Generac Power Systems H-100 User Manual

®

POWER SYSTEMS, INC.

H-100 Control Panel

Technical Manual

This manual should remain with the unit.

IMPORTANT SAFETY INSTRUCTIONS

H-100 Control Panel Technical Manual

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators

and potential operators of this equipment.

Study these SAFETY RULES carefully before installing, operating, or servicing this equipment. Become familiar with this manual and all literature pertaining to the generator set and related equipment. This equipment can operate safely, efficiently, and reliably only if it is properly installed, operated, and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the equipment, are, therefore, 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 procedure, work method, or operating technique utilized does not render the equipment unsafe.

GENERAL HAZARDS

•For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an Authorized Service Dealer or other qualified electrician or installation technician who is familiar with applicable codes, standards, and regulations. The operator also must comply with all such codes, standards, and regulations.

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

•Inspect the equipment regularly, and promptly repair or replace all worn, damaged or defective parts, using only factory-approved parts.

•Before performing any maintenance on the generator or any related equipment, disconnect the generator’s battery cables and remove panel fuse to prevent accidental startup. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first. Reconnect that cable last.

ELECTRICAL HAZARDS

•Generators produce dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the generator and related equipment are running. Ensure all appropriate covers, guards, and barriers are in place before operating the equipment. If working around an operating unit, stand on an insulated, dry surface to reduce potential shock hazards.

•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 people must stand on metal or concrete while installing, operating, servicing, adjusting, or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

•Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical current (amperage) to which they will be subjected to.

•Before installing or servicing this equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.

•When installed with an automatic transfer switch, the generator may crank and start anytime, without warning. To prevent injuries caused by sudden start-up, disable the generator’s automatic start circuit before working on, or around, the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

•In case of an 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 rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

•Never wear jewelry when working on this uipment. Jewelry can conduct electricity, resulting in electric shock, or may get caught in moving components, causing injury.

FIRE HAZARDS

•For fire safety, the generator and related equipment must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws, and regulations. Adhere

strictly to local, state, and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the equipment is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations.

Table of Contents

Table of Contents
Safety Rules ........................................	Inside Front Cover
General Information .........................................................		2
Introduction ....................................................................		2
Features ..........................................................................		2
Panel Setup .....................................................................		2
Changing the Controller Configuration ........................		2
Customization..............................................................		2
The Measurement “Engine”.............................................		3
Analog Channels ..........................................................		3
Analog Maths ...............................................................		3
Analog Alarms .............................................................		4
Other Analog Options ..................................................		5
Analog Sensor Ratings .................................................		5
Output Functions ............................................................		5
Spare Analog Channels................................................		5
Engine Management ........................................................		6
Generator Parameters..................................................		6
Engine Settings ............................................................		6
Starting and Stopping - Sequence Diagrams...................		7
Voltage Regulator (Option) ..............................................		8
Governor (Speed Regulator) Option ................................		8
Trending .........................................................................		9
Remote Trending .........................................................		9
Local Trending...........................................................		10
GenLink Local Trending Setup..................................		10
Trigger/Collection Type ..............................................		13
The ILC .........................................................................		10
The Front Panel Display................................................		11
Left Display................................................................		11
Right Display .............................................................		11
Left Display Pages......................................................		11
Right Display Pages....................................................		13
Alarms .......................................................................		13
Engine...........................................................................		14
Status............................................................................		16
Service ..........................................................................		17
Generator......................................................................		18
Diagnostics....................................................................		19
Exercise/HTS ................................................................		21
The Control Panel .........................................................		23
The Alarm Log ..............................................................		23

H-100 Control Panel Technical Manual

The Event Log ...............................................................	23
Maintenance Settings ....................................................	24
Air/Fuel Ratio Control (Option) .....................................	24
I2T Current Monitoring (Option) ...................................	24
Internal Exercise Function ............................................	25
QuietTest® Setup Using GenLink ..................................	25
Normal Exercise Setup Using GenLink .........................	26
QuietTest® Setup Using Front Panel ..............................	27
Set Date and Time ........................................................	33
Date and Time Setup Using GenLink.........................	33
Date and Time Setup Using Front Panel ....................	33
Adjust Display Contrast ................................................	34
Enable Generac Commercial Transfer Switch (HTS) ....	35
HTS Setup Using GenLink.........................................	35
HTS Setup Using Front Panel ....................................	35
Communications ...........................................................	37
Remote Annunciator Connection (Option).....................	37
New Generation GenLink (NGG)...................................	37
GenLink Relay Control ..............................................	37
Set Engine Hours.......................................................	37
Absolute Maximum Ratings .......................................	37
Environmental Ratings ..............................................	37
Appendix............................................................................	38
Appendix A — Analog Functions ...................................	38
Appendix B — H-100 General I/O and Connector
Information ...........................................	40
H-100 Analog Inputs..................................................	40
H-100 Digital Outputs................................................	41
H-100 Digital Inputs ..................................................	41
H-100 Digital Output Functions .................................	42
H-100 Connector Pin Descriptions ............................	46
Appendix C — Miscellaneous H-100
Internal Alsrms/Warnings ......................	47
Notes...................................................................................	48

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER, or visit the website at www.generac.com.

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General Information

H-100 Control Panel Technical Manual

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 PMDCP 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 controllers. Everything can be user customized from measurements to alarms to the screen displays.

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.

FEATURES

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

•Interface with up to four Generac Commercial Transfer Switches (HTS).

•Interface with up to two Remote Annunciator Panels.

•Customizable display.

•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.

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PANEL SETUP

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 laborious and prone to human error. Some of the settings require detailed knowledge of things like governor settings which are not easily discernable.

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 Generac Commercial Transfer Switch (HTS)

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 away to floppy or hard disk 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 to disk. 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 builtin ILC. The digital inputs can be moved, inverted, renamed, given delay times, 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.

General Information

H-100 Control Panel Technical Manual

THE MEASUREMENT "ENGINE"

The measurement “engine” is the key feature of the system. All the inputs to the controller are processed by this module. 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-con- figured and nothing needs to be done, however the manufacturer has provided complete flexibility to each measurement (except where product safety is concerned). The inputs are divided into analog and digital channels.

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.

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 numbers such as 1.1 or 0.987 etc.

THEN

M = M processed by function x:

Table 1

	CPU
	Channel			Derived
	No.	Channel Title	Update Rate	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 - Spare -	3.84 ms	No
	13	User Configurable #7 (Usually throttle position)	3.84 ms	No
	14	Special Oxygen sensor	3.84 ms	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
	-	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 (geared)	Yes
	-	Oxygen sensor zero crossings	Every O2 ZERO CROSSING	No

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General Information

H-100 Control Panel Technical Manual

Where x can be:

1.THERMISTOR

2.CURRENT

3.LINEAR

4.PRESSURE

5.UNALTERED

6.POLY_3RD

7.POLY_2ND

8.POLY_1ST

9.POLY_1ST_N1

10.POLY_1ST_N2

11.CAL_SCALE

12.CFM_SENSOR

13.GEN_FP_POLY

The function x may use any of the coefficients 1,2,3 and in some cases will use calibration factor as a 4th coefficient (in this case use scaling factor for calibration). The coefficients are used to allow adjustment of the basic functions to cater for future or alternate sensors. They perform different tasks in different functions, see APPENDIX A 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.

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 will be entered into the alarm log and will operate the audible alarm. Warnings will operate the audible alarm also, and will be put in the alarm log. The following list shows the alarm properties.

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 LT types.

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 LT types. The setpoints are in the same units that the measurement is displayed in.

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.

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

Shutdown

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

Dialout

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

Active When

You can select other criteria to determine when alarms and warnings become active. 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 active 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.

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General Information

IMMEDIATE = Alarms/Warnings with this qualification only become active immediately after the engine has started.

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 shut down the engine if so desired via the next field. The alarm will be entered in the alarm log.

H-100 Control Panel Technical Manual

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/warnings, 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 appendix B.

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.

OTHER ANALOG OPTIONS

Event Log

When set, the channel measurement is compared to the setpoint with either the GT or LT options. Once the condition is met (eg measurement GT setpoint) the event is logged along with a date/time stamp into the volatile memory 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 unit, the memory will be lost.

SPARE ANALOG CHANNELS

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

	Channel #	Normal function
	4	Coolant level
	5	Fuel Level
	6	Spare
	7	Throttle position
	8	Oxygen sensor 0-1Vdc
	9	Battery charge current 0-5Vdc

Analog Outputs

There are no analog outputs available for customization.

ANALOG SENSOR RATINGS

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

Temperature	35 - 300 deg. F
Pressure	0 - 150 psi

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General Information

H-100 Control Panel Technical Manual

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.

GENERATOR PARAMETERS

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

•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.

•Quiet-Test® RPM — The engine RPM used when running Quiet-Test®.

	Number	PARAMETER	UNITS
	1	Engine Flywheel Teeth	Teeth
	2	CT Ratio - Generator	-
	3	Generator Phase Configuration	1 or 3
	4	60 Hertz RPM	RPM
5		Quiet-Test® RPM	RPM

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

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

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

-Preheat disabled.

-Preheat during cranking.

-Preheat before and during cranking.

-Preheat before and during cranking and until load ready.

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 “Disabled”

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

•Engine Cooldown 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	Preheat Time	(S)econds
	2	Start Detection RPM	RPM
	3	Crank Time	S
	4	Alarm Hold-off Time	S
	5	Engine Warmup Time	S
	6	Target Frequency	Hz
	7	Target Voltage	Vrms
	8	Preheat Enable	-
	9	Engine Cooldown Time	S
	10	Pause Between Cranks Time	S
	11	Number of Start Attempts	-
	12	Load Accept Frequency	HZ
	13	Load Accept Voltage	Vrms

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

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General Information

H-100 Control Panel Technical Manual

STARTING AND STOPPING - SEQUENCE DIAGRAMS

2-wire Remote Starting and

Stopping Sequence

Keyswitch in Auto Position

NOTE: Shutdown Alarms will cause the engine to turn off or not start.

NO

Remote start contacts CLOSED?

Start the Engine

NO

At load accept

limits?

NO

Warmup timer expired?

Issue load accept signal

NO

Remote start contacts OPEN?

NO

Cooldown timer expired?

Exercise without transfer
starting and stopping sequence
keyswitch in auto position.				NO
	Time to
	exercise?
	Start the Engine
NOTE: Shutdown Alarms will
cause the engine to turn off				NO
or not start.	Exercise
	time
NOTE: A Remote Start signal	expired?
will terminate exercise and
proceed to normal running mode.
	Stop the Engine

Loss of utility with HTS starting and stopping sequence keyswitch in auto position.

NOTE: Shutdown Alarms will cause the engine to turn off or not start.

NO

HTS indicates loss of Utility?

Start the Engine

NO

At load accept

limits?

NO

Warmup timer expired?

Command HTS

to transfer to

Generator Power

NO

HTS indicates return of Utility?

NO

Cooldown timer expired?

Stop the Engine

Stop the Engine

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General Information

H-100 Control Panel Technical Manual

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 1 / 2. — These are 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 these setpoints, 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-

100Control 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

1frequency.

•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.

Voltage Regulator (Option) Chart

NO.	PARAMETER	UNITS
1	Voltage KP	-
2	Voltage KI	-
3	Voltage KD	-
4	PMG	Y/N
5	VF Corner 1	Hertz
6	VF Corner 2	Hertz
7	Panel Type	-
8	Volts per Hertz	V/Hertz
9	AVR Dump Improve	Y/N
10	Unit Rated Power	kW

GOVERNOR (SPEED REGULATOR)

OPTION

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

-BOSCH HORIZONTAL DIESEL — Bosch Diesel Arm with Horizontal Connecting Rod and current driven with position feedback

-BOSCH VERTICAL DIESEL — Bosch Diesel Arm with Vertical 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 - 3 Hz is reached. Therefore, if “soft start” is enabled, the actuator start position MUST be high enough to reach, Target Frequency - 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 - 3 Hz is reached. Therefore, if “soft start” is enabled, the actuator start position MUST be high enough to reach, QuietTest® Target Frequency - 3 Hz.

•Soft Start Time — The time to stay at each soft start step before moving on to 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 frequency 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” - 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”.

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

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General Information

•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.

•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 position at no load

•Integral limit/Antiwindup — Choose whether to use an integral limit or an anti-windup strategy.

YES = integral limit

NO = anti-windup

•Limit/windup parameter — 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 synchronizing 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.

H-100 Control Panel Technical Manual

Governor (Speed Regulator) Option Chart

NO.	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	Y/N
15	Dump Enable	-
16	Engine Linearization	-
17	Integral limit/Antiwindup	Y/N
18	Limit / windup parameter	-
19	Pwm Counts per ampx10	-
20	Desynch Offset	Hz

TRENDING

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

REMOTE TRENDING

GenLink performs remote trending by polling the controller for the selected data at the desired rate. Up to 8 analog channels can be 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 data to a file and/or display it as a near real-time graph. The file is MS Excel compatible ( 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.

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LOCAL TRENDING

Local trending is done inside the controller where up to 1000 samples can be stored in memory. GenLink provides an interface to select the analog channels to be trended, the rate to be sampled at, and optional triggers to be used to specify when to sample. Up to 6 analog channels can be sampled. However, the 1000 samples are divided by the number of channels. For example, there will be 1000 samples of 1 channel or only 166 samples of each of 6 channels. The analog samples can be sampled at one of three basic polling rates: Low Speed, Mid Speed, and High Speed. For the Low Speed and Mid Speed modes, there are also several settings that can be used to determine when to sample. GenLink can save the data to a file and/or display it as a snap-shot graph. The file is MS Excel compatible ( CSV format ).

GENLINK LOCAL TRENDING SETUP

When setting up the local trending, verify that the “Armed” box is unchecked and press “Apply”. To change the settings with the trending armed may result in corrupted data. Select a rate at which to take samples.

•Low Speed rate samples the processed analog channel values at a rate that is able to be set in increments of 0.1 seconds.

•Mid Speed rate is about 2 milliseconds which captures the new analog channel value as soon as it is processed by the measurement and alarm modules.

•High Speed rate is 0.4 milliseconds and is reserved for the raw AC wave forms of generator voltage and current.

There are 6 pull-down boxes that allow the selection of up to 6 analog channels. All channel pull-down boxes after the first pull-down box with NULL CHANNEL selected are ignored. If High Speed is selected, the pull-down boxes are not used. Instead, there are 6 check boxes that can be used to select which voltage and current lines are to be trended.

The “Capture When” pull-down box allows the trending to be limited to the engine running or engine being stopped. If the “Stop at End of Buffer” box is selected, then the trending will start when the “Capture When” condition is true and stop when the 1000 samples have been taken.

Any digital or analog channel can be used as an event trigger. The event trigger needs to be set up in that channel's setup screen. Checking the “Capture Only When Trigger is True” box will cause the samples to only be taken while the event trigger is true. Checking the “Capture on Shutdown Alarm” will cause the samples to start upon the setting of a shutdown alarm. The event trigger can be used to start sampling, stop sampling, or center the sampling by selecting the appropriate radio button:

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No Trigger

The event trigger is ignored and samples are continually being placed into the buffer.

Pre-Trigger

Samples are continually being placed into the buffer until the event trigger becomes true. Then no more samples are placed into the buffer.

Post-Trigger

No samples are placed into the buffer until the event trigger becomes true. Then samples are placed in the buffer until it is full.

Preand Post-Trigger

Samples are continually being placed in the buffer until the event trigger becomes true. This point is considered ½ of the buffer. Samples continue to be placed into the buffer until it is full.

Pressing the “View” button will show a graph of the samples in the buffer at the time the button is pressed. The graph has a “Save” button that allows the user to save the data out to a file in a MS Excel compatible ( CSV ) format.

THE ILC

The built-in ILC uses simple combinatorial logic to generate digital outputs and limited generator control. The ILC uses ladder logic for programming, and a separate offline programming tool is available to generate the ILC programs. These are then downloaded via GenLink and are started or stopped by means of a checkbox on the GenLink ILC page. Once downloaded and started, they will remain active unless they are stopped via GenLink, even if power is cycled.

The I/O scan time of the ILC is about 100 ms worst case. This means that all inputs and outputs are scanned within 100 ms. Also, the ILC processes one rung every 5 ms, so 5 rungs will take 25 ms. However, this is in parallel with the I/O scan and not added to it.

The offline tool uses graphic symbols to design the “rungs” of the ladder logic. The rungs are simple and can only have 2 combinatorial elements in them, but by the use of “soft contacts” the output of one rung can be fed into the input of another to provide more combinations. As well as the logical combinations, there are also analog comparisons, counters and timers available for use in the rungs. As an example this allows the following type of logic to be built:

IF (in automatic) AND (engine running) AND (air temperature >25 deg) FOR (20 seconds) THEN OPERATE (output 7).

General Information

Generator control is limited to the following output options (referred to as “Hooks”).

1.Use Keyswitch

2.Force Off – cleared with “Use Keyswitch” hook

H-100 Control Panel Technical Manual

field. Moving off an edit field while in edit mode automatically enters the value displayed. Also, while in edit mode, pressing the Home button will return the parameter to the last value entered.

3.Force Manual – cleared with “Use Keyswitch” hook

4.Force Auto – cleared with “Use Keyswitch” hook

5.Force Dialout

6.Halt ILC

7.Force Alarm/Warning #1

8.Force Alarm/Warning #2

9.Force Remote Start

For detail in programming the ILC, refer to the ILC manual.

LEFT DISPLAY PAGES

The left display has five “fixed” parameter pages: System Voltages, System Power, Transfer Switch Mimic Diagram, Generator Frequency Graph, and System Alarm Log. A sixth page is selectable, but has no function at this time. The left display page is determined by selecting the right display menu item, “Left Display”. To change the left display, do the following:

Press the “MENU” button.

THE FRONT PANEL DISPLAY

The front panel display consists of two LCD displays that are 4 rows of 20 characters each and a key pad with seven buttons and two LEDs.

LEFT DISPLAY

The left display is used to display a “fixed” set of parameter pages and has no cursor or entry fields. The key pad has no direct control of its contents. Its contents are determined by a menu selection on the right display.

RIGHT DISPLAY

The right display has several pages and responds directly to the key pad. There are two “quick” buttons on the key pad that are used to go directly to either the Home page or the Menu page. The Enter button is used to enter and exit edit mode, operate an output override, or select another page. When not in edit mode, the arrow buttons are used to navigate around the page to either an edit field or a control field. When in edit mode, the up/down buttons slew up or down through the available values and the right/left buttons are used to change to a different digit or edit

Press the button to move to the “Left Display” field.

Press the “ENTER” button to display the “Left Display” menu page.

The “>…..<” indicates which page is currently displayed on the left display. Use the arrow buttons to move the cursor to the desired page name and press the “ENTER” button. The left display will change to the new page and the “>…..<” will move to the selected page name.

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> Volts <

This is a typical three phase System Voltages page.

LINE 1: Phase titles for the voltage and current.

LINE 2: Line-to-line voltages in Volts RMS.

LINE 3: Line currents in Amps RMS.

LINE 4: Generator frequency in Hz and total system power in kilowatts.

This is a typical single phase System Voltages page.

LINE 1: Phase titles for the voltage and current

– voltage title/current title.

LINE 2: Line-to-line voltage for AB and Line-to- Neutral voltage for A and B in Volts RMS.

LINE 3: Neutral current and Line currents in Amps RMS.

LINE 4: Generator frequency in Hz and total system power in kilowatts.

> Switch <

This is the Transfer Switch Mimic Diagram page. It shows the position of the Utility Switch and the Generator Switch. This depicted display shows the Utility switch closed and the Generator switch open. There can be up to 4 HTS switches connected to the generator.

LINE 1: “Transfer Switch Name” indicates which switch inputs are being displayed such as “From HTS #1”. To select a switch to display, select the switch number on the HTS page (refer to the Right Display Pages - Exercise/HTS page). If there are no HTS switches connected, then the Line Power and Generator Power inputs are displayed and the “Transfer Switch Name” is “From Line/Gen Inputs”

LINE 2: Title line showing the left side is the Utility switch and the right side is the Generator switch.

LINE 3: Character graphics showing the switch states – open or closed.

LINE 4: Character graphics indicating the load coming off the bottom of the diagram.

> Alrm Log <

This is the System Alarm Log page. It displays the last 20 alarms or warnings that occurred with a time and date stamp. Two records are displayed at a time.

LINE 1/3: The record’s alarm or warning number (lowest number being the most recent) followed by the date and time that the alarm or warning occurred.

LINE 2/4: The alarm or warning description message. The depicted display shows a basic format in place of the first record and an empty record for the second. The records scroll up at about a 4 second rate.

The message format symbols are explained below:

First 2 characters:

??	–	Empty slot
Wr –		Warning
Al	–	Non-shutdown alarm
SD –		Shutdown alarm
Last 2 Characters:
Sn	–	Sensor failure
Hi	–	Tripped by being greater than threshold
Lo	–	Tripped by being less than threshold
	–	(blank) Internal alarm or warning

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General Information

> Power <

This is a typical System Power page.

LINE 1: Total system real power in kW.

LINE 2: Total system reactive power in kVAR.

LINE 3: Total system apparent power in kVA.

LINE 4: Total system power factor.

> Graph Hz <

H-100 Control Panel Technical Manual

Press the “MENU” button:

Use the arrow keys to move the cursor to the desired menu item and then press the “ENTER” button. Most menu items have multiple pages under them. When that is the case, there is a “More (x-y)” field at the lower right hand corner of the page where “x” is the page number and “y” is the total number of pages available under this menu item. To move forward or backward through the pages, the cursor is placed on the or character using the arrow buttons and the “ENTER” button is pressed. When a page is first displayed, the cursor normally starts on the character to promote ease of scanning through the pages.

This is the Generator Frequency Graph page. This graph provides a coarse representation of the generator frequency. The graph scrolls from right to left at 2 characters per second (last 10 seconds of data on the display). The bottom of the graph is 50 Hz and the top is 70 Hz. There are 32 levels between bottom and top. Therefore, each level is approximately 0.6 Hz.

> Other <

This is the Other page. At this time, it has no function and serves as a place holder.

RIGHT DISPLAY PAGES

The right display is menu based with eight main menu items: System Alarm and Warning pages, Engine Parameter pages, System Status pages, Maintenance Status Pages, Left Display Menu page, Generator Parameter pages, System Diagnostic pages, and Internal Exercise and HTS pages. To select a page for the right display, do the following:

ALARMS

There are three System Alarm and Warning pages. Each page is capable of displaying three alarms or warnings. If there are more than nine total alarms and warnings to list, then only the most recent nine will be visible. All alarms and warnings remain in the list until they are cleared. Warnings clear when they are no longer active. Normal Alarms clear when they are no longer active and have been acknowledged. Shutdown alarms clear only after the key switch has been placed in the OFF position and they are no longer active. There are a few shutdown alarms that will only clear after a power cycle of the controller and they are no longer active. Besides using the menu to get to the alarm pages, the right display immediately changes to the first alarm page when an alarm or warning first becomes active. If a shutdown alarm is active and an alarm or warning is not acknowledged, the displays will flash with the Alarm LED.

Do the following to view the alarm/warnings pages:

Press the “MENU” button.

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H-100 Control Panel Technical Manual

Press the “ENTER” button.

This is a typical System Alarm and Warning page. The n/a indicates there is not an alarm or warning to display on that line. As depicted, this display indicates a Fuel Pressure alarm for low pressure. This would be a common alarm for a system that has the gas line turned off. The “Al” indicates it is an alarm. The “*” indicates the alarm has not been acknowledged. The “DI2/FUEL PRESS” message indicates it is a fuel pressure alarm (DI2 was included in the text by the user to indicate it is Digital Input #2). The “Lo” indicates the alarm was tripped because the input value fell below a set threshold.

The message format symbols are explained below:

First 2 characters:

Wr – Warning

Al – Non-shutdown alarm

SD – Shutdown alarm

Third Character:

* – Has not been acknowledged

Last 2 Characters:

Sn – Sensor failure

Hi – Tripped by being greater than threshold

Lo – Tripped by being less than threshold

(blank) – Internal alarm or warning

Press the “ENTER” button while the cursor is on "ACK" to acknowledge the alarm.

The “*” is now gone since the alarm has been acknowledged.

Turn the gas line on.

The alarm has cleared since the gas pressure is now adequate.

Move the cursor to the on the bottom line by pressing the button twice or the button once.

Press the “ENTER” button to see the next page.

Press the “ENTER” button to see the next page.

ENGINE

There are four Engine Parameter pages. In most H- 100 Control Panels, there are spare analog channels available or unused analog channels. They can be displayed on these pages. If they are not configured, they will not be displayed.

Do the following to view the engine parameter pages:

Press the “MENU” button.

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