Generac Power Systems H-100 manual

PO WER SY STEMS, INC. ® H-100 Contr ol P anel T ec hnical Man ual This manual should remain with the unit.[...]

IM PORT ANT SAFETY INSTRUCTIONS H-1 00 Control Panel T echnical Manual  SA VE 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 install-[...]

T able of Cont ents H-1 00 Control Panel T echnical Manual 1 T able of Cont ents Safety Rules ........................................ Inside Front Cover General Information ......................................................... 2 Introduction .................................................................... 2 F eatures ......................[...]

I NTRODUCTION The H-100 Control P anel is an electronic control box that functions as an advanced standby generator controller . Its technology is based on the flagship PM- DCP 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 inter[...]

3 TH E M EA SU R EM ENT "ENGI N E" 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 out[...]

4 Where x can be: 1. THERMISTOR 2. CURRENT 3. LINEAR 4. PRESSURE 5. UNAL TERED 6. POL Y_3RD 7. POL Y_2ND 8. POL Y_1ST 9. POL Y_1ST_N1 10. POL Y_1ST_N2 11. CAL_SCALE 12. CFM_SENSOR 13. GEN_FP_POL Y 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 [...]

5 IMMEDIA TE = Alarms/W arnings with this qualifica- tion 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[...]

ENGI N E MANA GEM ENT 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 cer[...]

S T ARTING AN D ST OP P I NG - SEQUENCE DIAGRAMS Remote start contacts CLOSED? Start the Engine At load accept limits? Warm up timer expired? Issue load accept signal Remote start contacts OPEN? Cooldown timer expired? Stop the Engine 2-wire Remote Starting and Stopping Sequence Keyswitc h in Auto P osition NOTE: Shutdown Alarms will cause the engi[...]

V OL T A GE R E GU L A T OR (OPTION) All panels include automatic voltage regulation as standard. There are various settings that can be made to the voltage regulator via GenLink. The set - tings are normally factory preset and are shown here for completeness. V oltage KP/KI/KD — V oltage regulation stability constants. PMG — YES indicates a P [...]

Dump Enable — Indicates if extra load dump gov- ernor 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[...]

L OCAL TR EN DI NG 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 di[...]

Generator control is limited to the following output options (referred to as “Hooks”). 1. Use Keyswitch 2. F orce Off – cleared with “Use Keyswitch ” hook 3. F orce Manual – cleared with “Use Keyswitch ” hook 4. F orce Auto – cleared with “Use K eyswitch ” hook 5. F orce Dialout 6. Halt ILC 7. F orce Alarm/W arning #1 8. F orc[...]

> V olts < This is a typical three phase System V oltages page. LINE 1: Phase titles for the voltage and current. LINE 2: Line -to -line voltages in V olts 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 V oltages page. LINE 1: Phase titles fo[...]

> Power < This is a typical System P ower page. LINE 1: T otal system real power in kW . LINE 2: T otal system reactive power in kV AR. LINE 3: T otal system apparent power in kV A . LINE 4: T otal system power factor . > Graph Hz < This is the Generator F requency Graph page. This graph provides a coarse representation of the genera- t[...]

Press the “ENTER ” button. This is a typical System Alarm and W arning page. The n/a indicates there is not an alarm or warning to display on that line. As depicted, this display indi- cates a F uel 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[...]

Press the  button. Press the “ENTER ” button. This is a typical first engine parameter page. The three values on this page are not able to be configured as other values. LINE 1: Oil T emperature (Analog Channel #1) in degrees F ahrenheit. LINE 2: Oil Pressure (Analog Channel #3) in pounds per square inch. LINE 3: Coolant T emperature (Analog[...]

S T A TUS There are two System Status pages. These pages show the system status, system time, and system versions. Do the following to view the system status pages: Press the “MENU” button. Press the  button twice. Press the “ENTER ” button. This is a typical first System Status page. LINE 1: Engine Running Status. It can have the fol- l[...]

“W armed Up, Alarms On ” Generator is started, warmed up, and the hold- off alarms are enabled. “Running ,cooling down ” Generator is still running, but waiting for cool down timer to expire. “Stopping” Generator is running down after being turned off normally . “Stopping due to Alrm ” Generator is running down after being turned of[...]

Each line displays a maintenance item that has been set up via GenLink. The value displayed is the approximate % of life remaining before maintenance should be performed. Refer to the Maintenance setup using GenLink. Press the “ENTER ” button. This is a typical third Maintenance Status page. Each line displays a maintenance item that has been s[...]

This is a typical first Generator P arameter page for a single phase system. 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 V olts RMS. LINE 3: Neutral current and Line currents in Amps RMS. LINE 4: Generator frequency in Hz follow[...]

This is a typical first System Diagnostics page. It dis- plays ten of the discrete inputs into the H-100 Control P anel. Inputs to the controller are internally pulled to 5 v , so to activate an input you must short it to ground.The following names are normally assigned to these inputs: #1 K ey switch in A UTO position #2 K ey switch in MANU AL pos[...]

Press the “ENTER ” button. Press the “ENTER ” button. The above two pages are typical of communications diagnostics, one page for each port. The LCD display will show four lines of information about the port: LINE 1: W ill show the type of port protocol that has been selected. It will also show the Modbus address (if appropriate) and whethe[...]

This is a typical third Internal Exercise and HTS page. LINE 1: The left side shows the HTS switch number that the data on this page applies to. This field is editable in that switch numbers 1 – 4 can be selected. The Switch number selected on this page also selects the switch to use for the Left Display Switch Mimic diagram if that switch is ena[...]

23 23 page also selects the switch to use for the Left Display Switch Mimic diagram if that switch is enabled. In addition, it is the selected switch number for the pre - vious page, and for the remote annunciator lights for generator power and line power . The right side of the first line is the enable state of the HTS. It is editable and can have[...]

The event log, as its name implies, is designed to store events which are programmable from GenLink. Each measurement channel or output function can be set as an event along with a setpoint. F or example, if you set Digital Input #1 (the keyswitch in A UTO position) as an event with a setpoint of logical one, each time the keyswitch is set in the a[...]

25 I NTER NAL EXERCISE F U NCTION Generators best maintain their readiness by being exercised once per week. This prevents the machine from stagnating and provides an opportunity to dis- cover any maintenance items that may need service before the unit is actually needed for emergency power . In the past, the generator had to be exercised manually [...]

Select the day of week to run the exercise. Select the time of day to run exercise. Click on “QuietT est®” to enable the exercise mode with reduced sound levels. Press “ Apply”. Setup of QuietT est® is now complete. F or this exam- ple, QuietT est® will start every W ednesday at 10:30 AM and run until about 10:50 AM NOR MAL EXERCISE SE T[...]

27 Select the time of day to run exercise. V erify “QuietT est®” is not checked. P ress “ Apply”. Setup of Normal exercise is now complete. F or this example, exercise will start every W ednesday at 10:30 AM and run until about 10:50 AM If exercise of the HTS is desired, Click on “Transfer on exercise” to enable transferring of the loa[...]

Use the up and down arrow keys until a “Y ” appears in the field. Press the “ENTER ” button to exit edit mode. Move the cursor to the “Time Start ” day of week field on the second line. Press the “ENTER ” button to enter edit mode. Use the up and down arrow key until the desired day of the week is displayed. Press the "ENTER&qu[...]

29 Move the cursor to the “Time Start ” time of day min- utes field on the second line. Press the “ENTER ” button to enter edit mode. Use the up and down arrow key until the desired minute of the hour is displayed. Press the “ENTER ” button to exit edit mode. Move the cursor to the  on the bottom line. Press the “ENTER ” button t[...]

Setup of QuietT est® is now complete. F or this exam- ple, QuietT est® will start every W ednesday at 10:30 AM and run until about 10:50 AM While QuietT est® is running, the “Time Remaining” will display the approximate number of minutes left before QuietT est® is completed. NOR MAL EXERCISE SE TU P USI NG F RONT P AN EL Press the “MENU?[...]

31 Use the up and down arrow key until the desired day of the week is displayed. Press the "ENTER" button to exit edit mode. Move the cursor to the “Time Start ” time of day hours field on the second line. Press the “ENTER ” button to enter edit mode. Use the up and down arrow key until the desired hour of the day is displayed. NO[...]

Press the “ENTER ” button to exit edit mode. Move the cursor to the  on the bottom line. Press the “ENTER ” button to move to the second page. Move the cursor to the “QuietT est Selected” field on the first line. Press the “ENTER ” button to enter edit mode. Use the up and down arrow key until a “N” appears. Press the “ENTE[...]

33 Use the up and down arrow key until a “Y ” appears. Press the “ENTER ” button to exit edit mode. Setup of Normal Exercise with transfer to load dur - ing exercise is now complete. F or this example, exer- cise will start every W ednesday at 10:30 AM and run until about 10:50 AM. However , the HTS settings may change this time. While norm[...]

Press the  button twice. Press the “ENTER ” button. There are 5 editable fields on line 3. They are hours, minutes, month, day , and year . Use the arrow keys to move to each of the fields needing to be changed. Press enter to begin edit mode. Use the up and down arrow keys to slew to the desired value. Press enter to exit edit mode or use t[...]

35 Use the arrow buttons to change the contrast value (range is 00 to 37). Pressing the “HOME” button while in edit mode will return the value to the last entered value. Press the “ENTER ” button to exit edit mode. The contrast is now set and can only be changed by editing the value on this page. ENAB LE GEN ER A C C OM M ERCIAL TR ANSF ER [...]

Press the  button. Press the “ENTER ” button. Press the  button. Press the “ENTER ” button. This is the HTS enabling/disabling page. The HTS number needs to be selected first. Press the  button to go to the HTS # field. Press the “ENTER ” button to enter the edit mode. Select the appropriate HTS number using the up and down arr[...]

37 37 F or this example, HTS number 1 is now enabled. If HTS #1 is not connected or if the HTS is not #1, there will be a communications error indicated. C OMMUNI CA TI O N S There are 2 ports on the H-100 Control P anel, an RS -232 port and an RS -485. Each port can be recon- figured as to its function, however there can only be one master Modbus [...]

38 AP P EN DIX A — ANAL OG F U NCTIONS The User Configurable Analog Inputs have several parameters that affect the value interpreted from the A/D reading . In general, the following equation determines the final User Configurable Analog Input result: Result = Scale (F unction (Calibrate (Raw A/D read- ing))) F or functions that require 4 coeffici[...]

39 Where: M is the calibration factor A , B, C are polynomial coefficients S is the scaling factor Calibration = M * 1024 Coefficient 3 = C Coefficient 2 = B * 1024 Coefficient 1 = A Scaling = S * 1024 POL Y_1ST_N2: First order polynomial with 4 coefficients and a scal- ing factor X = raw_analog (A + BX + CX-1 + DX -2) * S Where: A , B, C, D are po[...]

AP P EN DIX B — H-1 00 GEN ER AL I/O AN D CONN ECT OR I N FORMA TION H-1 00 ANAL OG INPUT S Number Default Signal Name Default Signal Name T ype Connector Pin 1 OIL TEMP Oil T emperature 4-20 ma J1-9 source, J1-8 return 2 COOLANT TEMP Coolant T emperature 4-20 ma J1-15 source, J1-31 return 3 OIL PRESSURE Oil Pressure 4-20 ma J1-20 source, J1-19 r[...]

H-1 00 DIGIT AL OUTPUTS H-100 GenLink Number Number Signal Description Connector Pin 1 1 Starter Relay (reserved) J1-23 2 2 Fuel Relay (reserved) J1-1 1 3 3 Fault Relay (reserved) J1-34 4 4 13.3L Gas Relay (reserved for ILC on 13.3L gas) J1-22 5 5 Auxiliary #1 J2-23 6 6 Auxiliary #2 J2-22 7 7 Auxiliary #3 J2-33 8 8 Auxiliary #4 J2-21 9 9 13.3L Igni[...]

H-1 00 DIGIT AL OUTPUT F U NCTIONS Number Default Function Name Function Description 1 COMMON ALARM An alarm is active 2 COMMON W ARNING A warning is active 3 GEN RUNNING Generator is running 4 ALARMS ENABLED All alarm hold off delays have expired, so all alarms are enabled 5 READY FOR LOAD Generator is warmed up and ready to accept power loading 6[...]

43 Number Default Function Name Function Description 42 ANALOG 6 HI W ARN Analog Input #6 has gone above maximum warning limit FUEL PRS HI W ARN Fuel Pressure INL T TMP HI W ARN Inlet Air T emperature 43 ANALOG 6 LO W ARN Analog Input #6 has gone below maximum warning limit FUEL PRS LO W ARN Fuel Pressure INL T TMP LO W ARN Inlet Air T emperature 4[...]

44 Number Default Function Name Function Description 63 BA T VOL T LO W ARN Battery V oltage has gone below maximum warning limit 64 A VG CURR HI ALRM A verage Current has gone above maximum alarm limit 65 A VG CURR LO ALRM A verage Current has gone below minimum alarm limit 66 A VG CURR HI W ARN A verage Current has gone above maximum warning limi[...]

Number Default Function Name Function Description 103 CHCK V PHS ROT Detected voltage phase rotation as not being A-B-C 104 CHCK C PHS ROT Detected current phase rotation as not being A-B-C and not matching voltage 105 F AUL T RL Y ACTIVE Audible alarm/warning signal is active. 106 USR CONFIG 106 GenLink controlled: GenLink front panel radio button[...]

H-1 00 CONN ECT OR PI N DES CRI PTIONS J1 Wir e Signal Description J2 Wir e Signal Description 1 CAN (rtn) CAN Bus 1 391 RS485 (-) Diagnostic/Rem-An/HTS 2 CAN (+) CAN Bus (+) 2 388 RS232 (tx) GenLink 3 810 Gnd Modem Power (-) 3 IN7 IN (DB) 7 DI-3/Line Power 4 805 AN8 (rtn) Emissions Sensor/ 4 183 IN (DB) 4 Remote Start Fluid Basin Level 5 804 AN8 ([...]

AP P EN DIX C — M IS CELL AN E OUS H-1 00 I NTER NAL AL AR MS/W ARN I NGS “Strt Inhib:Oil” – Oil pressure is higher than expected for a stopped engine. “Overcrank” – Generator has attempted to start the designated number of times without success. “Mult Def Digtl” – More than one Digital Output F unction is assigned to the same D[...]

48 Notes H-1 00 Control Panel T echnical Manual[...]

49 Notes H-1 00 Control Panel T echnical Manual[...]

Part No. 0F3750 GENERAC ® POWER SY STEMS, INC. P .O. BOX 8 W AUKESHA, WI 53187 Revision A (03/13/06) Printed in U.S.A .[...]