed by the customer. Note that all alarms and warnings will be entered into the alarm log and will

operate the audible alarm. The following list shows the alarm properties.

2.4.3.1— Types

This section is used to turn alarms and warnings on or off and define if the input must be greater than a value (GT) or

less than a value (LT). There can be up to 2 alarms and 2 warnings, of which there can be a maximum of 2 GT or 2 LT

types.

2.4.3.2— Setpoints

There can be up to 4 setpoints to support 2 alarms and 2 warnings, of which there can be a maximum of 2 GT or 2 LT

setpoints. The setpoints are in the same units that the measurement is displayed in on the Analog Channels Diagnostic

screen.

2.4.3.3— Delay Time

There are 2 delay fields that can be set with different times in each. Any or none of these times can be applied to any of

the alarms or warnings via GenLink radio buttons.

For example, a measurement may have to be greater than the setpoint for 1 second to cause an alarm, or less than

another setpoint for 2 seconds to cause a warning. The resolution of this time interval is 0.1 seconds.

2.4.3.4— Hysteresis

Applied hysteresis in display or final units (for example battery voltage is displayed in units of 1/100ths of a volt). When

an alarm/warning has gone active, the hysteresis is subtracted from the GT setpoint or added to the LT setpoint to cal-

culate the modified setpoint needed to make the alarm go inactive.

2.4.3.5— Shutdown

When set, this alarm condition (alarms only, not warnings) has been selected to shutdown the engine.

2.4.3.6— Dialout

When this field is set, the dialout feature is selected. If an alarm or warning occurs for this channel the controller will

automatically call for assistance via telephone (if the external modem option is fitted). Dialout can be selected either for

warnings, alarms, neither, or both. There is a predefined and prioritized list of 10 phone numbers that will be tried. The

controller expects GenLink to answer the call and log the fault. It is possible for the customer to program any Modbus

device with a modem to respond to the call.

2.4.3.7— Active When

You can select other criteria to determine when alarms and warnings become enabled. This is further divided in that

you can define these criteria independently for LT and GT alarm types.

ALWAYS ENABLED = This alarm or warning is always enabled under every circumstance.

HOLD OFF = Alarms/Warnings with this qualification only become enabled after a programmable hold off time has

been met. The hold off timer starts after the engine has started. Stopping the engine cancels the hold off timer.

IMMEDIATE = Alarms/Warnings with this qualification only become enabled immediately after the engine has

started.

2.4.3.8— Sensor Failure Check

When this field is set, the input sensor is checked for short circuit or open circuit failure.Normally each of the inputs are

conditioned externally to be 4-20mA current loops. Any currents outside this range indicate a sensor failure.This will

cause an alarm to occur. The alarm can be selected to shutdown the engine if so desired via the next field. The alarm

will be entered in the alarm log.

2.4.3.9— Shutdown on Sensor Failure

When this field is set, the engine will shut down if there is a sensor failure. If the field is unchecked, the failure will just

cause an alarm message to appear and the audible alarm to sound. The alarm will be entered in the alarm log.

General Information

H-100 Control Panel Operations Manual 9

2.4.4— Other Analog Options

2.4.4.1— Event Log

When set, the channel measurement is compared to the setpoint with one of the GT or LT family of options. Once the

condition is met (eg. measurement GT setpoint) the event is logged along with a date/time stamp into the volatile mem-

ory based event log. Six other parameters, that can be chosen by the customer, will also be logged. Volatile means that

when power is removed from the controller, the event log will be lost.

2.4.4.2— Analog Outputs

There are no analog outputs available for customization on an H-100 controller.

2.4.5— Analog Sensor Ratings

Typically the sensors used by the manufacturer have the following ratings:

2.5 — Output Functions

Output functions are flags that are set/reset by the internal program to indicate a certain status, for example “Engine

Running”. The Measurement Engine allows these flags to be treated as “channels” that can be made into alarms/warn-

ings, display messages, operate real outputs and also be fed as inputs to the ILC. For example, use the “Ready To

Start” output function to operate a relay by mapping it to a physical output via GenLink, or you could feed it into the ILC

to do combinatorial logic.

See TABLE OF OUTPUT FUNCTIONS in Section 4 I/O and Connector Information.

2.5.1— Spare Analog Channels

Depending upon the particular configuration of your product, the following input channels may be available for custom

measurements:

2.6 — Engine Management

The engine management module is very similar to that used in the manufacturer's other products. It controls engine

cranking, engine starting, engine running and engine stopping. These functions are performed to a set of “rules” that

can be customized via parameters from GenLink. In turn, the module needs to know certain things about the engine

which it expects to be programmed in from GenLink.

Temperature 35 - 300° F

Pressure 0 - 150 psi

Channel # Normal Function

4 Coolant Level

5 Fuel Level

6 Ignition Module Alarm

7 Throttle Position

8 Oxygen Sensor 0-1 VDC

9 Battery Charge Current 0-5 VDC

General Information

10 H-100 Control Panel Operations Manual

2.6.1— Generator Parameters

• Engine Flywheel Teeth— Number of flywheel teeth or pulses per revolution for RPM input. RPM 1 is used for the

engine speed.

• CT Ratio/Generator—Current Transformer ratio for the generator. This value is the result from reducing the CT

ratio. E.G. If the CT ratio is 100 amps to 5 amps, the resulting value is 20. Normally, the CT ratio will be x amps to

1 amp on H-100 Control Panels.

• Generator Phase Configuration— Select either single-phase or three-phase configuration depending on how the

unit is supplied.

• 60 Hertz RPM— The engine RPM needed to supply 60 Hertz power.

NOTE: 60 Hertz RPM value is used for both 50Hz and 60Hz - Do Not Change!

• QuietTest® RPM— The engine RPM used when running QuietTest®.

2.6.2— Engine Settings

All of the following times are in seconds:

• Preheat Time— The time preheat is applied for before cranking if enabled.

• Start Detection RPM— The Engine must reach this RPM before disengaging the starter.

• Crank Time— The maximum time in seconds that each crank will last

• Alarm Hold-off Time— The time after starting at which the hold-off alarms become enabled.

• Engine Warm up Time— The engine will run for at least this time before issuing the “Accept load” signal.

• Target Frequency— The target generator frequency (Hz).

• Target Voltage— The target generator voltage (RMS).

• Preheat Enable—The following four options are selectable (only for Diesel):

- Preheat disabled.

- Preheat before cranking.

- Preheat during cranking.

- Preheat before and during cranking.

The Preheat output pin shares its function with the Air/Fuel Solenoid output.You must choose one of the two

functions as follows:

- To select Air/Fuel- set the “Diesel” parameter on the governor settings page to “No”. Set Preheat to “Dis-

abled”

- To select Preheat- set the “Diesel” parameter on the governor settings page to “Yes”. Set Preheat to one of

the enable selections.

• Engine Cool down Time— The generator will run for at least this time after remote start becomes inactive.

• Pause Between Cranks Time— The time between each successive crank operation.

• Number of Start Attempts— The maximum number of times the engine will attempt to start (crank) before faulting

out with overcrank.

• Load Accept Frequency— The generator must reach this frequency before issuing the “Accept load” signal.

• Load Accept Voltage—The generator must reach this voltage before issuing the “Accept load” signal.

Number Parameter Units

1 Engine Flywheel Teeth Teeth

2 CT Ratio - Generator -

3 Generator Phase Configuration 1 or 3

460 Hertz RPM RPM

5 QuietTest® RPM RPM

General Information

H-100 Control Panel Operations Manual 11

2.7 — Voltage Regulator (Option)

All panels include automatic voltage regulation as standard. There are various settings that can be made to the voltage

regulator via GenLink. The settings are normally factory preset and are shown here for completeness.

• Voltage KP/KI/KD— Voltage regulation stability constants.

• PMG— YES indicates a Permanent Magnet Excited alternator.

• VF Corner— Used for v/f control to reduce the output voltage when a large load is applied that slows down the

generator. If the frequency drops below this setpoint, the voltage is reduced proportionally as the frequency

drops according to the Volts per Hertz ratio.

• Panel Type— Indicates the panel type that the H-100 Control Panel has been programmed to be. It will normally

be H-100.

• Volts per Hertz— Number of volts to reduce the generator voltage for each hertz below VF Corner frequency.

• AVR Dump Improve— Makes the regulator module increase the gain temporarily on a load dump to improve the

transient voltage response.

• Unit Rated Power— This is the generator’s rated power in kW.

Number Parameter Units

1 Preheat Time (S)econds

2 Start Detection RPM RPM

3 Crank Time S

4 Alarm Hold-Off Time S

5 Engine Warm Up Time S

6 Target Frequency Hz

7 Target Voltage Vrms

8 Preheat Enable -

9 Engine Cool Down Time S

10 Pause Between Cranks Time S

11 Number of Start Attempts -

12 Load Accept Frequency HZ

13 Load Accept Voltage Vrms

Voltage Regulator (Option) Chart

Number Parameter Units

1Voltage KP -

2Voltage KI -

3Voltage KD -

4 Excitation Type DPE/PMG

5 VF Corner Hertz

6 Panel Type H-100

7 Volts per Hertz V/Hertz

8 AVR Load Dump Improve None/Enabled/8-Cycle

9 Unit Rated Power kW

General Information

12 H-100 Control Panel Operations Manual

2.8 — Governor (Speed Regulator)

All panels include automatic frequency (speed) regulation as standard. There are various settings that can be adjusted

for the governor via GenLink, these include the target frequency. The settings are normally factory preset and are

shown here for completeness, they do not apply to all governor types.

• Standby KP,KI,KD— Frequency regulation stability constants used for normal mode operation.

• QuietTest® KP,KI,KD— Frequency regulation stability constants used for QuietTest® mode operation.

• Actuator Type— Indicates the type of governor actuator. The following types are available:

- POWERFLOW— Barber Coleman Powerflow, voltage driven without position feedback

- BOSCH GAS— Bosch Butterfly, current driven with position feedback

- LINEAR CURRENT— Linear, Current Driven without position feedback

- DETROIT DIESEL— Detroit diesel PWM Driven

- HORIZONTAL DIESEL—Diesel Rack Arm with Horizontal Connecting Rod and current driven with position feed-

back

- VERTICAL DIESEL— Diesel Rack Arm with Vertical Connecting Rod and current driven with position feedback

- JOHN DEERE J1939 CAN— Controls speed by J1939 CAN bus commands using John Deere protocol

- VOLVO J1939 CAN— Controls speed by J1939 CAN bus commands using Volvo protocol

- HINO (do not use)— Not implemented; DO NOT USE.

- FPT NEF J1939 CAN— Controls speed by J1939 CAN bus commands using Fiat NEF protocol

- FPT CURSOR J1939 CAN— Controls speed by J1939 CAN bus commands using Fiat Cursor protocol

- PERKINS J1939 CAN— Controls speed by J1939 CAN bus commands using Perkins protocol

- HORIZONTAL GAS— Gas Butterfly Throttle Arm with Horizontal Connecting Rod and current driven with position

feedback

• Actuator Offset— Number corresponding to lowest actuator position (Close Throttle).

• Actuator Fullscale— Number corresponding to highest actuator position (Open Throttle).

• Actuator Normal Start Position— The position the actuator will be parked at from start up until the “Start detection

RPM” is reached. If “soft start” is enabled, this is also the maximum position of the throttle until the Target Frequency

minus 3 Hz is reached. Therefore, if “soft start” is enabled, the actuator start position MUST be high enough to reach

Target Frequency minus 3 Hz.

• Actuator QuietTest® Start Position— The position the actuator will be parked at from start up until the “Start detection

RPM” is reached. If “soft start” is enabled, this is also the maximum position of the throttle until the QuietTest® Target

Frequency minus 3Hz is reached. Therefore, if “soft start” is enabled, the actuator start position MUST be high

enough to reach, QuietTest® Target Frequency minus 3 Hz.

• Soft Start Time— The time to stay at each soft start step before moving onto the next step. (Only applies if soft start

is enabled).

• Soft Start Frequency— An entry of 0 Hz disables soft start. Any other value enables soft start which ramps up the

generator frequency at a rate determined by “Soft Start Time” to minimize smoke. This value selects the first fre-

quency to target after start up. Once this frequency is attained, the generator will hold this frequency for the “Soft

Start Time” and then move to the next step. Each step is 3 Hz higher with the final step being “Target Frequency”

minus 3 Hz. Each step is held for the “Soft Start Time”. During soft start, the throttle will not be allowed to exceed the

“Actuator Start Position”. Therefore, choose a start position that will allow the generator to attain full operating speed.

• Diesel— Indicates if this is a diesel powered generator. This modifies such features as frequency control, and others.

• Dump Enable—Indicates if extra load dump governor compensation is desired to reduce increase in frequency

caused by drop in load. The following three selections are available:

-No Dump— No additional compensation.

-Dump— Reset governor algorithm when load dump detected.

-Dump & Hold— Same as Dump, but also hold throttle closed until frequency back in range.

NOTE: This option will likely produce undesired frequency dips on load dumps.

General Information

H-100 Control Panel Operations Manual 13

• Engine Linearization— Selects engine torque to actuator position translation curve for Bosch Actuators.

0 = No conversion— torque = position

1 = Butterfly Actuator with minimum position same as unpowered actuator

2 = Diesel arm with Horizontal rod

3 = Diesel arm with Vertical rod

4 = Same as 1, but minimum position at actuator mechanical stop

5 = Same as 4, but with limited position resolution of 1

6 = Same as 4, but with added energy to accommodate throttles that normally operate in the nearly closed posi-

tion at no load

7 = Same as 6, but with limited position resolution of 1

8 = Same as 4, but with a graduated energy profile based on position to increase stability at all loads

• Governor Limit Type— Choose whether to use an integral limit or an anti-windup strategy.

Anti-Windup = an anti integral windup strategy is applied to the integral based on the “Governor Limit Value”

below.

Integral Limit = the Governor Integral is limited to the “Governor Limit Value” below.

• Governor Limit Value— If “Integral Limit” is selected, this is the maximum value the integral is allowed. If “Anti-

Windup” is selected, this is the integral value above which the anti-windup algorithm becomes active.

• PWM Counts per Ampx10—Number of PWM counts required to drive one tenth of an amp into a linear current driven

actuator. This only applies to the “Linear Current” actuator type.

• Desynch. Offset— Offset of –0.9 to +0.9 Hertz to be applied to the target frequency to improve passive synchroniz-

ing by Automatic Transfer Switches. If an in-phase or synchronized transfer is required, use this setting to adjust the

generator frequency to 0.1 Hz above nominal Utility frequency.

• Sensor Source— Indicates whether to use Engine Speed or Generator Frequency to govern speed. This should only

be “Flywheel” when severe electrical noise distorts the alternator frequency signal.

Governor (Speed Regulator) Option Chart

Number Parameter Units

1 Standby KP -

2 Standby KI -

3 Standby KD -

4 QuietTest® KP -

5 QuietTest® KI -

6 QuietTest® KD -

7 Actuator Type -

8 Actuator Offset -

9 Actuator Fullscale -

10 Actuator Normal Start Position -

11 Actuator QuietTest® Start Position -

12 Soft Start Time Seconds

13 Soft Start Frequency Hz

14 Diesel YES/NO

15 Dump Enable -

16 Engine Linearzation -

17 Governor Limit Type Anti-Windup/Integral Limit

18 Governor Limit Value -

19 WM Counts per Ampx10 -

20 Desynch. Offset Hz

21 Sensor Source Alternator/Flywheel

General Information

14 H-100 Control Panel Operations Manual

2.9 — Starting and Stopping Sequence Diagrams

2.10 — Trending

Just like in the PM-DCP, there are two types of trending available- Remote and Local.

2.10.1— Remote Trending

GenLink performs remote trending by polling the controller for the selected data at the desired rate. Up to 16 analog

channels can be visually monitored at a 0.3 second rate. If a faster rate is desired, reducing the number of analog

channels monitored will allow for a 0.1 second rate. The polling rate can be varied from 0.1 seconds to several hours.

GenLink can save the time stamped data to a file and/or display it as a near real-time graph. The file is MS Excel com-

patible (CSV format). Examples of things you can trend are the generator frequency response (in 0.1 second steps) to

a block load or Generated power over a day. When saving to a file in normal mode, all 23 analog channels are saved.

When saving to a file in fast mode, only the displayed analog channels are saved.

NO

Remote start

contacts

CLOSED?

Start the

Engine

At load

accept limits?

Warm up

timer expired?

Issue load

accept signal

Remote start

contacts OPEN?

Cool down

timer expired?

Stop the

Engine

NO

NOTE: Shutdown Alarms will cause

the engine to turn off or not start.

2-wire Remote Starting and Stopping

Sequence Key switch in Auto Position

Time to

exercise?

Start the

Engine

Exercise time

expired?

Stop the

Engine

NO

HTS indicates

loss of

Utility?

Start the

Engine

At load

accept limits?

Warm up

timer expired?

Command HTS

to transfer to

Generator Power

HTS indicates

return of Utility?

Cool down

timer expired?

Stop the

Engine

NO

NOTE: Shutdown Alarms will cause

the engine to turn off or not start.

Exercise without transfer starting and

stopping sequence key switch in auto

position.

NOTE: A Remote Start signal will ter-

minate exercise and proceed to nor-

mal running mode.

Loss of utility with HTS starting and

stopping sequence key switch in auto

position.

NOTE: Shutdown Alarms will cause

the engine to turn off or not start.

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