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KUTAI ELECTRONICS INDUSTRY CO., LTD.
TEL : +886-7-8121771 FAX : +886-7-8121775 Website : www.kutai.com.tw
Headquarters : No.3, Lane 201, Chien Fu St., Chyan Jenn Dist., Kaohsiung 80664, TAIWAN
GCU-3000 Ver1.0
Automatic Engine Control and
Protection Module Operators Manual
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2 GCU-3000
TABLE OF CONTENTS
Section Page
SECTOIN 1 : INTRODUCTION
1.1 Panel Layout ............................................................................................................................................... 4
1.2 Front Panel Layout...................................................................................................................................... 4
1.3 Unit Dimensions (Measurement : mm) ....................................................................................................... 5
1.4 Panel Cut-Out (Measurement : mm)........................................................................................................... 5
SECTOIN 2 : OPERATOR
2.1 Summary ..................................................................................................................................................... 6
2.2 AUTO .......................................................................................................................................................... 6
2.3 Manual ........................................................................................................................................................ 6
2.4 Off & Reset ................................................................................................................................................. 6
SECTION 3 : SYSTEM SETTING & OPERATION
3.1 DC Input Power ........................................................................................................................................... 7
3.2 System Setting (Programming) ................................................................................................................... 7
3.3 The Hour Meter ........................................................................................................................................... 7
3.4 AC Voltage & Current Setting ..................................................................................................................... 7
3.5 Over-Load Protection Setting ..................................................................................................................... 8
3.6 Shutdown Override ..................................................................................................................................... 8
3.7 Magnetic Pick-up (MPU) Setting ................................................................................................................. 8
3.8 The Additional Inputs Alarm1 & Alarm2 ...................................................................................................... 9
3.9 Setting the Service Reminder ..................................................................................................................... 9
3.10 Screen Viewing ........................................................................................................................................... 9
3.11 Engine Idle Operation Function .................................................................................................................. 9
3.12 Digital Temperature Sensor (Optional) ....................................................................................................... 9
3.13 Ceramic Capacitive Oil Pressure Sensor (Optional) .................................................................................. 9
3.14 The Event Log ............................................................................................................................................. 9
3.15 Communication With PC (KCU-XX) .......................................................................................................... 10
3.16 CANBus J1939 Transducer KCU-04 (Optional) ....................................................................................... 12
3.17 System Setting Line-by-Line Programming Table .................................................................................... 12
SECTOIN 4 : FAILURE WARNING DESCRIPTION
4.1 Failure Signal Reference Table ................................................................................................................ 15
4.2 Warning ..................................................................................................................................................... 15
4.3 Shutdown .................................................................................................................................................. 15
SECTOIN 5 : SPECIFICATION
SECTION 6 : TERMINAL & WIRING DESCRIPTION
6.1 Connection Detail...................................................................................................................................... 16
6.2 Wiring Diagram ......................................................................................................................................... 17
SECTION 7 : TROUBLESHOOTING
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GCU-3000 3
SECTION 1 : INTRODUCTION
The GCU-3000 is an integrated modular Automatic
Generator Control & Protection unit with the largest
LCD screen in the market. It is suitable for use on all
conventional generator applications. The module uses
easy to recognize icons and powerful software to
protect the generators. The GCU-3000 makes the
complicated simple by providing an easy to install and
easy to Program Generator Controller.
To simplify installation you can program the GCU
directly from the front panel without complicated
computer setup. After programming, all the new
settings are recorded into the internal (EEPROM) and
protected from erasure.
The main advantages of using the GCU-3000 are：
● Integrated design including an emergency stop
button, AVR control, fuses, and positive outputs
● Large easy to see LCD screen
● Programmable start cycles
● Programmable idle speed timer
● Programmable cool down timer
● Maintenance notifications
● Engine block heater control
● Digital temperature sensor included
● High precision oil pressure sensor included
● Full monitoring and protection
LCD information includes the following：
● Full phase AC voltage monitoring
● Full phase AC line voltage monitoring
● Full phase load current monitoring
● KVA output
● Frequency
● Hour Meter
● Battery voltage Indicator
● Oil pressure readings in Psi or Bar
● Temperature in C or F
● Universal Failure Warning icons
The module includes a front panel emergency stop
button and a built in potentiometer (VR) to adjust the
Automatic Voltage Regulators (AVR) directly from the
front panel. It also comes with all AC and DC fuses and
relays for quick installation and operation.
When a generator failure occurs, the built in warning
buzzer and LCD graphic display, gives you the reasons
for the warnings instantly. In addition, it provides a
remote failure-warning signal to the control room; to
also notify the maintenance personnel. It also
incorporates a Failure Event Log program, which
records the previous 15 failures; then you can read the
log directly from the front panel screen.
The Engine Block Heater control is also integrated into
the GCU using its build in digital temperature sensor.
The generator is then able to maintain smooth and
good starts in the coldest weather.
Maintenance personnel can obtain; Engine
Temperature, Battery voltage and hours of operation at
any time by pressing the Mute Button. Even with the
engine off.
GCU Monitoring and Protects：
● High engine temperature protection
● Low oil pressure protection
● Over & Under speed protection
● Full phase AC over & Under voltage and loss of
phase monitoring
● Full phase load current monitoring
● Battery over & under voltage monitoring
● Low Fuel Level Monitoring
● Temperature & Pressure Sensor Failure
● Magnetic Pick-up (MPU) Failure
The GCU also reserves two extra inputs for future
expansion.
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4 GCU-3000
1.1 Panel Layout
Icon
Function
Down
Arrow
UP Arrow
Auto
Off
Manual
Pen
Mute
1.2 Front Panel Layout
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GCU-3000 5
1.3 Unit Dimensions (Measurement : mm)
1.4 Panel Cut-out (Measurement : mm)
GCU-2000
GCU-3000
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6 GCU-3000
SECTION 2 : OPERATION
2.1 Summary
The GCU has 3 main control buttons :
1. Auto
2. Manual
3. Off
In addition, we have the (UP Arrow), (Down Arrow),
(Pen Button) and the (Mute Button). Everything you
need to operate the generator is on the front panel.
2.2 AUTO
In AUTO, the generator starts & stops automatically
under the control of the remote start signal. (Usually
from an ATS)
Press the AUTO key and notice the screen flashes
(AUTO). When the control receives a remote start
signal the flashing stops and the start sequence
begins.
First the Pre-Heat timer is activated and (Pr.Ht) shows
up on the screen. (However, if the Pre-Heat timer is set
to 0 (See setting Line 41) then the system omits the
pre-heat countdown and proceeds to crank start. If it
fails to start the first time, it tries to (restart) three times
after a 5 seconds rest.
The starter cranking time is factory pre-set for 6
seconds (See settings Line. 43). When cranking (Strt)
shows on the screen. If the engine fails to start, the
system goes back to Pre-Heat and tries again. If it fails
to start within the preset number of tries, then the
system declares a start failure with a flashing FAIL
signal comes up on the screen together with the sound
alarm. The GCU also sends out the warning output.
The starter motor stops cranking when any of the
condition below is established, in order to prevent
damage to the starter and flywheel ring gear.
● Oil pressure builds up and oil pressure sensor is
activated
● Oil pressure sensor sees more than 25Psi
● AC voltage
● The AC Frequency reaches 20% of the rated
Frequency
● MPU sensing 20% of rated speed (needs to be
pre-set).
The GCU can also provide idle speed. Once started
the system enters into idle speed operation and the
word (Idle) appears on the screen. The idle speed can
be cancelled if the genset does not need it. See setting
reference Line 50 and set countdown timer to 00 to
cancel.
After starting, the GCU implements a 30 sec grace
period to confirm that speed, oil pressure, voltage and
all other parameter are normal. If the generator fails to
reach normal operational parameters, the GCU sends
a shutdown signal and FAIL appears on the screen.
But if all parameter are reached and stabilized, the
GCU proceeds to Warm Up, and once the countdown
ends, the genset connects the load, and activates all
protections.
(If the generator has no load contactor then this step is
omitted.)
If the remote start signal disappears during operation,
the load contactor disconnects. The no load Cool-down
is initiated and on the screen the word COOL appears
and the Cool-down times out. If the remote signal
returns during Cool-down, The GCU once again
connects to load contactor and goes back to normal
operations.
Once the Cool-down ends, the GCU executes a stop
countdown and stops the generator on either “energize
to start” or “energize to stop”. In addition, the word
Stop appears on the screen.
NOTICE
When the generator is on Cool-down the
protection system remains in effect and if any
failure occurs, the module bypasses the
countdown and shutdown the generator
immediately.
2.3 Manual
In MANU (manual), the start command is initiated by
pushing the MANU button on the front panel. After the
generator starts the, GCU automatically, connect the
load. To stop press OFF or AUTO and the generator
executes the normally pre-programmed shut-down.
In manual, the procedure is the same as in AUTO.
2.4 Off & Reset
Pushing the OFF button represents a shutdown
command or a RESET. If OFF is selected during
normal genset operation, the generator proceeds to
shut-down disconnecting the load contactor, executes
a Cool-down without load, and stops.
If the system senses a major failure during normal
operation, it immediately stops the genset; and after it
comes to a complete stop, the failure is showed on the
screen. The service personnel can use this information
to conduct service and repair accordingly. If there are
more than two failures, all of the failures are shown on
the screen. And by pressing OFF again, the failure
notices are erased and the GCU is RESET.
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GCU-3000 7
SECTION 3 : SYSTEM SETTING & OPERATION
NOTICE
Before proceeding to system setting, you must
install correctly all the wirings connection and
connect the Battery.
3.1 DC Input Power
GCU works with a wide range of battery power inputs
from 9 to 36VDC, and the GCU is protected from any
incorrect DC voltage input and connections.
3.2 System Setting (Programming)
There are 68 lines of programming. You must adjust
each line according to the generator type and
protection requirements.
You can preprogram the GCU-3000 away from the
generator just by using a small power supply.
To enter Line-by-Line programming, first press (OFF)
and then press the (UP Arrow)(Down Arrow) (Pen)
and (MUTE) buttons together for 4 seconds.
The software version appears for 2 seconds, followed
by the word (Prog) for 4 seconds, and then the screen
shows the Line number and value entered for that line
(See illustration below).
(Ln.01) indicates Line.1, and (00) representing the
entered value. You press (UP Arrow) or (Down Arrow)
to change the value. Each time you press the Pen
Button we move to the next Line. If the setting is left
unattended for 30 seconds or if the last Line 68 is
reached the word END indicates that you finished and
all modified values are saved.
To end programming at any time press the (OFF) and
(Pen) Buttons together for 4 seconds until the END
appears.
To restore factory setting at any time press (AUTO)
and (Pen) Buttons together for 4 seconds until the
word (Au.PO) appears.
3.3 The Hour Meter
The (Hour-Meter) is the total accumulation of the
generator operating hours stored in memory. The GCU
never erases or resets the hour meter to zero.
However, to set a new value on the hour-meter
memory, enter programming mode and before the
word (Prog) disappears from the screen (about 4
seconds), press the (OFF) button for 4 seconds, the
panel should now read (Ch.Hr), see the illustration
below. The (0567Hr) displays the current accumulated
operation hour stored in memory.
Now press (UP Arrow) or (Down Arrow) button to
change the hour reading. By holding down the button
you increase the scrolling speed.
To END at any time press the (OFF) and (Pen) Buttons
together for 4 seconds or until the word END appears
on the screen or just leave all keys alone for 10
seconds.
3.4 AC Voltage & Current Setting
The voltage and current reading are set at the factory.
However, when the generator operates in heavy
inductive or capacitive loads, the waveform distortion
causes minor voltage differences.
If you need to correct the voltage or amperage
readings, on the GCU enter System Setting lines (3),
(4), (10), and (11) and increase or decrease the values.
Remember that the high/low voltage and load current
protections utilize these new values for shutdown, and
overload protection, etc.
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8 GCU-3000
3.5 Over-load Protection Setting
GCU provides Over-load Protection from the
amperages calculated in the GCU.
To set the overload protection each unit value is equal
to 50 Amps, for example: If you enter 20 then the Over
current protection value equals to 20 times 50A or
1000A.
When the GCU senses a temporary generator
over-load, it starts the timer and waits for the over load
to disappear within the time allocated. If the generator
over-load is longer than the time allocated, the GCU
executes the Protection shutdown, showing Over-load
failure on the screen.
The GCU has two types of over-load protections.
● Stop : For immediate shutdown.
● Warning : Does not stop the generator but, Shows
the failure message on the screen and sends out the
trip signal output. It is up to the operator to then stop
the generator.
For Over-load Protection related settings refer to
chapter 3.15 system setting lines (12), (13), (14), (15).
ATTENTION
The GCU uses the internal current reading to
calculate over-load protection, you need to pay
special attention to these settings they cannot
exceed the CT rated value, otherwise field
saturation on the CT causes the system to
compute incorrect values and loose Over-load
Protection.
For example, If the CT ratio is 1000/5, then the
over load current setting cannot exceed
1000Amps.
3.6 Shutdown Override
Override Start & Stop We use this feature to manually
start and stop a newly assembled genset, without
annoying shutdowns. Giving you time to set and adjust
the AC voltage speed, oil pressure shutdowns, etc.
Before entering shutdown override, you should
complete all wiring connections and perform a
Line-by-Line check, confirming that all systems are
working. Then, enter Line (67) and select shutdown
override. Also define the type of engine shutdown
system you are using on Line 48 before activating
Shutdown Override.
In override, the manual icon appears on the screen.
To crank and start the engine press and hold the
(MANU) button, to stop the engine, press and hold the
(AUTO) button. (The starter is activated only when you
hold the button down and the same is true to stop the
engine).
Once all adjustment and setting are completed, you
need to set the system back to normal. To return to
normal presses the (OFF) button, the GCU stops the
generator and automatically resets back to normal
operation.
For manual override, go to System Setting Line (67).
ATTENTION
Under manual override, the GCU cancels all
protections, and if a failure occurs while in
override operation, the system does not
shutdown the engine. Therefore, it is strongly
recommended that manual override be used only
for adjustment and servicing the generator.
3.7 Magnetic Pick-up (MPU) Setting
The MPU (Magnetic Pick-up) is the sensing device
installed on the flywheel bell housing, which detects the
engine RPM according to the frequency generated by
the flywheel ring gear. Most generators with electronic
speed controllers use a MPU.
MPU operational frequency range：100 Hz 10K Hz
To program the MPU, Manually start the engine and
run at rated speed (50 Hz or 60 Hz) by holding the
governor actuator by hand, Then quickly press the Pen
Button, and read the MPU frequency, and when (Au.Po)
appears on the screen the MPU programming is
complete.
If the system detects that the MPU frequency is below
100 Hz, this is considered a MPU failure and the (FAIL)
message appears up on the screen, and the MPU
signal failure icon appears on the screen, confirming
procedure failure. At this point, you should check for
incorrect wiring or bad contacts. Repeat the setup
procedure after the cause of the failure has be
identified and corrected.
If the system detects the MPU frequency above 10 K
Hz, then it considers it as MPU failure and the (FAIL)
message appears on the screen, and at the same time
the Over speed failure icon appears on the screen,
confirming a programming failure. At this point, you
should first check the MPU for, incorrect wiring or a bad
installation. Repeat the setup procedure after the
correcting the problem.
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GCU-3000 9
Note : 10 to 15 Vac open circuit is about the right
output voltage for a MPU measured directly into a
digital voltmeter with the engine running at rated speed
50 or 60 Hz.
Some Electronics Speed Controllers or Governors do
not allow sharing the MPU with other devices. If a MPU
is required for over-speed protection we recommend
an extra independent Magnetic Pick-up or a dual coil
(MPU) If the GCU is programmed to use an MPU, and
the MPU is defective or open or its, unable to read the
MPU, the system shutdown the engine and the MPU
signal failure icon appears on the screen.
For MPU related settings refer to chapter 3.15 System
Setting lines (1), (16), (17), (18), (19), (20), (44).
3.8 The Additional Inputs Alarm1 & Alarm2
The GCU is equipped with 2 spare inputs to add two
extra protections.
To set Alarm1 & Alarm2 go to chapter 3.15 System
Setting Lines (56), (57), (58), (59), (60), (61).
3.9 Setting the Service Reminder
The maintenance icon on the screen is a reminder to
the service personal that it is time to carry out
maintenance on the generator. When setting the
service timer, each unit entered is equal to 10hrs, for
example if entering 20 is equal to 20 x 10Hrs = 200
Hrs.
After completing maintenance, you need to clear the
record and set a future maintenance point. See System
Setting Line (68).
For Service & Maintenance related settings refer to
System Setting Lines (62), (68).
3.10 Screen Viewing
You can freeze the screen parameter or leave them to
cycling one by one. When cycling, each parameter
paused for 2 seconds, but pressing the (UP Arrow)
button, you can select either AC Voltage or AC Current
readings, also pressing the (Down Arrow) key permits
you to cycle though the phases, The Hour meter,
Battery Voltage, Hz, engine temperature measurement
in C or F and oil press measurement in Psi or Bar.
When using the (UP Arrow) and (Down Arrow) keys
to select specific parameters, the selected value
freezes for 30 seconds and if the system is left
unattended it automatically return to cycling.
For Panel related settings refer to chapter 3.15 Setting
Lines (63), (64), (65).
3.11 Engine Idle Operation Function
You can idle the generator automatically before
working at full load.
For Idle Operation related settings refer to chapter 3.15
System Setting Line (50).
3.12 Digital Temperature Sensor (Optional)
You can install the most accurate temperature sensor
available on the market. It greatly improves accuracy
from traditional thermal sensors.
Digital Temperature Sensor accuracy：-55 to +125 ˚C
+/- 2 ˚C
Temperature Display Unit：˚C or ˚F
3.13 Ceramic Capacitive Oil Pressure Sensor
(Optional)
The Ceramic Capacitive Oil Pressure Sensor is most
the most accurate oil pressure sensor available on the
market. It greatly improves the accuracy from
traditional oil pressure sensors.
Ceramic Capacitive Oil Pressure Sensor accuracy：0 to
120 Psi +/- 2.5%
Oil Pressure measurements in Psi or Bar
ATTENTION
The GCU uses a special Digital Temperature
Sensor and a Ceramic Capacitive Oil Pressure
Sensor. Do not replace with any others. If you
have, any questions concerning the sensors
contact our technical staff.
3.14 The Event Log
Use the Failure Event Log to assist the service
personnel identify and determine the cause of a
problem. To retrieve the event log from memory go to
Line 66 and set (YES) The GCU retains the last
15-recorded failures in memory. Pressing the (UP
Arrow) our (Down Arrow) recalls the events and the
time of the event. To end the program press the (OFF)
key, or leave the system unattended for 10 seconds
and the system automatically closes the program and
the word END pops up on the screen.
The diagram below is an example of the Failure Event
Log :
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10 GCU-3000
The (FAIL) and (01) represent the event log screen (is
the memory lines 1 to 15), the (567 Hr) represents the
hour when the failure occurred and the Overheat icon
represents the cause of the failure.
For Failure Event Log related settings refer to chapter
3.15 system setting Line (66).
3.15 Communication With PC (KCU-XX)
The GCU with the optional USB / RS485 and Ethernet
remote communications modules, can easily read all
the real time information and remote control the local
device via communication interface modules. There
are 3 different purpose interface modules show as
below :
WARNING
You can remotely control the gcu and the
attention the generator can start at anytime.
Place a visible sign “DANGER!” “This generator
can start up at any time!” next to the generator
and install a warning buzzer or flash warning
light. Unwarned or unscheduled remote start
scan result in serious injury or death. When
performing service and maintenance, always
disconnect the remote signal input to the
generator.
Free App developed by Kutai Electronics to enables
you to remotely monitor and operate generator via
portable mobile device. Software currently available
with Apple iOS5.1 and Android Ver.2.3.3 system and
above. Other operating system software will be
available at a later time.
Free software can be downloaded from App Store or
Google Play by simply key in “ Kutai ” and hit search.
KCU-01 – USB interface module
KCU-02 – RS-485 interface module
KCU-03 – Ethernet interface module
For remote communication settings, See setting Line
(69), (70), (71).
When the item (69) set to 00, then user can read all the
real time information from the controller only. But when
it set to 01, it allow remote control from PC also.
The items (70), (71) are for when KCU-02 RS485
interface module is used only, others do not apply.
For information that is, more detailed refer to the
KCU-XX manual.
NOTE
When using the KCU-02 to make a closed LAN
connection A different controller address setting
must be programmed and the Baud rate setting
must be the same.
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GCU-3000 11
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12 GCU-3000
3.16 CANBus J1939 Transducer KCU-04 (Optional)
The KCU-04 module is used with CPU equipped
engines using the J1939 CAN Bus protocol. It is
connected to any one of the four slots on the back of
the GCU-3000 controller.
For J1939 related settings refer to Setting Line (21).
Installing the KCU-04 provides the GCU with the
following information.
● Temperature reading in ˚C or ˚F
● Oil Pressure reading in Psi or Bar
● High temperature warning and shut-down alarm
● Low oil Pressure warning and shut-down alarm
● Over-speed warning and shut-down alarm
● Under-speed warning and shut-down alarm
● Low fuel level warning and shut-down alarm
When you connect the KCU-04 module the GCU
disables the High Temperature, Low Oil Pressure and
Low Fuel Level protections automatically and all related
programming lines are automatically eliminated. You
don’t need to install any of sensors, this information
now comes from the CAN Bus, and protections
relegated to the engine CPU. The GCU’s job is to show
warning, alarm and shutdown messages using the
universal icons on the front panel.
The GCU does not disable its own over speed and
under speed protection, Both of GCU and the engine
CPU will shut-down the generator for over speed.
3.17 System Setting Line-by-Line Programming Table
NO.
DESCRIPTION
SETTING
FACTORY
PRE-SET
1
Frequency (60 or 50 Hz)
00 60 Hz 01 50 Hz
00
2
How is the generator wired?
(3Ø 4W, 3Ø 3W, 1Ø 3W or 1Ø )
00 3Ø 4W 01 3Ø 3W
02 1Ø 3W 03 1Ø
00
3
Correct the Voltage reading on the display (If needed)
Add or subtract the amount on line 4 to your reading
00 Do not correct
01 Add volts from line 4
02 Deduct volts from line 4
00
4
Volts reading display correction (If needed)
01 99 V
05 V
5
(Faulty voltage) protection time delay
00 99 sec
(0 Do not Protect)
15
6
Set Under-Voltage protection
08 47 (80 470V)
18(180V)
7
Under voltage protection Warning or Shutdown
00 Warning
01 Shutdown
01
8
Set Over-Voltage protection
11 50 (110 500V)
25(250V)
9
Over-voltage protection Warning or Shutdown
00 Warning 01 Shutdown
01
10
Correct Amps reading on the display (If needed)
Add or subtract the amount on line 11 to your reading
00 Do not correct
01 Add amps from line 11
02 Deduct amps from line 11
00
11
Amps reading display correction (If needed)
01 99 A
05 A
12
Set the (CT)
Example : 5 if you use a 100/5 CT for current reading
(Choosing the wrong CT will give you a erroneous
current reading)
01 25/5 02 50/5 03 60/5
04 75/5 05 100/5 06 150/5
07 200/5 08 250/5 09 300/5
10 400/5 11 500/5 12 600/5
13 750/5 14 800/5 15 1000/5
16 1200/5 17 1500/5 18 1600/5
19 2000/5 20 3000/5
05
13
Over-load protection activation time delay
00 99 sec
(00 Option Cancelled)
00
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GCU-3000 13
NO.
DESCRIPTION
SETTING
FACTORY
PRE-SET
14
Setting the over-load protection
(One unit is equal 50 amps)
Example : 20 units is equal to 1000A overload
protection
20 * 50A = 1000A
01 60 (50 3000A)
02(100A)
15
Over-load protection Warning or Shutdown
00 Warning 01 Shutdown
00
16
Over-speed / Under-speed protection activation time
delay
00 99 sec
(0 Option Cancelled)
05
17
Magnetic Pick-up (MPU) used with the GCU-3000?
00 NO 01 Yes
00
18
RPM info taken from the generator or MPU
00 AC Hz 01 MPU
00
19
Over-speed protection setting
51 75 Hz
65 Hz
20
Under-speed protection setting
40 59 Hz
55 Hz
21
Use the Oil (PS-01) pressure sensor or get info from
J1939 (KCU-04) transducer
00 (None)
01 PS-01 Sensor
02 J-1939 + KCU-04
01
22
Oil pressure reading in Psi or Bar
00 Psi 01 Bar
00
23
If the (PS-01) Oil pressure sensor fails do I want a
Warning or a Shutdown
00 Warning 01 Shutdown
00
24
Low oil pressure protection activation time delay
02 99 sec
10
25
Use the (PS-01) sensor to detect low oil pressure
00 NO 01 Yes
00
26
Low oil pressure warning setting
Psi：00 99 45 Psi = 3 Bar
45 Psi
27
Low oil pressure Shutdown setting
Psi：00 99 14.5 Psi = 1 Bar
15 Psi
28
Backup oil pressure switch sender installed?
NO (Normal Open) or NC (Normal Close)
00 Installed but Not Used
01 NO 02 NC
02
29
Is the (TS-01) temperature sensor installed?
00 No 01 Yes
01
30
Temperature display
(You can change from C to F under operation)
00 Centigrade 01 Fahrenheit
00
31
If the temperature sensor (TS-01) fails do I want a
Warning or a Shutdown
00 Warning 01 Shutdown
00
32
High temperature protection activation time delay
02 99 sec
05
33
Use the temp sensor to detect high water temperature
00 NO 01 Yes
00
34
High temperature warning setting
(Every unit is equal to 5 Degree Centigrade)
10 20 units 18 = 194 F
18
(90 ˚C)
35
High temperature shutdown setting (HIGH / HIGH)
(Every unit is equal to 5 degree C)
10 24 units 21 = 221 F
21
(105 ˚C)
36
Is the (PS-01) temp sensor used to control the block
heater
00 NO 01 Yes
00
37
Block heater max temp OFF setting
00 50 ˚C
25 ˚C
38
Additional Temp switch type sensor installed
NO (Normal Open) or NC (Normal Close)
00 Not installed
01 NO 02 NC
01
39
Battery under voltage protection setting
08 23 Vdc
08 Vdc
40
Battery over voltage protection setting
13 35 Vdc
32 Vdc
41
Pre-heat timer setting
00 99 sec
06
42
Start attempt
01 09 Start Attempts
03
43
Cranking timer setting
2 30 sec
06
44
Magnetic Pick-up (MPU) used for verify engine start
00 No 01 Yes
00
45
Oil pressure sensor disengages starter (At 25 Psi)
00 No 01 Yes
00
Page 14
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14 GCU-3000
NO.
DESCRIPTION
SETTING
FACTORY
PRE-SET
46
Additional oil pressure switch sensor to confirming
engine start
00 No 01 Yes
01
47
Set activation timer for the energize stop solenoid
(Time needed to pull the energize to stop Solenoid)
02 99 sec
10
48
Method used to stop the engine
(Energize to Stop or Energize to Start)
00 Energize to stop
01 Energize to start
00
49
Cool-down timer
00 60 min
00
50
Idle timer (Used only if governor capable)
00 60 min
00
51
Time in Warm up before connecting load contactors
00 99 sec
10
52
Activate the warning buzzer
00 NO 01 Yes
01
53
Fuel level indicator switch sender type
NO (Normal Open) or NC (Normal Close)
00 Not used
01 NO 02 NC
00
54
Low fuel level activation time delay
02 99 sec
10
55
Low fuel level Warning or Shutdown
00 Warning 01 Shutdown
00
56
Defined Alarm1 (switch type)
NO (Normal Open) or NC (Normal Close)
00 Do Not use Alarm1
01 NO 02 NC
00
57
Alarm1 activation time delay
02 99 sec
10
58
Alarm1 Warning or Shutdown
00 Warning 01 Shutdown
00
59
Defined Alarm2 (switch type)
NO (Normal Open) or NC (Normal Close)
00 Do Not use Alarm2
01 NO 02 NC
00
60
Alarm2 activation time delay
02 99 sec
10
61
Alarm2 Warning or Shutdown
00 Warning
01 Shutdown
00
62
Service and maintenance reminder
(Every unit is equal to 10 hrs) 20 x 10hr is a 200 hr
reminder
00 99
(00 No Service reminder)
00
63
Voltage and Amps display setting
00 Fixed Display
01 Cycle Display
01
64
Also display each phase to Neutral (L1-N, L2-N, L3-N)
In 4W 3Ø (Phase systems)
00 NO 01 Yes
01
65
Display only Hour Meter, Battery Volts, or Hertz at one
time or cycle though all readings
00 Hour meter
01 Battery voltage
02 Hertz
03 Display all values
02
66
To retrieve the last 15 Failure event from memory
program this line to Yes and press the Pen button
00 NO 01 Yes
00
67
Override shutdowns & start and stop the engine
manually
Useful when servicing the generator
00 Normal 01 Manual
00
68
Erase service log and maintenance warning signal and
reset service timer
00 NO 01 Yes
00
69
Enable R486 remote control by KCU-XX module
00 NO 01 Yes
00
70
KCU-02 module address setting
00 None
01 99
00
71
KCU-02 baud rate setting
01 115200 02 57600
03 38400 04 19200
05 14400 06 9600
07 4800 08 2400
09 1200
03
Page 15
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GCU-3000 15
SECTION 4 : FAILURE WARNING
DESCRIPTION
4.1 Failure Signal Reference Table
GCU-3000 is equipped with a large highly illuminating
LCD screen were all of the failure notices are
graphically and audible indicated with the built in failure
warning alarm.
Universal Failure Icons Reference Table
WARNING
SIGNAL
DESCRIPTION
EXECUTION
Start failure
Stop
Under speed
Stop
Over speed
Stop
Emergency stop
Stop
Coolant overheat
Stop or Warning
Lubricant under
Pressure
Stop or Warning
Overload
Stop or Warning
Ac under voltage
Stop or Warning
Ac over voltage
Stop or Warning
Dc under voltage
Warning
Sensor failure
Stop or Warning
MPU signal failure
Stop
Low fuel level
Stop or Warning
Block Heater
In manual
Service
maintenance
Warning
You Defined 1
Stop or Warning
You Defined 2
Stop or Warning
4.2 Warning
When the GCU detects a problem during operation, but
the situation do not pose immediate danger to the
genset or the operating personnel, the GCU gives you
a warning not a shutdown
With a Warning, the genset continues normal operation
and provides power to the load. The warning
message(s) continue to flash on the screen and the
failure Signal / Alarm output is activated. The warning
is automatically reset once the failure is corrected.
4.3 Shutdown
When a major failure is detects and it poses immediate
danger to the genset and its personnel, the system
shut-down immediately, the failure is noted on the
screen activating the alarm. After the failure(s) are
cleared, press the (OFF) button to confirm and reset
the failure warning notice(s).
SECTION 5 : SPECIFICATION
ITEM
SPECIFICATION
DC input
9 36 Vdc
AC input
15 500 Vac (Ph-Ph)
AC frequency
50 60 Hz
MPU Signal Strength
+/- 2 to 70V Peak
MPU Input Frequency
100 10,000 Hz
Start signal
10 Amp @ 12/24 Vdc
Stop signal
10 Amp @ 12/24 Vdc
pre-heat signal
2.5 Amp @ 12/24 Vdc
Accessory “ON”
Output
2.5 Amp @ 12/24 Vdc
System Operating
Signal
2.5 Amp @ 12/24 Vdc
Failure Warning signal
2.5 Amp @ 12/24 Vdc
Preheat Signal
2.5 Amp @ 12/24 Vdc
Block Heater Signal
2.5 Amp @ 12/24 Vdc
Overload Signal
2.5 Amp @ 12/24 Vdc
Idle Control Conductor
Capacity
1.0 Amp @ 12/24 Vdc
DC Fuse
15 Amps (F4)
AC Fuse
1.0 Amps (F1 F3)
AC Voltage
Potentiometer
1000 ohms
System Inactive Power
Consumption
Below 7W
Operating Temperature
-20 to 70 ˚C
Relative Humidity
Below 95%
CT capacity
Above 2.5VA
Secondary Rated
Current
5A
Weight
1341 g +/- 2%
Page 16
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16 GCU-3000
SECTION 6 : TERMINAL & WIRING DESCRIPTION
6.1 Connection Detail
PIN No.
DESCRIPTION
ATTENTION
1
AC Input (L1)
Connect to AC Input Phase R
3
AC Input (L2)
Connect to AC Input Phase S
5
AC Input (L3)
Connect to AC Input Phase T
7
AC Neutral Input (N)
Connect to AC Input Phase N
8
Battery Positive ( V )
Connect to battery positive (12/24V)
9
Battery Negative ( V )
Connect to battery negative
10
CT Secondary for (L3)
Connect to Secondary Phase T (L3) Monitoring CT
11
CT Secondary for (L2)
Connect to Secondary Phase S (L2) Monitoring CT
12
CT Secondary for (L1)
Connect to Secondary Phase R (L1) Monitoring CT
13
CT (COMM) Terminal Input
Connect to External CTs Common Position
14
Starter Motor Signal Output
Connect to Starter Motor.
Supply (+V) (Max. rated output 10 Amp)
15
Fuel Solenoid Signal Output
Connect to Fuel Solenoid or Fuel Valve Control.
Supply (+V) (Max. rated output 10 Amp)
16
Overload Alarm Signal Output
Used to Trip the AC Output Breaker.
Supply (+V) (Max. rated output 2.5 Amp)
17
Panel Illumination Output
Connect to the Panel Lamp
(Max. rated output 2.5 Amp)
18
Normal Operation Auxiliary Output
Connect to the Operation Indication Lamp
(Max. rated output 2.5 Amp)
19
Failure Signal Output
Used to Control External Alarm Buzzer.
Supply (+V) (Max. rated output 2.5 Amp)
20
Preheat Signal Output
Used to Control the Internal Heater.
Supply (+V) (Max. rated output 2.5 Amp)
21
Warm up Contactor Control Output
Connect to Warm up Contactor
(Max. rated output 2.5 Amp)
22
You defined signal Input 2
Negative Input When Action
23
You defined signal Input 1
Negative Input When Action
24
Low Fuel signal Input
Connect to Fuel Level Switch
25
High Water Temperature Signal Input
Connect to water temperature switch
26
Low Oil Pressure Signal Input
Connect to oil pressure switch
27
Remote Start Signal Input
Connect to A.T.S or remote start terminal
28
Remote Start Signal Input
Connect to A.T.S or remote start terminal
29
Magnetic Pick-up Input
Connect to Magnetic Pick-up to monitor speed
30
Magnetic Pick-up Input
Connect to Magnetic Pick-up to monitor speed
31
Idle Speed Control Signal Output (CO.)
Connect to Electronic Governor for idle speed
control
32
Idle Speed Control Signal Output (NC.)
Connect to Electronic Governor for idle speed
control
33
Idle Speed Control Signal Output (NO.)
Connect to Electronic Governor for idle speed
control
34
Block Heater Output
Connect to Block Heater
(Max. rated output 2.5 Amp)
35
Voltage Potentiometer Output
Connect to Automatic Voltage Regulator (GAVR)
36
Voltage Potentiometer Output
Connect to Automatic Voltage Regulator (GAVR)
Page 17
___________________________________________________________________________________________
GCU-3000 17
6.2 Wiring Diagram
6.2.1 3 Phase 4 Wires System Wiring Diagram
AUXILIARY
BLOCK HEATER
STOP
START
OVER LOAD
RUNNING
PRE-HEAT
ALARM
AUX.2
AUX.1
LOW FUEL SW
BATTERY
+
GOVERNOR
OIL PRESSURE SW
REMOTE START
REMOTE START
TEMPERATURE SW
Pick-up
Meganetic
OIL PRESSURE SENDER(4C)
TEMPERATURE SENDER(5C)
IDLE CONTROL
IDLE CONTROL
IDLE CONTROL
1A
GCU3000 CONTROLLER
CONTACTOR
10A
34
15
14
10A
16
L3
LOAD
N
L1
L2
10A
17
18
19
20
21
10
13
22
8
9
23
24
11
7
12
30
26
25
27
28
29
1
3
5
1A
1A
VOLTAGE
J2
J1
33
31
35
36
G
L3
AVR
N
L1
L2
32
CT
CT
CT
Page 18
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18 GCU-3000
6.2.2 3 Phase 3 Wires System Wiring Diagram
VOLTAGE
L1
LOW FUEL SW
OIL PRESSURE SENDER(4C)
TEMPERATURE SENDER(5C)
IDLE CONTROL
IDLE CONTROL
IDLE CONTROL
Meganetic
Pick-up
REMOTE START
TEMPERATURE SW
REMOTE START
OIL PRESSURE SW
33
32
31
J1
J2
G
27
29
30
28
3
1
5
26
25
24
7
12
ALARM
RUNNING
PRE-HEAT
+
BATTERY
AUX.2
AUX.1
START
STOP
BLOCK HEATER
AUXILIARY
OVER LOAD
13
23
22
9
8
11
10
19
20
10A
18
21
15
17
16
34
10A
10A
14
LOAD
L3
L2
L1
36
35
AVR
1A
1A
1A
GCU3000 CONTROLLER
L3
L2
GOVERNOR
CONTACTOR
CT
CT
CT
Page 19
___________________________________________________________________________________________
GCU-3000 19
6.2.3 1 Phase 3 Wires System Wiring Diagram
AUXILIARY
BLOCK HEATER
STOP
START
OVER LOAD
RUNNING
PRE-HEAT
ALARM
AUX.2
AUX.1
LOW FUEL SW
BATTERY
+
OIL PRESSURE SW
REMOTE START
REMOTE START
TEMPERATURE SW
Pick-up
Meganetic
OIL PRESSURE SENDER(4C)
TEMPERATURE SENDER(5C)
IDLE CONTROL
IDLE CONTROL
IDLE CONTROL
1A
GCU3000 CONTROLLER
10A
34
15
14
10A
16
LOAD
L2
N
L1
10A
17
18
19
20
21
10
13
22
8
9
23
24
11
7
12
30
26
25
27
28
29
1
3
5
1A
1A
VOLTAGE
J2
J1
33
31
35
36
G
AVR
L2
N
L1
32
GOVERNOR
CONTACTOR
CT
CT
Page 20
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20 GCU-3000
6.2.4 Single Phase System Wiring Diagram
BLOCK HEATER
START
STOP
OVER LOAD
AUXILIARY
ALARM
RUNNING
AUX.2
+
BATTERY
PRE-HEAT
TEMPERATURE SW
REMOTE START
OIL PRESSURE SW
LOW FUEL SW
AUX.1
TEMPERATURE SENDER(5C)
OIL PRESSURE SENDER(4C)
REMOTE START
Meganetic
Pick-up
IDLE CONTROL
IDLE CONTROL
IDLE CONTROL
19
10A
14
10A
15
34
16
17
18
21
LOAD
L1
L2
28
GCU3000 CONTROLLER
8
20
10A
9
22
11
10
12
24
23
25
27
26
1A
5
7
1A
3
1
1A
VOLTAGE
J2
29
30
J1
36
35
31
33
32
L2
G
AVR
L1
13
CT
GOVERNOR
CONTACTOR
Page 21
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GCU-3000 21
SECTION 7 : TROUBLESHOOTING
SYMPTOM
SYMPTOM CONFIRMATION
EXECUTION
Connected to battery, but
GCU does not respond
• Check battery, If voltage is < 9 Vdc
• Check the battery positive and negative
connection for reversed connection
• Test DC connection terminal for bad contact
• Check DC input protection fuse (F4)
• None of the above
• Change battery
• Correct error
• Correct error
• Change fuse
• Change another GCU-3000
GCU responds normally, but
the starter motor does not
respond
• Check battery, If voltage is < 9 Vdc
• Check the starter motor circuit for incorrect
connection
• Test start output terminal for bad contact
• Check if the starter motor assisting relay
comply with the battery requirement
• Check starter motor assisting relay
• Change battery
• Correct error
• Correct error
• Change starter motor assisting
relay
Start motor responds
normally, but fails to start,
panel appears start failure
• Check fuel level
• Check stop settings
• Check governor and actuator
• Check if fuel solenoid for jamming
• Add fuel
• Reset to correct stop settings
• Change governor or actuator
• Change fuel solenoid
Starter motor disengages
immediately during cranking,
can not start successfully
• Check battery, If voltage is < 9 Vdc
• Check Starter motor circuit
• Check for poor contact from the start signal
terminal
• Check oil pressure sensor
• Change battery
• Correct error
• Correct error
• Change suitable oil pressure
switch or cancel oil pressure
switch to confirm start
starts successfully, but starter
motor does not disengage
• Check AC voltage (5 500 Vac)
• Check AC input protection fuse (F1, F2, F3)
• Check for AC open circuit
• Check oil pressure switch operation
• Check starter motor operation
• Change AVR
• Change fuse
• Correct error
• Change to suitable oil
pressure switch
• Change starter motor
When starter does not
respond, GCU executes stop
• Check oil pressure switch for NO, NC setting
• Check oil pressure switch operation
• Check oil pressure sensor operation
• Correct internal setting
• Change oil pressure switch
• Change GCU exclusive oil
pressure sensor
preheat does not respond
• Check Preheat timer if equal to “0 Zero”
• Check for preheat wiring open circuit
• Correct internal setting
• Correct error
MPU does not respond
• Check MPU operation
• Check open circuit in wiring
• Check MPU signal strength if below +/- 2V
• Change MPU
• Correct error
• Change MPU
Remote start signal initiated
under AUTO, but does not
start
• Check if energize to start and energize to
stop setting
• Check remote start input signal
• Check for starter motor open circuit
• Check start signal output
• Correct internal setting
• Correct error
• Correct error
• Correct error
Page 22
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22 GCU-3000
SYMPTOM
SYMPTOM CONFIRMATION
EXECUTION
Emergency signal does not
erase, can not be started
• Check emergency stop button operation
• Check for wiring open circuit
• Change emergency stop
button
• Correct error
Temperature can not be read
under operation
• Check temperature sensor type
• Check for temperature sensor open circuit
• Check if temperature sensor setting turned
off
• None of the above
• Change GCU exclusive
temperature sensor
• Correct error
• Correct internal setting
• Change GCU exclusive
temperature sensor
Oil pressure can not be read
under operation
• Check oil pressure sensor
• Check for open circuit
• Check system setting if oil pressure sensor
deselected
• Non of the above
• Change GCU exclusive oil
pressure sensor
• Correct error
• Correct internal setting
• Change GCU exclusive oil
pressure sensor
Frequency can not be read
under operation
• Check AC voltage (5 500 Vac)
• Check AC input protection fuse (F1, F2, F3)
• Change AVR
• Change fuse
Under normal operation. The
GCU load current value
differs to the actual
measured current value
• Check internal CT if comply with the external
CT ratio
• Check external CT secondary if ratio equals
to 5A
• Check external CT circuit
• Check system setting internal current reading
and adjustment setting if correct
• Correct CT ratio setting
• Change secondary CT to
value : 5A ratio CT
• Correct error
• Correct internal setting
Module appears overload
failure during operation
• Check system setting if overload failure
setting is reasonable
• Check internal CT if comply with the external
CT ratio
• Check external CT secondary if ratio equals
to 5A
• Check system setting if overload failure
confirmation time is too short
• Correct internal setting
• Correct CT ratio setting
• Correct internal setting
• Correct internal setting
Module appears low oil
pressure warning during
operation
• Check lubricant level
• Check oil pressure switch operation
• Check NO or NC setting
• Check oil pressure sensor operation
• Check for wiring open circuit
• Add lubricant to correct level
• Change oil pressure switch
• Correct internal setting
• Change GCU exclusive oil
pressure sensor
• Correct error
Module appears high water
temperature warning during
operation
• Check temperature
• Check water temperature switch operation
• Check temperature sensor operation
• Check for wiring open circuit
• Correct error
• Change water temperature
switch
• Change GCU exclusive
temperature sensor
• Correct error
Page 23
___________________________________________________________________________________________
GCU-3000 23
SYMPTOM
SYMPTOM CONFIRMATION
EXECUTION
Module appears over voltage
or under voltage warning
during operation
• Check AC voltage
• Check over voltage and under voltage setting
• Check for AC open circuit
• Check AC power input protection fuse (F1,
F2, F3)
• Change AVR
• Correct internal setting
• Correct error
• Change fuse
Module appears over speed
or under speed warning
during operation
• Check governor and actuator operation
• Check MPU operation
• Check AC power input protection fuse (F1,
F2, F3)
• Check 50/60 Hz RPM setting
• Check over speed or under speed setting
• Change governor or actuator
• Change MPU
• Change fuse
• Correct internal setting
• Correct internal setting
can not shut off successfully
when switching to OFF
during operation
• Check cool down setting if over delayed
• Check stop timer setting if too short
• Check if energize to start and energize to
stop setting
• Check for stop open circuit
• Check governor and fuel solenoid operation
• Correct internal setting
• Correct internal setting
• Correct internal setting
• Correct internal setting
• Change governor or fuel
solenoid
Single phase system Voltage
valued normal, but module
appears under voltage failure
warning
• Check system phase setting (1 Phase or 3
Phase)
• Check under voltage setting
• Check AC power input protection fuse (F1,
F2, F3)
• Correct internal setting
• Correct internal setting
• Change fuse
Contactor can not execute,
under normal operation
• Check idle speed timer setting for over delay
• Check load contactor
• Check wiring for open circuit
• Correct internal setting
• Change load contactor
• Correct error
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