n N o R tf ep o r ro du ct io Operation Instructions GC1031 GENSET Controller Copyright © Briggs & Stratton Corporation Milwaukee, WI USA. All Rights Reserved.
Safety Definitions For your safety, the safety of others, and to protect the performance of equipment, obey the warnings in the manual before operation, during operation, and during maintenance procedures. indicates a potential personal injury hazard. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
List of Abbreviations and Acronyms Description Alternating Current Acknowledge Alternator Auto Mains Failure Auxiliary Automatic Voltage Regulator Charging Circuit Current Transformer Direct Current Digital Input Electronic Governor Engine Temperature Genset Control Unit Generator Set Ground Gain Schedule Trigger Human Machine Interface High Side Driver High Water Temperature Identifier Liquid Crystal Display Light Emitting Diode Low Idle Mode Low Lube Oil Pressure Lube Oil Pressure Level Manual Control Pa
Table of Contents Key Highlights of the Product .....................................................................................................1 1 Installation ..............................................................................................................................1 1.1 2 Description of Control Keys .................................................................................................4 2.1 3 Functions of Control Keys ................................................
List of Figures Figure 1: GC1031 Genset controller from the backside .................................................................1 Figure 2: Control key function ........................................................................................................4 Figure 3: Configuration mode screen .............................................................................................5 Figure 4: Configuration mode authentication page screen ....................................................
List of Tables Table 1: Voltage input terminology .................................................................................................2 Table 2: Details of the GC1031 terminals .......................................................................................2 Table 3: Control keys in different modes ........................................................................................4 Table 4: Parameters ..................................................................................
Key Highlights of the Product Auto, Manual and Remote Start /Stop Modes for 1-phase & 3-phase gensets Electronic governor controller integration RPM sensing using frequency and MPU Supports Auto Exercise Modes Real time clock-based event logs PC connectivity via USB port, RS485, CAN J1939 protocol Backlit and full graphics display with power saving feature 1 Installation 1.
Table 1: Voltage input terminology Sr. No.
Name Description 35 CT – IN B1 CT input 1 from Phase B / L3 36 CT – IN B2 CT input 2 from Phase B / L3 37 CT – IN Y1 CT input 1 from Phase Y / L2 38 CT – IN Y2 CT input 2 from Phase Y / L2 39 CT – IN R1 CT input 1 from Phase R / L1 40 CT – IN R2 CT input 2 from Phase R / L1 41 SENSOR COMM Sensor common point 42 MPU I/P (Speed Sensor) Input from engine speed sensor (Inductive) N o R tf ep o r ro du ct io n Sr. No.
2 Description of Control Keys 1 4 2 5 Figure 2: Control key function N o R tf ep o r ro du ct io 1. Menu Navigation Up key n 3 2. Menu Navigation Down key 3. Stop/Config key 4. Start/Select key 5. Auto/Manual Mode selection key 2.1 Functions of Control Keys The table that follows gives a brief overview of different functions of control keys in different modes.
3 Configuration of GCU To configure the controller, please do the instructions that follow: To enter the configuration mode, push and hold the “STOP” key for at least 3 seconds. The following screen will appear on the GCU: Figure 3: Configuration mode screen If you want to only view the configuration, push the “STOP” key on the GCU. If you wish to change the configuration, push the “START” key on the GCU.
Level 1 (On screen) Display (DISPLAY) Communication (COMMUNICATION) Parameters (On screen) Contrast (CONTRAST) 0 – 100 % Power Save Mode (POWER SAVE MODE) Disable/Enable Communication Mode (COMM MODE) None/MODBUS * Slave ID (MODBUS SLAVE ID) 1 – 247 * Baudrate (MODBUS BAUDRATE) 1200/2400/4800/9600/19200/ 38400/57600/115200 bps * Parity Bit (PARITY BIT) None/Even/Odd Exercise Option (EXER OPTN) No Exercise/Standard Exercise Cycle (EXER CYCLR) No run/0.
Level 1 (On screen) (AMB TEMP/DIG G) Level 2 (On screen) (USE INPUT AS) Parameters (On screen) In Amb Temp * Circuit Fault Action (CKT FAULT ACTION) None/Notification/Warning/ Electrical Trip/Shutdown * Ambient Temperature Sensor Calibration Table * Use Input As (USE INPUT AS) Not used/Digital Input H/Anlg In Fuel LVL * (Digital) Source ((DIG) SOURCE) Close to Activate/Open to Activate * (Digital) Action ((DIG) ACTION) None/Notification/Warning/ Electrical Trip/Shutdown * (Digital) Activation ((DI
Level 0 Level 1 (On screen) Level 2 (On screen) ((DIG) ACTIVATION DELAY) Parameters (On screen) * Low Level Shutdown (SHUTDOWN) Disable/Enable * Low Level Shutdown Threshold (SHUTDOWN THRESHOLD) 0.0 – 9.8 bar * Low Level Warning (WARNING) Disable/Enable * Low Level Warning Threshold (WARNING THRESHOLD) 0.2 – 10.
Level 1 (On screen) (GENERAL TIMER) Level 2 (On screen) (SAFETY MONITOR DELAY) Parameters (On screen) Mains Detect Delay (MAINS DETECT DELAY) 1 – 300 sec * Alternator Detect Delay (ALT DETECT DELAY) 1 – 60 sec Warm-Up Delay (WARM UP DELAY) 0 – 60 sec Return To Mains Delay (RETN-TO-MAINS DELAY) 0 – 600 sec * Engine Cooling Time (ENG COOL TIME) 0 – 300 sec * Stop Action Time (STOP ACTION TIME) 10 – 120 sec * Additional Stopping Time (ADDN STOPPING TIME) 0 – 120 sec Load Transfer Delay (LOAD T
Level 2 (On screen) Parameters (On screen) * Under-voltage Warning (UNDER VOLT WARNING) Disable/Enable * Under-voltage Warning Threshold (UV WARNING THRESHOLD) 55 – 300 Volt Ph-N * Over-voltage Shutdown (OVER VOLT SHUTDOWN) Disable/Enable * Over-voltage Shutdown Threshold (OV SHUTDWN THRESHLD) 105 – 350 Volt Ph-N * Over-voltage Warning (OVER VOLT WARNING) Disable/Enable * Over-voltage Warning Threshold (OV WARNING THERSHOLD) 100 – 345 Volt Ph-N * Under-frequency Shutdown (UNDER FREQ SHUTDOWN)
Level 1 (On screen) Configuration (MAINS CONFIG) Level 2 (On screen) Parameters (On screen) * Over-load Monitoring Delay (OVERLOAD MON DELAY) 1 – 600 sec * Unbalanced Load Action (UNBAL LOAD ACTION) None/Notification/Warning/ Electrical Trip/Shutdown * Unbalanced Load Threshold (UNBAL LOAD THRESHOLD) 5 – 200 % * Unbalanced Load Delay (UNBAL LOAD DELAY) 1 – 600 sec * Extended Over-load Trip (EXT OL TRIP) Disable/Enable * Extended Over-load Trip Threshold (EXT OL THRESHOLD) 50 – 150 % Mains Mo
Level 2 (On screen) Sensor (DISCONN ON LOP SENS) Parameters (On screen) * Pressure Sensor Monitoring Threshold (DISCONN LOP THRESH) 0.5 – 10.0 bar * Monitor Pressure Switch Before Crank (MON LLOP BEFR CRANK) Disable/Enable * Monitor Pressure Sensor Before Crank (MON LOP BEFR CRANK) Disable/Enable * Disconnect On Oil Pressure Switch (DISCONN ON LLOP SW) Disable/Enable * Pressure Switch Transient Time (LLOP SW TRANS TIME) 0.0 – 3.
Level 1 (On screen) Maintenance (MAINTENANCE) Maintenance Alarm (MAINT ALARM) Alarm Due Date (ALARM DUE DATE) General (GENERAL) Level 2 (On screen) Parameters (On screen) * High Battery Voltage Threshold (HIGH VOLT THRESHOLD) 9.0 – 32.
Level 1 (On screen) (MISC SETTINGS) Parameters (On screen) * Derivative Gain (Kd) (DERIVATIVE GAIN) 0 – 1000 * Friction Setoff (FRICTION SETOFF) 0 – 1000 * Gain Schedule Trigger (GAIN SCHEDULE TRIGGER) 0.0 – 100.
transferred to the genset. If the Mains voltage returns to normal, the controller will sense this and return the load back to the Mains, further it will stop the genset after a cool down period.
4.1.2 Remote Start/Stop (2 Wire) To use the Remote Start/Stop Mode of the controller, the Mains monitoring should be disabled first before using the Remote Start/Stop feature. In this mode, the genset can be commanded to start and stop by activating/deactivating the preconfigured Remote Start/Stop input (active low) in a continuous state. The controller will latch the genset contactor when the controller confirms that the engine and genset are healthy.
Exercise Exercise start time is reached and No Warning / Electrical Trip / Shutdown Present Emergency shutdown input = 1 or Genset shutdown action = 1 Time >= Genset cooling down time and stopping conditions = 1 Engine OFF Engine Start N o R tf ep o r ro du ct io n Engine cooling down in LIM Time >= Auto exerciser mode ON time or Electrical Trip Auto exerciser mode Remaining time < exercise (Auto exercise mode ON Duration – 6) LIM Engine ON The genset will be ON even if the Mains is healthy durin
Engine Off Stop input from key = 1 or Electric trip Engine On n * Genset healthy conditions = 1 and Time >= Warm up Time N o R tf ep o r ro du ct io Engine cooling down in LIM Engine Starts in LIM Start command from key pad = 1 and (No Warning / Electrical Trip / Shutdown Present) (Engine On Time > Warm Up Time) Start command from key pad = 1 And No Warning / Electrical Trip / Shutdown present = 1 Engine enters in Normal Mode Genset healthy condition is as follows: Voltage and frequency of genset
5 Alarms An alarm condition occurs when a preconfigured parameter is outside of a pre-set level. On initiation of an alarm, the Alarm LED will start blinking and the fault output pin will be activated if configured. The controller will display the name of the alarms along with a count on the ALARMS screen and the nature of alarm on the ENGINE STATUS screen. For acknowledging and clearing the alarms, press the “UP + DOWN” keys simultaneously.
Sr. No. Alarms Causes the pre-set over voltage threshold 15 R/L1 Phase Under Voltage Indicates that genset L1(R) Phase voltage has fallen below pre-set under voltage threshold.
Sr. No. Alarms Causes alarm. Clears at the next successful exercise cycle 6 Troubleshooting WARNING Autostart Hazard. With the battery connected the generator may crank and start without warning, resulting in death or serious injury. Before servicing, stop the generator and disconnect the negative (-) cable at the battery. N o R tf ep o r ro du ct io n WARNING Electric shock hazard. Electric shock could result in death or serious injury.
Table 7: Common faults and their remedial actions Sr. No. Faults Remedial Actions Possible Issues in MANUAL Mode 1 The controller does not power ON. 2 The controller fails to crank-start the engine. Check the battery voltage. Check the fuse on the battery supply. Check continuity between battery positive and controller terminal # 2. Check continuity between battery negative and controller terminal # 1. Check the battery voltage.
Possible Issues in AUTO Mode 10 The controller does not start the engine even when a “Remote Start” command is sent from an external device such as a telecom PIU. 11 Controller does not stop engine even when a “Remote Stop” command is sent from an external device such as a telecom PIU. 12 While in Auto Mode, controller issues “Start” command even if the Mains present. Check the wiring of the “Remote Start” signal to the controller's respective digital input terminal.
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N o R tf ep o r ro du ct io n Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice.
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