INSTALLATION INSTRUCTIONS · DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614...
Transcript of INSTALLATION INSTRUCTIONS · DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614...
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · www.deif.com
INSTALLATION INSTRUCTIONS
Compact Genset Controller, CGC 400● Mounting● Terminal overview● Wiring● Communication wiring● Unit dimensions and cutouts
Document no.: 4189340785CSW version: 1.00
1. General information1.1. Warnings, legal information and safety..................................................................................................3
1.1.1. Warnings and notes ......................................................................................................................31.1.2. Legal information and disclaimer ..................................................................................................31.1.3. Safety issues ................................................................................................................................31.1.4. Electrostatic discharge awareness ...............................................................................................31.1.5. Factory settings ............................................................................................................................3
1.2. About the installation instructions...........................................................................................................41.2.1. General purpose ...........................................................................................................................41.2.2. Intended users ..............................................................................................................................41.2.3. Contents and overall structure ......................................................................................................4
2. Mounting2.1. CGC 400 mounting.................................................................................................................................5
2.1.1. Mounting of the unit.......................................................................................................................52.1.2. Unit dimensions and panel cutout..................................................................................................52.1.3. Tightening torques.........................................................................................................................6
3. Terminals3.1. Terminal overview and description.........................................................................................................7
3.1.1. Terminal overview..........................................................................................................................73.1.2. Terminal description .....................................................................................................................7
4. Wiring4.1. Wiring diagram.....................................................................................................................................114.2. DC connections....................................................................................................................................12
4.2.1. Communication, multi-input and tacho wiring instructions ..........................................................124.2.2. Binary inputs................................................................................................................................12
4.3. Breaker selection..................................................................................................................................134.3.1. Breaker selection.........................................................................................................................13
4.4. Connection of the 3-phase voltage and current...................................................................................154.4.1. Connection of the 3-phase voltage and current...........................................................................154.4.2. 3-phase AMF wiring ....................................................................................................................16
4.5. Connection of the 1-phase voltage and current...................................................................................174.5.1. 1-phase wiring ............................................................................................................................174.5.2. 1-phase AMF wiring ....................................................................................................................18
4.6. Connection of the split-phase voltage and current...............................................................................194.6.1. Split-phase wiring .......................................................................................................................194.6.2. Split-phase AMF wiring ...............................................................................................................20
5. Communication5.1. Wiring instructions................................................................................................................................215.2. Modbus RTU........................................................................................................................................22
5.2.1. Connection with 2-wire shielded cable (recommended) .............................................................225.2.2. Connection with 3-wire shielded cable........................................................................................23
5.3. CAN bus engine communication..........................................................................................................245.3.1. Connection with 2-wire cable (recommended) ...........................................................................245.3.2. Connection with 3-wire shielded cable .......................................................................................25
CGC 400 installation instructions4189340785 UK
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1. General information1.1 Warnings, legal information and safety
1.1.1 Warnings and notesThroughout this document, a number of warnings and notes with helpful user information will be presented.To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-al text.
Warnings
Warnings indicate a potentially dangerous situation, which could result in death, personal in-jury or damaged equipment, if certain guidelines are not followed.
Notes
Notes provide general information, which will be helpful for the reader to bear in mind.
1.1.2 Legal information and disclaimerDEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about howto install or operate the engine/generator controlled by the unit, the company responsible for the installation orthe operation of the set must be contacted.
The unit is not to be opened by unauthorised personnel. If opened anyway, the warranty will belost.
DisclaimerDEIF A/S reserves the right to change any of the contents of this document without prior notice.
1.1.3 Safety issuesInstalling and operating the unit may imply work with dangerous currents and voltages. Therefore, the instal-lation should only be carried out by authorised personnel who understand the risks involved in working withlive electrical equipment.
Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-puts as this could lead to injury or death.
DEIF do not recommend to use the USB as the primary power supply for the unit.
1.1.4 Electrostatic discharge awarenessSufficient care must be taken to protect the terminal against static discharges during the installation. Once theunit is installed and connected, these precautions are no longer necessary.
1.1.5 Factory settingsThe unit is delivered from factory with certain factory settings. These are based on average values and arenot necessarily the correct settings for matching the engine/generator set in question. Precautions must betaken to check the settings before running the engine/generator set.
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General information
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1.2 About the installation instructions
1.2.1 General purposeThese Installation Instructions mainly include general product and hardware information, mounting instruc-tions, terminal strip descriptions, I/O lists and wiring descriptions.
The general purpose of this document is to give the user important information to be used in the installation ofthe unit.
Please make sure to read this document before starting to work with the unit and the genset tobe controlled. Failure to do this could result in human injury or damage to the equipment.
1.2.2 Intended usersThese Installation Instructions are mainly intended for the person responsible for the design and installation.In most cases, this would be a panel builder designer. Naturally, other users might also find useful informationin the document.
1.2.3 Contents and overall structureThis document is divided into chapters, and in order to make the structure simple and easy to use, eachchapter will begin from the top of a new page.
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2. Mounting2.1 CGC 400 mounting
2.1.1 Mounting of the unitThe unit is designed for mounting by means of six fixing clamps, which are included at delivery.
2.1.2 Unit dimensions and panel cutoutThe unit is designed for mounting in the panel front.
In order to ensure optimum mounting, the panel door must be cut out according to the following measure-ments:
H × W (mm) = 160.0 × 220.0 (+0.4/-0.0)
H × W (inches) = 6.30" × 8.66" (+0.01575/-0.0)
17
4.1
(6.8
5)
234.1 (9.22)
15
8.5
(6.2
4)
218.5 (8.60)
38
.1 (
1.5
0)
45
.6 (
1.8
0)
0.3 Nm
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2.1.3 Tightening torques
Unit panel door mounting: 0.3 Nm (see diagram in "Unit dimensions and panel cutout")Plug connections (terminals): 0.5 Nm
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3. Terminals3.1 Terminal overview and description
3.1.1 Terminal overviewCGC 400 unit rear view
6 7 83 4 51 2
+ -
Power
supplyStatus
Multi-functional
inputs
Co
m
Generator voltage
33 34 35 36 37 38
L1 N L2 L3NA NA
10 11 12 13 14 15 16 1817
Binary inputs
20 21 22 24 2523 26 27
Mains voltage
28 29 30 31 32
L1 N L2 L3NA
45 46 47 48
L1 L2 L3
Generator current
39 40 41 42 43 44
MP
U
Co
m
W/L
RPM inputs
GB MB
USB
Emer.
stop
58 59
Relays
RS485
Modbus
55
54
53
B(-)
GND
A(+)
CAN J1939
50
49
CAN H
CAN L
51
GND
s1 s2 s1 s2 s1 s2
56 57
Terminals 28-32, 56-57 and 58-59 are not available in CGC 412.
3.1.2 Terminal description
Description of terms For the relay outputs, the following terms will be used:NO means Normally Open.NC means Normally Closed.Com. means common terminal for the individual relay.
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Term Technical data Description
1 Power supply + Auxiliary supply
2 Power supply -
3-4* Status output 2 A @ 35 Vdc General status output/configurable
Digital input
10 Digital input Remote start/configurable
11 Digital input Remote stop/configurable
12 Digital input Remote alarm ack./configurable
13 Digital input Shutdown override/configurable
14 Digital input Configurable
15 Digital input Configurable
56** Digital input Configurable
57** Digital input Configurable
Output
20 Emergency stop and common for21 to 23
Common for relay start prepare, starter (crank) and run coil,and input for emergency stop
21 Relay output 21 Start prepare/configurable, function NO
22 Relay output 22 Starter (crank)/configurable, function NO
23 Relay output 23 Run coil/configurable, function NO
24-25 Relay output 24 Horn/configurable function NO
26-27 Relay output 26 Configurable, function NO
Multi-functional inputs
5 Common Common for term. 6 to 8 and 58 to 59
6 RMI6 4 to 20 mA/binary input Fuel level/configurable
7 RMI7 4 to 20 mA/binary input Oil pressure/configurable
8 RMI8 4 to 20 mA/binary input Water temp./configurable
58** RMI58 4 to 20 mA/resistive/binaryinput
● Resistive input or● 4 to 20 mA from active transducer or● Binary with wire break● Pt100● Pt1000
59** RMI59 4 to 20 mA/resistive/binaryinput
● Resistive input or● 4 to 20 mA from active transducer or● Binary with wire break● Pt100● Pt1000
Tacho RPM input
16 RPM input (MPU) Magnetic pickup/tacho generator
17 RPM-GND Common for RPM input. Internally connected to terminal 2
18 RPM input (W/L) Magnetic pickup. PNP, NPN or charge alternator W term.
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Term Technical data Description
3-phase generator voltage input
33 Gen. voltage L1 GENERATOR VOLTAGE
34 Gen. neutral
35 Not used, must not be connected
36 Gen. voltage L2
37 Not used, must not be connected
38 Gen. voltage L3
3-phase generator current input
39 Gen. current L1, s1 GENERATOR CURRENT
40 Gen. current L1, s2
41 Gen. current L2, s1
42 Gen. current L2, s2
43 Gen. current L3, s1
44 Gen. current L3, s2
3-phase mains voltage inputs
28** Mains voltage L1 MAINS VOLTAGE
29** Mains voltage neutral
30** Mains voltage L2
31** Not used, must not be connected
32** Mains voltage L3
Breaker relays
45 Relay R45 Generator circuit breaker/configurable, function NO (normallyopen)46 Relay R45
Optional relay for closing mains breaker
47 Relay R47 Mains circuit breaker/configurable, function NC (normallyclosed)48 Relay R47
Modbus RS 485
49 B(-) Modbus RS-485 RTU. Speed is fixed to 9600 bit/s.
50 GND
51 A (+)
CAN bus port: engine interface
53 CAN-H The CAN bus interface to J1939. The 120 ohm termination re-sistor is wired internally. It is not needed to add an external re-sistor.
54 CAN-GND
55 CAN-L
* The status relay is the uP watchdog output. This relay is normally energised, and the switchis closed after power-up. If the uP fails or the power is lost, the relay will de-energise and theswitch will open. If the unit fails to start up at power-up, then the relay switch will remain open.
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**Terminals are not available in CGC 412.
The relay output functions are configurable via the PC utility software and can be configured to cover the fol-lowing functions:
● Alarm/limit● Engine run indication● Horn● Idle speed output● Not used● Prepare● Run coil● Starter● Stop coil● Engine heater● Fuel pump
It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with doublesystems.
The multi-functional inputs can be configured to cover the following functions:● RMI sensor input● Pt100 and Pt1000● 4 to 20 mA input● Binary input with wire break (switch function)
Tacho RPM input (MPU) can be configured to cover the following functions:● Magnetic pickup (2-wire)● NPN or PNP pickup (these RPM inputs require external equipment)
Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:● Magnetic pickup (2-wire)● W terminal on charger alternator● NPN or PNP (these RPM inputs require external components)
The generator voltage and current input can be configured to the following:● Voltage 100 to 25000 V primary● Current 5 to 9000 A primary
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4. Wiring4.1 Wiring diagramThe wiring diagram below shows the default factory settings, but the use of inputs and outputs can be chosenfreely.
+
56
57
-
Remote stop
17
5
Common
Common
- + - +
27
26
25
12
CGC 400
1
2
R24
R23
USB
R22
R21
24
23
22
21
20
4
3
15
14
13
11
10
Shutd. override
Alarm ack.
Remote start
Programming
tool
Battery
Emer. STOP
Status
Start prep.
Starter
RUN coil
Fuse
Alarm horn
AlarmR26
It is important to protect the unit against damage caused by high voltages. Therefore, the fusemust not be more than 2 A slow-blow.
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4.2 DC connections
4.2.1 Communication, multi-input and tacho wiring instructions
Multi-functional inputs
PT100/1000 sensors
GND
A (+)
B (-)
Modbus
49
50
51
Multi-functional inputs
RMI sensors
Multi-functional inputs
Analogue 4-20 mA
8
7
6
Multi-functional inputs
Binary input w.wirebreak
5
8
7
6
5
- +
- +
- +
R
R
R
53
54
55
CGC
GND
CAN L
CAN H
Engine communication
Tacho input
Magnetic pickup/
Tacho generator
16
17
Tacho input
NPN/PNP pickup
18
17
Tacho input
W input from charger
alternator
18
17out
+24V DC B+W
B-
CGC
CGC CGC
CGC CGC CGC
8
7
6
RMI
RMI
RMI
5
CGC
8
7
6
PT 100
PT 100
PT 100
5
CGC
Wiring of RMI 58 and 59 is done the same way as RMI 6-8
4.2.2 Binary inputsBinary inputs 10 to 15 and 56 to 57 have an internal common positive (+), this means that they are triggeredby a connection to negative (-).
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Wiring
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Dig. input
CGC 400
Term. 5
Com
The binary inputs use fixed signals. Only the mode shift input and the test input (if the timer isused) use pulse signal.
4.3 Breaker selection
4.3.1 Breaker selectionThe controller can handle pulse, continuous and compact breakers. Selection of the breaker type is done inthe application configuration with the PC utility software. Output for breaker handling is chosen in the I/O con-figuration of the PC utility software. In the table below is listed which outputs are needed for breaker handlingdepending on the breaker type.
Breaker type GB on/MB on/TB on GB off/MB off/TB off
Pulse breaker X X
Continuous breaker X
Compact breaker X X
The pictures below are examples of how to set up breakers.
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Wiring
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Continuous breaker output selection Pulse breaker output selection
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4.4 Connection of the 3-phase voltage and current
4.4.1 Connection of the 3-phase voltage and currentWiring, AC interface
33
36
34
38
40I1
39
42I2
41
44I3
43
s1
s1
s2
s2
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
Consumer
L1 L2 L3 N CGC 400
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4.4.2 3-phase AMF wiring
MAINS
L1 L2 L3 N
28 UL1
29
UL230
UL332
N
33
36
34
38
40I1
39
42I2
41
44I3
43
s1
s1
s2
s2
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
CGC 400
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
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Wiring
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4.5 Connection of the 1-phase voltage and current
4.5.1 1-phase wiring
33
34
40I1
39
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
L1 N CGC 400
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4.5.2 1-phase AMF wiring
MAINS
L1 N
28 UL1
29 N
33
34
40I1
39
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
CGC 400
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
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4.6 Connection of the split-phase voltage and current
4.6.1 Split-phase wiring
33
36
34
40I1
39
42I2
41s1
s2
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
Consumer
L1 L2 N CGC 400
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4.6.2 Split-phase AMF wiring
MAINS
L1 L2 N
28 UL1
31
UL230
N
33
36
34
40I1
39
42I2
41s1
s2
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
CGC 400
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
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5. Communication5.1 Wiring instructionsCableBelden 3106 A or equivalent. 22 AWG (0.324 mm2) shielded twisted pair, min. 95 % shield coverage.
Cable shieldConnect the cable shield to earth at one end only.
GND terminal connectionIn case of communication problems, the GND terminals of the CGC 400 unit and the external device can belinked together using a third wire.
CAN bus termination resistorThe size of the terminating resistors should be 120 Ω 1 %, 0.5 W resistor.
Never connect the GND terminal to earth directly or through the shield!
If the GND terminal is connected to a PLC or other device, the GND connection of this devicemust be isolated from earth!
Maximum length of the CAN bus line is 400 m.
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5.2 Modbus RTU
5.2.1 Connection with 2-wire shielded cable (recommended)
CGC DA
TA
- (B)
49 50 51
DA
TA
(GN
D)
DA
TA
+ (A
)
CGCDA
TA
- (B)
49 50 51
DA
TA
(GN
D)
DA
TA
+ (A
)
DA
TA
+ (A
)
PLC or other device
DA
TA
(GN
D)
DA
TA
- (B)
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5.2.2 Connection with 3-wire shielded cable
CGCDA
TA
- (B)
49 50 51
DA
TA
(GN
D)
DA
TA
+ (A
)
CGCDA
TA
- (B)
49 50 51
DA
TA
(GN
D)
DA
TA
+ (A
)
DA
TA
+ (A
)
PLC or other device
DA
TA
(GN
D)
DA
TA
- (B)
For wiring details, please refer to “Wiring instructions” in this section.
In case of very long lines on the network, terminating resistors might be needed (typically 120Ω 1 %, 0.5 W).
The calculation should be based on the following data:A line internal pull-up bias resistor: 22 kΩB line internal pull-down bias resistor: 22 kΩReceiver input sensitivity: +/-200 mVReceiver input impedance: 12 kΩ
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5.3 CAN bus engine communication
5.3.1 Connection with 2-wire cable (recommended)
CGC
CA
N-H
53 54 55
Co
m
CA
N-L
CA
N-L
ECM
engine control module
Co
m
CA
N-H
R
R
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5.3.2 Connection with 3-wire shielded cable
CGC
CA
N-H
53 54 55
Co
m
CA
N-L
CA
N-L
ECM
engine control module
Co
m
CA
N-H
R
R
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