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C6200 FlexGen
Generator Controller
Installation Manual
!
4560 River Bottom Drive
Norcross, GA 30092
P: +1-770-455-9110
W: SELCOUSA.com
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Selco C6200 FlexGen
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Table of Contents
1 Preface..........................................................................................................................................3
2 Front View ...................................................................................................................................4
3 Installation....................................................................................................................................5
4 Isolation and Grounding ..............................................................................................................6
5 Connections..................................................................................................................................7
5.1 Power Supply ........................................................................................................................... 7
5.2 Voltage Inputs..........................................................................................................................8
5.3 Current Inputs ........................................................................................................................10
5.4 Programmable Inputs ............................................................................................................. 12
5.5 Analogue Inputs ..................................................................................................................... 14
5.5.1 Voltage Input .....................................................................................................................14
5.5.2 Frequency Input .................................................................................................................14
5.6 Parallel Lines .........................................................................................................................15
5.7 GOV/AVR Control ................................................................................................................16
5.8 Inputs......................................................................................................................................18
5.8.1 C/B .....................................................................................................................................18
5.8.2 Manual ...............................................................................................................................18
5.8.3 Unload................................................................................................................................18
5.8.4 Reset................................................................................................................................... 18
5.8.5 F/V Ctrl. Disable................................................................................................................18
5.8.6 Dead Bus lock .................................................................................................................... 19
5.9 Relays..................................................................................................................................... 19
5.9.1 C/B Close ........................................................................................................................... 19
5.9.2 Protection Trip ...................................................................................................................19
5.9.3 Unload Trip........................................................................................................................20
5.10 Programmable Outputs ..........................................................................................................20
5.11 Analogue Outputs ..................................................................................................................20
5.12 Alarm .....................................................................................................................................21
5.13 RS485.....................................................................................................................................22
5.14 CAN bus.................................................................................................................................23
6 Specifications:............................................................................................................................24
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1 Preface
The Littelfuse Selco C6200 FlexGen provides integrated generator protection, frequency
stabilization, voltage stabilization, check and automatic synchronisation, voltage matching, active
and reactive load sharing, basic and programmable I/O and data acquisition.
The Littelfuse Selco C6200 FlexGen can operate in parallel with other C6200 FlexGen modules and
interface with the C6500 User Interface Module via the on-board RS232 interface. SCADA and
HMI systems can be connected via the RS485 MODBUS interface.
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2 Front View
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3 Installation
The C6200 FlexGen must be secured to the rear of the switch board using four 5 mm. screws. DIN
rail mounting is not advisable due to the weight.
Please ensure that enough space is given around the module so that the plug-in terminals can be
removed and reinserted without stressing the wires. The length of the cables should allow for the
easy removal and insertion.
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4 Isolation and Grounding
In marine installations ground (switchboard chassis) and common reference (COM) should not be
connected together. In a marine installation the vessels hull is considered as “ground”.
Connecting any of the COM connections on the C6200 FlexGen to ground (hull) or switchboard
chassis may cause electrical noise to be injected into the system.
The general rule is:
COM terminals should not be connected to ground (vessels hull) or to the switchboard chassis.
Negative poles of the power supplies should not be connected to ground (vessels hull) or to the
switchboard chassis.
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5 Connections
The C6200 FlexGen is wired up through plug-in terminals. The plug-in terminals provide safe and
durable connections without sacrificing ease of installation and servicing. One exception is the
inputs for the currect transformers, which are fixed terminals to avoid shock from accidental
disconnection of live current inputs.
5.1 Power Supply
The circuitry of the the C6200 FlexGen must be powered by a single external power supply. The
supply must provide a nominal voltage of +24 V DC. The C6200 FlexGen will tolerate relatively
wide variations in the supply voltage (please refer to the specifications). The supply is connected to
terminal 30 and 32 of the AUX SUPPLY plug-in connector.
Terminal
Signal
Description
30
+24 V DC
Positive terminal of primary supply
31
FREE (unused / no connection)
32
-24 V DC
Negative terminal of primary supply
The auxiliary power supply is not isolated from the remaining circuitry. This means that the supply
reference terminal (terminal 32) has connection to the module’s COM terminal.
The front AUX SUPPLY LED illuminates with a steady green light to indicate that the supply
voltage is OK and within the tolerated limits for safe operation.
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External switching of the supply (e.g. to power the units on and off) should be done by making
or braking positive supply (terminal 30). Do not use terminal 32 to make and break the
supply.
5.2 Voltage Inputs
The AC voltages connect to the BUS BAR VOLTAGE and GENERATOR VOLTAGE plug-in
terminals.
The voltage inputs can operate with high voltage (up to 690 V AC nominal), so precaution
must be taken to avoid electrical shock and personal injury. Do not touch the voltage input
plug-in terminal unless you are absolutely sure that both the busbar and generator is off. The
generator should be stopped and blocked against starting – the busbar should be dead. Also
make sure that there is no risk of another power source being connected to the busbar while
you are working with the voltage inputs.
Voltages above 690 V AC are supported through use of external transformers (PT). When using
PTs please ensure that the PT does not affect the phase of the AC voltage measurement. Phase shift
in the PT will directly affect the calculation of power factor, and thereby the calculation of active
and reactive currents and loads.
The phases L1, L2 and L3 of the busbar and generator voltage must be connected to L1, L2 and L3
of the busbar/generator voltage input plug-in terminals. Intermediate 2 A slow-blow fuses should be
inserted between the individual phases and the related voltage inputs.
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It is important that the phases are connected in the correct order (correct phase sequence).
Interchanging the phases will result in an incorrect power factor calculation and thereby incorrect
calculation of active/reactive currents and loads. It is important that the phases are connected to the
corresponding terminals (phase 1 to L1, phase 2 to L2 and phase 3 to L3).
Terminal
Signal
Description
5
AC voltage
Generator phase L1
6
AC voltage
Generator phase L2
7
AC voltage
Generator phase L3
The BUSBAR VOLTAGE LED shows (by steady light) whether the voltage levels measured
between the phases are within limits. The reference is the nominal phase-phase voltage
(NOMVOLT) that has been entered in the configuration. The toleance is defined by the voltage OK
window (VOLTOKWND) also present in the configuration.
The same scheme applies to the GENERATOR VOLTAGE LED. However, on older versions of
the C6200 FlexGen the LED will also flash while the generator breaker is open. This depends on
the firmware revision.
Terminal
Signal
Description
1
AC voltage
Bus bar phase L1
2
AC voltage
Bus bar phase L2
3
AC voltage
Bus bar phase L3
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5.3 Current Inputs
The C6200 FlexGen measures current through external current transformers (CTs). The C6200
FlexGen supports 5 A CTs. Class 1 CTs for protection is recommended. The CTs can be shared
with third-party equipment provided that this equipmed due not place a burden on the CTs (that the
CT inputs are isolated by e.g. transformers inside the third-party equipment).
The CT ratio should cover the maximum current of the generator.
The CTs must be capable of coping with limited time short-circuit currents without going into
saturation (Protection Transformers).
The external CTs connect to the GENERATOR CURRENT terminals. It is important to ensure that
the direction of the current flow is correct. The current flow is usually indicated by S1 and S2
notations on the CT enclosure. S1 of the CT on phase 1 connects to terminal 9 and S2 connects to
terminal 10.
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Terminal
Signal
Description
9
AC current
S1 of the CT on phase L1
10
AC current
S2 of the CT on phase L1
11
AC current
S1 of the CT on phase L2
12
AC current
S2 of the CT on phase L2
13
AC current
S1 of the CT on phase L3
14
AC current
S2 of the CT on phase L3
Make sure that the secondary side of the CT is shorted (make a connection between S1 and
S2) before you disconnect the CT cables from the GENERATOR CURRENT terminals.
Please note that incorrect connection of the current transformers (e.g. by reversing the terminals S1
and S2) will result in wrong current, power and power factor readings.
Correct measurement of the current is extremely important. The C6200 FlexGen relies upon the
current measurements for the calculation of power factors, active currents and loads, reactive
currents and loads, integrated protection functions and load sharing.
Connection of bus & generator voltages and currents
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5.4 Programmable Inputs
The programmable input connector provides a number of digital inputs. The digital inputs work
with negative reference (COM), meaning the inputs are considered active when they are connected
to minus supply, and inactive when left open (disconnected). The inputs are used for external
activations of various programmable features. The functions are described in the C6200 FlexGen
Configuration Manual.
Terminal
Signal
Description
15
NO contact to COM
Programmable input 1
16
NO contact to COM
Programmable input 2
17
NO contact to COM
Programmable input 3
18
NO contact to COM
Programmable input 4
19
NO contact to COM
Programmable input 5
20
NO contact to COM
Programmable input 6
21
NO contact to COM
Programmable input 7
22
NO contact to COM
Programmable input 8
23
FREE
Example for connection of a digital input:
The figures on the next page show the programmable inputs and outputs being used for control of a
conventional speed governor (with increase descrase relay pulses) and for load depending start and
stop.
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Programmable inputs and outputs used for control of conventional speed governor.
Programmable inputs and outputs used for load depending start and stop.
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5.5 Analogue Inputs
The analogue inputs are used for external control of voltage, frequency and load. For example, the
analogue inputs can be used when two busbar sections are to be synchronized together or when the
gerator is to be synchronized to an incoming sharft generator (or the grid). The analogue inputs can
also be used in case the load of the generator needs to be remotely controlled e.g. in grid paralleling
application.
5.5.1 Voltage Input
The voltage input (terminal 24) is an analogue input. The input can be used for external control of
the generator voltage, provided that the F/V CTRL. DISABLE input has been activated (connected
to COM) or a grid parallel operation scheme is activated. The analogue control signal must be a
voltage between 0 and +5 V DC. The voltage input uses the COM terminal as reference. When not
used its is recommended that the voltage input is connected to COM. This is especially important if
the F/V CTRL. DISABLE input is made active while no signal is provided to the voltage input.
Terminal
Signal
Description
24
0 to +5 V DC
Remote Voltage Control
26
COM
Common reference
Please note that terminal 26 (COM) is internally connected to terminal 32 (Supply minus). In
rare situations “gound loops” can cause noise to be injected into the application. Ground
loops happen when multiple COM connections between modules (e.g. parallel operating
C6200 units) exist. Ground loops can be avoid by only using terminal 32 as the common
connection point for all COM connections.
5.5.2 Frequency Input
Like thr voltage input, the frequency input is an analogue input. The input can be used for external
control of the generator frequency, provided that the F/V CTRL. DISABLE input is active
(connected to COM) or a grid parallel operation scheme is activated. The analogue control signal
must be a voltage between 0 and +5 V DC. The frequency input uses the COM terminal as
reference. When not used its is recommended that the frequency input is connected to COM. This is
especially important if the F/V CTRL. DISABLE input is made active while no signal is provided
to the frequency input.
Terminal
Signal
Description
25
0 to +5 V DC
Remote Frequency Control
26
COM
Common reference
Please note that terminal 26 (COM) is internally connected to terminal 32 (Supply minus). In
rare situations “gound loops” can cause noise to be injected into the application. Ground
loops happen when multiple COM connections between modules (e.g. parallel operating
C6200 units) exist. Ground loops can be avoid by only using terminal 32 as the common
connection point for all COM connections.
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5.6 Parallel Lines
The parallel lines are used for balancing the active and reactive currents/loads between parallel
running C6200 FlexGen modules. The signal level of the parallel lines can also be adapted to suit
other types of Littelfuse Selco load sharers (e.g. the Littelfuse Selco T4800).
Terminal
Signal
Description
27
DC voltage
kW BALANCE of other FLEXGEN
modules
28
Common reference
COM of the other FLEXGEN modules
29
DC voltage
kVAr BALANCE of other FLEXGEN
modules
Please note that terminal 28 (COM) is internally connected to terminal 32 (Supply minus). In
rare situations “gound loops” can cause noise to be injected into the application. Ground
loops happen when multiple COM connections between modules (e.g. parallel operating
C6200 units) exist. Ground loops can be avoid by only using terminal 32 as the common
connection point for all COM connections.
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5.7 GOV/AVR Control
Two sets of analogue outputs are provided for the control of speed and voltage. The analogue
outputs are intended for direct control of electronic speed governors and AVRs. Each analogue
output can be configured to provide either a DC voltage within the range of -10 to +10 V DC, a DC
current within the range of 0 to 20 mA or a PWM signal with a default base frequency of 500 Hz.
The analogue outputs are isolated from each other and from the remaining circuitry. This means
that the references of the outputs have no connection to each other or to the common reference
(COM).
Terminal
Signal
Connection
33
reference (isolated)
Governor reference
34
PWM signal
Governor PWM input
35
DC current
Governor current input
36
DC voltage
Governor voltage input
37
reference (isolated)
AVR reference
38
PWM signal
AVR PWM input
39
DC current
AVR current input
40
DC voltage
AVR voltage input
It is important to note that each analogue output is protected against short circuit by an internal 10
kΩ resistor. The resistor is located inside the C6200 and placed in series with the output. The output
resistor might affect the magnitude of the output signal if the internal resistance of the external
equipment (e.g. the aux speed input of the governor) is low. The principle of voltage division
applies between the output resistor and the internal resistance of the external equipment. Most
governors and AVRs have high impedeance inputs, so the 10 kΩ resistance will typically not be an
issue.
Example: A governor with aux speed input having an internal resistance of only 10 kΩ would
reduce a +10 VDC output voltage to +5 VDC. The two 10 kΩ resistors in series would make a 1:2
voltage divider.
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C6200 FlexGen controlling electronic speed governor by a DC voltage.
C6200 FlexGen controlling ECU by a PWM signal.
Note that the amplitude of the PWM signal is determined by the configuration of the DC
voltage output range (e.g. 0 to 10 V DC).
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5.8 Inputs
The inputs plug-in connector houses a number of general purpose inputs. The inputs work with
negative reference, meaning that the inputs are considered active when connected to negative
supply and inactive when disconnected.
Terminal
Signal
Description
41
C/B
External switch, output or relay
42
Manual
External switch, output or relay
43
Unload
External switch, output or relay
44
Reset
External switch, output or relay
45
F/V Ctrl Disable
External switch, output or relay
46
Dead Bus Lock
To be interconnected with the Dead Bus Lock terminals of each
C6200 FlexGen module in the system
5.8.1 C/B
The C/B input provides feedback from the generator circuit breaker and is used to determine wether
the breaker is open or closed. C/B is typically connected to COM through an auxiliary contact of
the breaker. The breaker is considered closed when the C/B input is at COM level.
Please note that the C/B input is very important to the function of the C6200 FlexGen. The
C/B input is used (together with the state af the voltage inputs) to determine the operational
situation of the system.
5.8.2 Manual
Activating the manual input will prevent the C6200 FlexGen from interfering with the speed and
voltage controls of the generator, unless it gets a command to do so via the programmable inputs
(terminals 15 to 22). The manual input is active when at COM level and inactive if left
disconnected.
5.8.3 Unload
The UNLOAD input is used to initiate a controlled unload of the generator whereafter the C6200
FlexGen will issue a trip signal to the breaker. Unload starts when the signal is put to COM level.
Disconnecting the unload signal during operation will causes reload and/or reconnection of the
generator.
5.8.4 Reset
Reset Alarm is used to reset the alarm relay. Reset Alarm is active when the input is at COM level.
5.8.5 F/V Ctrl. Disable
The F/V CTRL. DISABLE input is used to deactivate the voltage and frequency stabilization. This
input is considered active when the input is connected to COM level, and inactive when
disconnected. The signal is typically used when the generator is operated in parallel with a shaft
generator or the grid (power sources that determine the voltage and frequency). Other applications
are where the voltage and frequency is controlled by third-party equipment (through the voltage and
frequency analogue inputs on terminals 25 and 26).
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5.8.6 Dead Bus lock
The dead bus lock signal is used to prevent more than one generator from connect simultaneously to
a dead bus bar (e.g. in a blackout situation).
The Dead Bus Lock signal (terminal 46) must be interconnected between all C6200 FlexGen
modules that operates generator connecting to the same busbar.
Wiring of Dead bus Lock signal
5.9 Relays
5.9.1 C/B Close
The C/B close relay is a change-over relay intended for control (Closure) of the generator circuit
breaker. The C/B close relay has two contact sets and is normally de-energized by default. Note that
this relay can be reconfigured to normally energized operation.
Terminal
Signal
Description
47
Relay de-energized position
Breaker remote close
48
Relay contact
Signal source
49
Relay energized position
Breaker remote close
5.9.2 Protection Trip
The protection trip relay is a change-over relay intended for tripping the circuit breaker in case of a
protection fault (e.g. over-curremt or reverse power). The built-in protection trip relay has two
contact sets and is normally energized by default. Note that the protection trip relay can be
reconfigured to normally energized operation.
Terminal
Signal
Description
50
Relay de-energized position
Breaker remote trip
51
Relay contact
Signal source
52
Relay energized position
Breaker remote trip
The protection trip relay connects to the remote trip input of the generator circuit breaker.
Terminals 50 and 52 are typically not connected at the same time. Only one of these signals is taken
to the breaker, depending on whether the Protection Trip relay is configured for normally energized
or de-energized operation.
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5.9.3 Unload Trip
The unload trip relay connects to the remote trip input of the generator circuit breaker. Terminals 52
and 55 are typically not connected at the same time. Only one of these signals is taken to the
breaker, depending on whether the unload trip relay is configured for normally energized or deenergized operation. The unload trip relay disconnects the circuit breaker after the generator has
been unloaded by the unload function.
Terminal
Signal
Description
53
Relay de-energized position
Breaker remote trip
54
Relay contact
Signal source
55
Relay energized position
Breaker remote trip
5.10 Programmable Outputs
The programmable outputs are potential free relay outputs (Normally opened). The common
reference of all programmable outputs is terminal 64 (REF). The outputs are used for indication and
control of external equipments (e.g. common alarms or speed/voltage control relay pulses).
Terminal
Signal
Description
56
Normally open relay output
Programmable output 1
57
Normally open relay output
Programmable output 2
58
Normally open relay output
Programmable output 3
59
Normally open relay output
Programmable output 4
60
Normally open relay output
Programmable output 5
61
Normally open relay output
Programmable output 6
62
Normally open relay output
Programmable output 7
63
Normally open relay output
Programmable output 8
64
COM
Reference
5.11 Analogue Outputs
The analogue outputs are intended for use with analogue meters or external indication equipment.
Each of the two outputs can be individually configured in relation to any one of the measured or
calculated parameters provided within the C6200 FlexGen.
Each analogue output can be configured to provide a DC voltage within the range of -10 to +10 V
DC. The two outputs both uses COM as reference.
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Terminal
Signal
Description
65
DC voltage
External voltage input
66
DC voltage
External voltage input
67
Reference (COM)
Internal reference
It is important to note that each analogue output is protected against short-circuit by an internal 10
kΩ resistor. Resistors are placed in series on the output terminal. The output resistor might affect
the magnitude of the output signal if the internal resistance of the driven equipment is low. The
principle of voltage division applies between the output resistor and the internal resistance of the
driven equipment. Example: equipment with an internal resistance of only 10 kΩ would reduce a
+10 VDC output voltage to +5 VDC. The two 10 kΩ resistors in series would make a 1:2 voltage
divider.
5.12 Alarm
The alarm relay includes two contact sets. The alarm relays can only operate as normally energized
relays. This is to ensure that the alarm relay will trip in case the supplies fail.
The alarm relay can also be configured to trip on a protection fault.
Terminal
Description
Signal
Connection
68
Alarm Contact
Relay de-energized position
Alarm system
69
Alarm Contact
Relay contact
Signal source
70
Alarm Contact
Relay energized position
Alarm system
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5.13 RS485
The C6200 FlexGen module includes an isolated RS485 interface.
Terminal
Description
Signal
Connection
Left
A -
RS485 A
B signal of the RS485 bus
Middle
B +
RS485 B
A signal of the RS485 bus
Right
REF
Reference (isolated)
Reference of the RS485 bus
It is important to note that the RS485 reference is isolated from the common COM of the module.
The 3-wire RS485 bus is connected from module to module.
A RS485 bus needs termination resistance (150 Ω) between terminals A and B at end end of the
cable. It is not necessary to connect external termination resistors as the C6200 FlexGen contains
internal resistors that can be enabled by toggeling DIP switch 5 to ON position. The termination
resistor must be enabled only on the first and on the last unit on the RS485 bus.
The maximum cable length for RS485 is 1.000 meters. The cable must be twisted pair (A and B
twisted inside the cable). The cable should be shielded. One end of the shield (and only one end)
nust be connected to switchboard chassis.
Cri abT Cable KB81P1E-DEXN/BT can be used
It is sometimes necessary to fix the potential of the RS485 + and – lines due to interference from
other sources. This is done with two 1 kΩ resistors using a technique called “Biasing”. One resistor
is fixed between RS485 B and an external +5 V DC supply, the other is fixed between RS485 A and
the reference of the -5 V DC supply. The reference of the 24 VDC (terminal 32) supply must then
be connected to rightmost terminal of the RS485 plug on each and every module.
PLC
Set 7 Dip-switch
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5.14 CAN bus
The CAN bus is used in connection with the load dending start/stop features of the C6200 FlexGen.
The CANbus terminals are located on the front plate in the right side. The terminals are module
standard used in Data communication equipment. Therefore, use standard twisted pair patch cable
for CANbus wiring. The maximum cable length is 40 meters. The cable type should be 0.25 - 0.34
mm2(AWG23/AWG22). Cable resistance should be less than 26 mΩ per meter.
The first and the last module on the CANbus need a termination resistor (150 Ω) between lines A
and B. It is not necessary to connect external resistors. The C6200 FlexGen contains internal end of
line resistors for the CAN bus that can be activated by toggeling DIP switch 6 to ON position.
Therefore, on the first and on the last unit on the CAN bus, DIP switch 6 has to ON. Every C6200
FlexGen module must be connected to the same CAN bus network. Third party CAN nodes may
not be connected to the FLEXGEN CAN bus.
RJ45 Connector for CAN bus:
150Ω resistor
via dip switch
150Ω resistor
Set 8 dip-switch
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6 Specifications:
Voltage supply : 10 VDC to 36 VDC (24VDC -58% / +50%)
Generator Voltage 63V to 690V
Generator rated frequency 50Hz/ 60Hz
Generator max current 30.000A
Current transformer secondary current 5A
Power Consumption 7W
Ambient temp range -20 ºC / +70 ºC
Vibration: IEC 60068-2-6
Humidity: IEC 60068-2-30
EMC: IEC 61000-4-3:2006, IEC 61000-4-6:2004, IEC 61000-4-
5:2005, IACS E10:2006 Test No.15, CISPR 16-1:1999,
CISPR 16-2:2002
Relay contacts 230VAC / 2A & 30VDC / 2A
External communication MODBUS RTU
Programmable digital inputs 8
Programmable digital outputs 8
Programmable analogue outputs 2
Current measurement 3 phase
Enclosure: IP20
Weight 1,5 Kg
3.31Lbs/
Dimension (mm) 282 x 182 x 50mm Inch .1 97x7.17x11.10/
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