USER MANUAL FOR EG1298 FIXED SPEED … · BTS Base Transceiver Station ... Table 8 : Table for shutdown and warning alarms ... 2G in X, Y and Z as per IEC 60068-2-6 Humidity

USER MANUAL FOR

EG1298 FIXED SPEED

CONTROLLER Product Manual Revision # 1.00

ABSTRACT This manual is intended as

an information guide for

operating SEDEMAC's

EG1298 fixed speed governing

solution.

Doc #SED-MAN-EG1298-002 Date: 11-Sep-2017

Copyright

All rights reserved. No part of this publication may be reproduced, distributed or transmitted

by any means (including photocopying or storing in any medium by electronic means or other)

without the prior written permission of the copyright holder. Any reference to trademarked

product names used within this publication is owned by their respective companies.

SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document

without prior notice. For permission requests and applications to reproduce any part of this

publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned

contact details.

SEDEMAC Mechatronics Pvt. Ltd. C9-10, C Block, MIDC Bhosari Pune 411026, INDIA Web Support: Email: [email protected] Website: www.sedemac.com Telephonic Support: +91-20-67313500 +91-8551039888 +91-8551041888 +91-8551043888

mailto:[email protected]

http://www.sedemac.com/

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Safety Instructions

General Instructions ✓ This document includes important instructions that should be followed during installation and mainte-

nance of the Generator Set controller.

✓ For safety reasons, the manufacturer recommends that this equipment be installed and serviced by

an Authorized Service personnel. Follow all applicable state and local electrical codes.

✓ Efficient and safe operation of the controller can be acquired only if the equipment is correctly oper-

ated and maintained. Many accidents arise due to ignorance or illiteracy towards the elemental rules

of safety and precautions.

The following safety notations found throughout this document indicate potentially hazardous conditions to the

operator, service personnel or the equipment.

• Highlights an essential element of a procedure to ensure correctness

• Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment

• Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly

Electrical safety ✓ Electric shock can cause severe personal injury or death.

✓ Ensure the generator set must be grounded before performing any installation or service.

✓ Generators produce high electrical voltages direct contact with it can cause fatal electrical shock. Pre-

vent contact with terminals, bare wires, connections, etc., while the generator and related equipment

are running. Do not tamper with interlocks.

✓ To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wir-

ings must be appropriate to which they will be subjected to.

In operation safety ✓ Before installing Genset controller, ensure that all power voltage supplies are positively turned off at

their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental

start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first. Re-

connect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical

shock.

✓ Remove electric power supply before removing controller or touching other electrical parts.

✓ Use extreme caution when working on electrical components. High voltage can cause injury or death.

✓ Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when

working near Generator set or other electrical equipment.

✓ Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling

electrical equipment.

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✓ Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or

feet are wet. IT MAY RESULT IN SEVERE ELECTRICAL SHOCK.

✓ Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock

or burning.

✓ In case of an accident caused by electric shock, immediately shut down the electrical power source. If

this is not possible, try to release the victim from the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the

live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

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List of Abbreviation This list contains the list of acronyms used in this document and it can be used to refer their respective description. This List Does not contain units of measure.

Acronym Description

AC Alternating Current

ACK Acknowledge

ALT Alternator

AMF Auto Mains Failure

AUX Auxiliary

BTS Base Transceiver Station

CHG Charging

CKT Circuit

CT Ratio Current Transformer Ratio

DC Direct Current

DG Diesel Generator

DIG IN Digital Input

ENG TEMP Engine Temperature

GCU Genset Control Unit

Genset Generator Set

GND Ground

HMI Human Machine Interface

HSD High Side Driver

HWT High Water Temperature

LCD Liquid Crystal Display

LED Light Emitting Diode

LLOP Low Lube Oil Pressure

LOP Lube Oil Pressure

LVL Level

MCP Manual Control Panel

MPU Magnetic Pickup Unit

OV Over Voltage

PID Proportional Integral Derivative

PWM Pulse Width Modulation

RMS Root Mean Square

RPM Revolutions Per Minute

R-Y-B Red-Yellow-Blue

SCP Sensor Common Point

SMD State Machine Diagram

TEMP Temperature

USB Universal Serial Bus

UV Under Voltage

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Table of Contents 1 Introduction .......................................................................................................................... 9

1.1 Features .......................................................................................................................... 9

2 System Components ........................................................................................................... 9

2.1 EG1298 Controller .......................................................................................................... 9

2.2 Actuator ......................................................................................................................... 10

2.3 O/E/N Relays: 741-12-1A-25A ...................................................................................... 10

3 Configurations ................................................................................................................... 11

3.1 Terminals diagram ......................................................................................................... 12

3.2 Circuit Diagram ............................................................................................................. 13

3.3 Specifications ................................................................................................................ 15

4 Module Display .................................................................................................................. 16

4.1 Monitoring Mode ........................................................................................................... 16

5 Description of Control Keys ............................................................................................. 19

6 Mode selection in EG1298................................................................................................. 20

7 Configuration Mode ........................................................................................................... 20

7.1 Configurable Parameters .............................................................................................. 21

8 Deep Sleep Mode ............................................................................................................... 25

9 Paralleling Mode ................................................................................................................ 25

9.1 Paralleling concept ........................................................................................................ 25

9.2 Speed Bias/ Paralleling Support Mode .......................................................................... 25

9.3 Configuration in EG1298 ............................................................................................... 25

10 Shutdown and Warning alarms ........................................................................................ 26

11 Do's and Don'ts .................................................................................................................. 27

12 Troubleshooting ................................................................................................................. 27

13 Maintenance ....................................................................................................................... 29

14 MODBUS Based Protocol ................................................................................................. 30

14.1 Connection Details ..................................................................................................... 30

14.2 Supported Functions .................................................................................................. 30

14.3 Register Map ............................................................................................................. 32

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List of Figures Figure 1: Representative drawing of the EG1298 electronic governor’s front fascia .................... 9

Figure 2: ACTZ02A (Standard), ACTZ06A (Mid Torque), ACTZ11A (High Torque) ..................... 10

Figure 3: O/E/N Relays: 741-12-1A-25A .................................................................................... 10

Figure 4: O/E/N Relays: 741-12-1A-25A .................................................................................... 11

Figure 5: Representing configuration diagram of EG1298 ......................................................... 11

Figure 6: Terminals diagram ....................................................................................................... 12

Figure 7: Fixed speed governing for single phase genset. ......................................................... 13

Figure 8: Fixed speed governing for three phase genset. .......................................................... 14

Figure 9: Control keys function ................................................................................................... 19

Figure 10: Mode selection in EG1298 ........................................................................................ 20

Figure 11: Paralleling of genset .................................................................................................. 25

Figure 12: Representing analog voltage input terminal of EG1298 ............................................ 26

Figure 13 : Governor configuration screen in SEDEMAC's Smart Config .................................. 26

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List of Tables Table 1: Environmental specifications ........................................................................................ 15

Table 2 : Technical specifications ............................................................................................... 15

Table 3 : Screens of engine status and operating mode............................................................. 16

Table 4 : Screens of configuration mode .................................................................................... 20

Table 5 : Configurable parameters ............................................................................................. 21

Table 6 : List of digital input sources selection ........................................................................... 24

Table 7 : List of digital output source selection ........................................................................... 24

Table 8 : Table for shutdown and warning alarms ....................................................................... 27

Table 9 : List of do's and don'ts .................................................................................................. 27

Table 10 : List of faults and remedial actions .............................................................................. 27

Table 11 : Command from MODBUS master for Function 4 ....................................................... 30

Table 12: Normal response from EG1298 slave for Function 4 .................................................. 30

Table 13 : Command from MODBUS master for function 16 ...................................................... 31

Table 14 : Normal response from EG1298 slave for function 16 ................................................ 31

Table 15: Command from MODBUS master for Function 3 ........................................................ 31

Table 16 : Normal response from EG1298 slave for Function 3 ................................................. 31

Table 17 : Register map for input registers ................................................................................. 32

Table 18 : Interpretation of alarm status results .......................................................................... 34

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1 Introduction

This document presents the information necessary for operating SEDEMAC's EG1298 controller. It also provides the user with the necessary background for using EG1298 controller in an application that involves communication of the genset controller with an external system such as a server or a remote data communication system.

SEDEMAC's EG1298 is a modern and feature rich engine controller with user-friendly HMI and full graphics LCD. The EG1298 provides the Isochronous speed governing feature along with the option to switch over load based droop governing and paralleling support. The EG1298 also offers engine safety and load monitoring. The EG1298 controller comes bundled with highly versatile software & extensive I/O's and thereby supports a wide variety of industry standard features in diesel/gasoline engines. The EG1298 can be configured through SEDEMAC's Windows PC utility, (Refer section SEDEMAC Smart

Config). Also, all parameters can be configured using the keypad of the controller.

1.1 Features

• Isochronous speed governing with paralleling support

• Configurable load based droop governing

• Engine safety and load monitoring

• PC connectivity via USB port, RS485

• Real time clock based event logs

• RPM sensing using frequency & Magnetic Pickup

• Backlit and full graphics display with power saving feature

2 System Components

2.1 EG1298 Controller

Figure 1: Representative drawing of the EG1298 electronic governor’s front fascia

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2.2 Actuator

Figure 2: ACTZ02A (Standard), ACTZ06A (Mid Torque), ACTZ11A (High Torque)

2.3 O/E/N Relays: 741-12-1A-25A

Figure 3: O/E/N Relays: 741-12-1A-25A

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Figure 4: O/E/N Relays: 741-12-1A-25A

3 Configurations

Figure 5: Representing configuration diagram of EG1298

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3.1 Terminals diagram

Figure 6: Terminals diagram

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3.2 Circuit Diagram

Fixed Speed Application

Figure 7: Fixed speed governing for single phase genset.

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Figure 8: Fixed speed governing for three phase genset.

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3.3 Specifications

Table 1: Environmental specifications

Operating/Storage Temperature

-20 to 65˚C as per IEC 60068-2-1, 2

Vibration

2G in X, Y and Z as per IEC 60068-2-6

Humidity

0 to 95% RH as per IEC 60068-2-78

EMI/ EMC

Compliance as per IEC 61000-6-2, 4

Power Supply

8V – 32V DC continuous

Ingress Protection

IP65 for front face with optional gasket as per IEC 60529

Shock 15g for 11 ms, compliance as per IEC 60068-

2-27

Table 2 : Technical specifications

Power Consumption

~1.2A @12V or 24V DC

Digital Output

6 x 1A high-side drivers configurable for over speed, under speed, engine running etc.

Digital Input

5 switch-to-ground inputs configurable for engine start, engine stop, emergency stop

Analog Input 1 analog input (0V - 5V) for E-Gov speed bias

E-governor Module Interface

1A, 2-phase output for Rotary Actuator 0V – 5V input for target speed bias; 2.5V for zero bias

Genset Current Measurement

0A – 5A AC RMS for Current Transformer (CT) secondary

Magnetic Pickup Measurement

0.2V – 45V AC RMS @100 Hz – 10 kHz

EG1298 controller dimension External dimensions: 139 x 114 x 37.5 mm3 Mounting panel cut: 118 x 93 mm2

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4 Module Display

4.1 Monitoring Mode

In monitoring mode, the screen will scroll automatically after a predefined time which can be configured in configuration menu or you can use the “Navigation Up/Down” keys to scroll/browse the screens.

Table 3 : Screens of engine status and operating mode

Screen 1: ENGINE STATUS Screen 2: ENGINE STATUS



(The controller will display engine status and the configured governing mode on ENGINE STATUS screen.)

Screen 7: GENERATOR L-N VOLT Screen 8: GENERATOR L-L VOLT

((L2 and L3) / (L2L3 and L3L1) / (PF2 and PF3) will be visible only if the controller is configured for 3 phase genset.

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Screen 9: LOAD CURRENT Screen 10: GENERATOR LINE kW

Screen 11: GENERATOR TOTAL kW Screen 12: GENERATOR LINE kVA

Screen 13: GENERATOR TOTAL kVA Screen 14: GENERATOR LINE kVAr

Screen 15: GENERATOR TOTAL kVAr Screen 16: GEN LINE PF

Screen 17: GEN TOTAL PF Screen 18: GEN FREQ

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Screen 19: GENERATOR POWER COUNT Screen 20: ENGINE SPEED

Screen 21: ENGINE RUN TIME Screen 22: DATE AND TIME

Screen 23: PRODUCT ID Screen 24: ENGINE SR NO.

Screen 25: ALARMS Screen 26: ENGINE STATUS

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5 Description of Control Keys

Figure 9: Control keys function

1. Menu Navigation UP key

2. Menu Navigation DOWN key

3. Stop key

4. To acknowledge and clear the alarm

5. Mode select key

1

2

3

4

5

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6 Mode selection in EG1298

Figure 10: Mode selection in EG1298

7 Configuration Mode

To configure the controller, please follow the below mentioned instructions.

To enter the configuration mode press and hold “Stop” and “Ack” keys simultaneously. Please note that, while pressing keys, press “Ack” key just before “Stop” key otherwise controller will start Stop Wait Delay.

Table 4 : Screens of configuration mode

Screen 27: Configuration Mode Screen 28: Configuration mode: Authentication Page

To enter the edit/write mode press “Mode/Select” key. If you wish to read the configuration, press “Stop” key (Refer Screen 27). To access the configuration menu, please enter your 4-Digit PIN here using “Navigation Up/Down” keys (Refer Screen 28). Once you enter the “EDIT” mode, scroll to the parameter that you wish to edit and press “Mode/Select” key to edit the parameter. At this moment, the parameter will start blinking and you can change the parameter value using “Up” and “Down” keys (Refer section

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Configurable Parameters). After selecting the required value, press “Mode/Select” key to save parameter or “Stop” key to discard the value.

7.1 Configurable Parameters

* Level 2 names in sentence case are written how they display on Smart Config GUI and names in bracket with capital case are written how they display on controller

Table 5 : Configurable parameters

Level 0 Level 1 (On screen) Level 2 (On screen) * Possible Value (On screen)

Module (MODULE)

General (GENERAL)

Profile Name

Engine ID XXXXXXXXXXXX

Power on Lamp Test (POWER ON LAMP

TEST)

Disable, Enable

Deep Sleep Mode (DEEP SLEEP MODE)

Disable, Enable

Display (DISPLAY)

Contrast (CONTRAST)

0 – 100 %

Power Save Mode Enable (POWER SAVE MODE)

Disable, Enable

Communication (COMMUNICATION)

Communication Mode MODBUS

Slave ID (MODBUS SLAVE ID)

1 – 247

Baudrate (BAUDRATE)

1200, 2400, 4800, 9600, 19200, 38400, 57600,

115200

Parity Bit (PARITY)

None, Even, Odd

Digital Inputs (INPUTS)

Digital Input A (DIG IN A)

Source (SOURCE)

Refer Table 6

Name Auxiliary Input A

Polarity (POLARITY)

Close to Activate, Open to Activate

Action (ACTION)

None, Warning, Shutdown

Activation (ACTIVATION)

Never, From Engine Start, From Monitoring On, Always

Activation delay (ACTIVATION DELAY)

1 – 60 Sec

Digital Input B (DIG IN B)

Source (SOURCE) Refer Table 6

Name Auxiliary Input B

Polarity (POLARITY)

Close to Activate, Open To Activate

Action (ACTION)





1 – 60 Sec

Digital Input C (DIG IN C)

Source (SOURCE)

Refer Table 6

Name Auxiliary Input C

Polarity (POLARITY)

Close To Activate, Open To Activate

Action (ACTION)


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1 – 60 Sec

Digital Input D (DIG IN D)

Source (SOURCE)

Refer Table 6

Name Auxiliary Input D

Polarity (POLARITY)


Action (ACTION)





1 – 60 Sec

Digital Input E (DIG IN E)

Source (SOURCE)

Refer Table 6

Name Auxiliary Input E

Polarity (POLARITY)


Action (ACTION)





1 – 60 Sec

Outputs (OUTPUTS)

Output A (OUT A)

Source (SOURCE)

Refer Table 7

On Activation (POLARITY)

De-energise, Energise

Output B (OUT B)

Source (SOURCE)

Refer Table 7



Output C (OUT C)

Source (SOURCE)

Refer Table 7



Output D (OUT D)

Source (SOURCE)

Refer Table 7



Output E (OUT E)

Source (SOURCE)

Refer Table 7



Output F (OUT F)

Source (SOURCE)

Refer Table 7



Timers (TIMERS)

General (GENERAL)

Safety Monitoring Delay (SAFETY MON DELAY)

10 – 60 Sec

Engine Stop Hold Delay (ENG STOP HOLD

DELAY)

0 – 120 Sec

Stop Action Delay (STOP ACTION TIME)

10 – 120 Sec

Power Save Mode Delay 5 – 1800 Sec

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(PWR SAVE MODE DELAY)

Screen Changeover Time (SCRN CHNGOVER

TIME)

1– 1800 Sec

Deep Sleep Mode Delay (DEEP SLP MODE

DELAY)

5 – 1800 Sec

Generator (GENERATOR)

Generator Configuration

(ALT CONFIG)

Number of Poles (NUMBER OF POLES)

2, 4, 6, 8 Poles

Alternator AC System (ALT AC SYSTEM)

1, 3 Phase

Current Monitoring (CURR MON)

CT Ratio (CT RATIO)

0 – 8000/5

Load Monitoring (LOAD MON)

Generator Rating (GEN RATING)

0.0 – 6000.0 kVA

Engine (ENGINE)

Speed Monitoring (SPEED MON)

Engine Speed Sense Source (SPEED SENSE

SOURCE)

Magnetic Pickup, Alternator frequency (Alt Freq)

Flywheel Teeth (FLYWHEEL TEETH)

1 – 300

Under-Speed Action (UNDER SPEED

ACTION)


Under-speed Threshold (UNDER SPEED THRESHOLD)

0 – 3600 RPM

Under-speed Delay (UNDER SPEED DELAY)

1 – 60 Sec

Over Speed Action (OVER SPEED ACTION)

Shutdown

Over-speed Threshold (OVER SPEED THRESHOLD)

1000 – 4000 RPM

Over-speed Delay (OVER SPEED DELAY)

1– 20 Sec

Rotary Actuator (ROTARY

ACTUATOR)

General (GENERAL)

Actuator speed (ACTUATOR SPEED)

1 – 10 x25 Hz

Actuator Direction (ACTUATOR DIRECTION)

Clockwise, Anti-Clockwise

Governing Mode (GOVERNING MODE)

PID Fixed Speed, Auto Tune Fixed Speed

Set Speed Selection (SET SPEED SELECTION)

Fixed Speed (0% Droop), Load Based Droop, Speed

Bias Input (0-5 V)

Cranking Steps (CRANKING STEPS)

50 – 5000

Load Droop (LOAD DROOP)

0 – 4 %

RPM Step-up Rate (RPM STEP UP RATE)

1 – 50 RPM/Sec

RPM Stepdown Rate (RPM STEP DOWN

RATE)

1 – 50 RPM/Sec

Target Speed (TARGET SPEED

500 – 4000 RPM

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/RECOVERY)

Generator Egov Configuration (GEN EGOV

CONFIG)

Proportional Gain (Kp) (PROPORTIONAL GAIN)

0 – 1000

Integral Gain (Ki) (INTEGRAL GAIN)

0 – 2000

Derivative Gain (Kd) (DERIVATIVE GAIN)

0 – 1000

Friction Setoff (FRICTION SETOFF)

0 – 1000

Gain Schedule Trigger (GAIN SCHEDULE

TRIGGER)

0.0 – 100.0 % RPM error

Loading Factor (LOADING FACTOR)

0 – 1000

Unloading Factor (UNLOADING FACTOR)

0 – 1000

Engine Start Strategy (ENG START

STRGY)

Initial Low Speed Delay (INIT LOW SPEED

DELAY)

0 – 180 Sec

Initial Low Speed (INIT LOW SPEED)

500 – 1800 RPM

PID Trigger Speed (CRANK SENSE SPEED)

20 – 2800 RPM

Ramp Up Time (RAMP UP TIME)

1 – 180 Sec

ID

Engine Sr. No. (ENGINE SR NO)

############ 0 – 9, A – Z for each digit

PIN 1 #### 0 – 9 for each digit

PIN 2 #### 0 – 9 for each digit

Active profile Active profile (ACTIVE PROFILE)

PROFILE NAME Profile 1

Table 6 : List of digital input sources selection

# Source (On screen) # Source (On screen)

1 Not Used 4 Engine Start

2 User Configured 5 Engine Stop

3 Emergency Stop (Emergency Stop)

Table 7 : List of digital output source selection

# Output source (On screen) # Output source (On screen)

1 Disable 6 Digital Input E

2 Digital Input A 7 Emergency Stop

3 Digital Input B 8 Over Speed

4 Digital Input C 9 Under Speed

5 Digital input D 10 Engine Running

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8 Deep Sleep Mode

Deep Sleep Mode is a useful feature to prolong the battery life.

The controller goes in Deep Sleep Mode when engine is off and there is no user interaction for the pre-set Deep Sleep Mode Delay duration. To wake up controller from Deep Sleep Mode, press and hold “Stop” key for minimum one sec. The controller will wake up from Deep Sleep Mode, on reception of Engine Start or Engine Stop or Emergency Stop command. If engine is failed to start, the controller will enter the Deep Sleep Mode again.

9 Paralleling Mode

9.1 Paralleling concept

Figure 11: Paralleling of genset

Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset must match within prescribed limits before they can be paralleled. By considering linear relation between speed of the engine and frequency of the alternator output, the speed must be controlled until the genset is synchronized with the grid or other genset with the help of electronic governor. A Load Sharing Module controls the speed and the voltage of the genset by controlling the AVR and E-governor of the genset. To control these two devices the LSM provides the DC analog voltage signal to the both devices. The speed bias signal is generally in the range of 0-5 V-DC.

9.2 Speed Bias/ Paralleling Support Mode

This system can be configured in Fixed Speed mode with Speed Bias/Paralleling support. In this mode, EG1298 controller maintains the engine speed in accordance to the speed bias signal provided by Load Sharing Module (LSM).

9.3 Configuration in EG1298

Following is the stepwise procedure for configuring EG1298 for paralleling operation.

• Select Governing Mode as PID Fixed Speed or Auto Tune Fixed Speed.

• Select Set Speed Selection as Speed Bias Input (0-5 V).

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• Select proper thresholds for over Speed and under Speed.

• Provide 0-5 V analog signal from the LSM to EG1298 controller at terminal no. 23, as a speed bias signal (Refer Figure 13).

Figure 12: Representing analog voltage input terminal of EG1298

Screenshot representing configuration of paralleling support mode using SEDEMAC's Smart Config

.

Figure 13 : Governor configuration screen in SEDEMAC's Smart Config

10 Shutdown and Warning alarms

The EG1298 controller allows to configure several shutdown and warning alarms.

An alarm condition occurs when the preconfigured parameters are outside the pre-set level. On initiation of an alarm, the Alarm LED will start blinking. The controller will display number of alarms and the nature of alarm on Alarms screen. All the alarms will be activated at the end of Safety Monitoring Start delay.

When Shutdown alarm occurs, controller commands genset to stop. Warning alarms serves to draw operators attention to an undesirable condition without affecting the operation of the genset. Different shutdown and warning alarms are as mentioned below.

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Table 8 : Table for shutdown and warning alarms

Sr. No.

Shutdown / Warning Alarms

Description

1 Auxiliary Input/user defined name

Configured auxiliary input has triggered longer than pre-set duration

2 Emergency Stop Indicated that engine is required to stop immediately

3 Under Speed The engine speed has fallen below the preset RPM

4 Over Speed The engine speed has exceeded above the preset RPM

5 No Speed Signal Indicates that MPU connections are lost

11 Do's and Don'ts

Table 9 : List of do's and don'ts

Sr. No.

Do's Don'ts

1 SEDEMAC's EG1298 is auto tuned for engine. It is just plug and play type.

Do not change governing parameters without consulting SEDEMAC's experts.

2 FIP's stop lever is free to rotate. Do not disturb throttle setting for FIP.

3 Follow recommended wiring diagram for CT connections and alternator phase (R-Y-B) sequence.

Do not change CT connections and alternator phase sequence.

4 Follow Actuator fitment diagram for proper working.

Do not disturb Actuator setting.

5 Check engine high idle by pulling FIP's lever to full position.

Do not disturb engine high Idle setting.

12 Troubleshooting

This section explains the common faults and their remedial actions.

Table 10 : List of faults and remedial actions

Sr. No.

Fault Remedial Actions

1

Engine speed hunting OR Engine runs at wrong speed

• Check FIP throttle setting I. Start the engine.

II. Manually take the FIP's stop lever to full position. III. Check whether range for engine speed is correct. IV. If engine speed is wrong, adjust the FIP's throttle setting.

• Make sure that FIP's stop lever is free to rotate. Check whether grease is present in linkage bearings.

• Check floating link length is as per the design.

• Check whether FIP's fuel filter is clean. Check that

• FIP's stop lever spring is removed. Check FIP further.

• Check engine.

2 Engine cranks but does not start

• Check wiring of Actuator and MPU (if used) for loose connections: Refer connection diagrams.

• Check whether EG1298 controller is powered ON.

• If not, I. Check the battery voltage.

II. Check the fuse on the battery supply. III. Check continuity between battery positive and controller

terminal # 2. IV. Check continuity between battery ground and controller

terminal # 1.

• Check MPU (if used) on crank wheel I. Crank the engine. During cranking, check EG1298

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Sr. No.

Fault Remedial Actions

controller's power. II. Check continuity between battery positive and controller

terminal # 42. III. Use multimeter in "AC voltage" mode. When engine is

running, check voltage at MPU terminal. IV. Check whether MPU voltage is in correct range. V. If MPU voltage is low, stop the engine. Remove the MPU

from flywheel housing & install it again. VI. If MPU voltage found to be zero, MPU is faulty. VII. If the MPU's voltage is correct and check wiring harness.

VIII. Check MPU configuration in EG1298.

• Check START signal wiring to EG1298 I. Check whether the MPU signal (if used) and main

alternator voltage signal (R phase) are received by the EG1298 controller's terminals. Check wiring harness.

II. If the reading of the voltage is found wrong, refer to the connection diagram.

• Check Actuator on FIP I. Keep multimeter in “resistance mode”. II. Remove the 4-pin Actuator connector. Check resistance

between Actuator wires- BLUE & ORANGE wires. III. Check resistance between Actuator wires- RED &

YELLOW. IV. Correct voltage range is as per design.

• If the resistance reads wrong, then Actuator is faulty. Replace the Actuator.

3 Engine starts, but automatically stops after some time or Engine runs properly, but does not stops

• Check STOP signal wiring to EG1298 I. Check whether EG1298 controller is powered ON. II. Check whether the MPU signal (if used) and main

alternator voltage signal (R phase) are received by the EG1298 controller's terminals. Check wiring harness.

III. If the voltage reading is wrong, refer connection diagram.

• Check Actuator on FIP I. Keep multimeter in “resistance mode”. II. Remove the 4-pin Actuator connector. Check resistance

between Actuator wires- BLUE & ORANGE wires. III. Check resistance between Actuator wires- RED &

YELLOW. IV. Correct voltage range is as per design.

• If wrong resistance is found in the reading, then Actuator is faulty. Replace the Actuator.

4 The controller displays incorrect PF value or kW or load current.

• Check wiring of the respective alternator phase voltage and the CT to the EG1298 controller.

• Check the CT ratio (if kW or current reading is faulty).

• Check generator current and load monitoring configuration in the controller.

5 The controller displays incorrect main alternator voltage.

• Check the wiring of the respective phase to the controller.

• Check mains configuration in the controller.

6 The controller displays incorrect engine RPM.

• Check MPU (if used) connection and configuration.

• Check the main alternator's voltage signal to the controller.

• Check wiring of the main alternator’s R phase and neutral to the controller.

• Check engine speed monitoring configuration in the EG1298 controller.

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13 Maintenance

For the smooth functioning, following regular maintenance is needed after 3 month's run time.

• Greasing to spring, for Actuator with spring.

• All fasteners tightening

• Rod end bearing greasing

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Communication protocol for EG1298

14 MODBUS Based Protocol

The EG1298 engine controller implement a custom protocol based on the standard MODBUS protocol.

This controller operates in a slave mode and responds to the commands received from an external MODBUS master. The EG1298 controller can send alarm messages and can receive operational commands over MODBUS communication.

14.1 Connection Details

The transmission mode used by EG1298 controller is MODBUS RTU (not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits, with/without parity bit and 1 stop bit. The baud rate is selectable between 1200 kbps to 115200 kbps through the configuration options. For more details on how the baud rate can be set, please refer the section Configurable Parameters in this document. Similarly, the slave ID can be selected through the configuration options in EG1298 controller.

14.2 Supported Functions

The EG1298 controller operates as a MODBUS slave that responds to certain commands (or functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate format. Supported functions and respective command-response structure is as shown below. If the command received from the MODBUS master is other than the three functions mentioned below, an exception message is generated.

Function 4 (0x04): Read Input Registers

This function is used to read measurement parameters and status from the EG1298 controller. The command-response pattern is as shown in Table 11 and Table 12.

Table 11 : Command from MODBUS master for Function 4

Table 12: Normal response from EG1298 slave for Function 4

Byte Field Remarks

0 Slave address As configured in EG1298

1 Function code (0x04)

2 Byte count (n) Equals to number of registers to be read times two. 8-bit even number between 2 to 250

3 First register – high byte

4 First register – low byte

... ...

1+n Last register – high byte

2+n Last register – low byte

3+n/4+n Error check CRC

Byte Field Remarks



2 First register address – high byte 16-bit register address, register address map is described in Table 23 3 First register address – low byte

4 Number of registers to read – high byte Number of registers to read must be between 1 to 255 5 Number of registers to read – low byte

6/7 Error check CRC

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Function 16 (0x10): Write Holding Registers

This function is used to issue certain commands to the controller. The command-response pattern is as

shown in Table 13 and Table 14.

Table 13 : Command from MODBUS master for function 16

Byte Field Remarks




4 Number of registers to write – high byte Number of registers to write must be between 1 to 255 5 Number of registers to write – low byte

6 Number of data bytes to follow (n)

7 Value at first register

... ...

6+n Value at last register


Table 14 : Normal response from EG1298 slave for function 16

Function 3 (0x03): Read Holding Registers

This function is used to read holding register to read the commands that have been issued to the controller. The command-response pattern is as shown in Table 15 and Table 16.

Table 15: Command from MODBUS master for Function 3

Table 16 : Normal response from EG1298 slave for Function 3

Byte Field Remarks



2 Byte count (n) Equals to number of registers to be read times two. 8-bit even number between 2 to 250

3 First register – high byte

4 First register – low byte

... ...

1+n Last register – high byte

2+n Last register – low byte


Byte Field Remarks




4 Number of registers written – high byte Number of registers that have been written

5 Number of registers written – low byte

6/7 Error check CRC

Byte Field Remarks




4 Number of registers to read – high byte Number of registers to read must be between 1 to 255 5 Number of registers to read – low byte

6/7 Error check CRC

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14.3 Register Map

The register map for input registers is as shown in Table 17.

Table 17 : Register map for input registers

Register Offset

Value Scale Factor

Unit/Interpretation Bits/Sign

0 Protocol version 1 -- Unsigned

1 – 4 Reserved -- -- Unsigned

5 Battery voltage 0.1 V Unsigned

6 Number of starts 1 -- Unsigned

7 Number of trips 1 -- Unsigned

8 Engine run time 1 Hrs Unsigned

9 Engine speed 1 RPM Unsigned

10 Generator L1 frequency 0.1 Hz Unsigned



13 Generator L1-N voltage 0.1 V Unsigned



16 Generator L1-L2 voltage 0.1 V Unsigned

17 Generator L2-L3 voltage 0.1 V Unsigned

18 Generator L3- L1 voltage 0.1 V Unsigned

19 Generator L1 current 0.1 A Unsigned



22 Generator L1 power 0.1 KW Unsigned



25 Generator total power 0.1 KW Unsigned

26 Generator L1 apparent power

0.1 KVA Unsigned


0.1 KVA Unsigned


0.1 KVA Unsigned

29 Generator total apparent power

0.1 KVA Unsigned

30 Generator L1 reactive power 0.1 KVAr Unsigned



33 Generator total reactive power

0.1 KVAr Unsigned

34 Generator power factor L1 0.01 -- Unsigned



37 Generator average power factor

0.01 -- Unsigned

38 – 39 Generator cumulative energy

0.1 KWh Unsigned

40 – 41 Generator cumulative apparent energy

0.1 KVAh Unsigned

42 – 43 Generator cumulative reactive energy

0.1 KVArh Unsigned

44 – 52 Reserved -- -- Unsigned

53 Reserved -- --

54 Alarm 1 -- --

Reserved -- -- 13/16-16/16

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Register Offset

Value Scale Factor


Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

55 Alarm 2 -- --

Under speed -- -- 13/16-16/16

Over speed -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

56 Alarm 3 -- --

Reserved -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

57 Alarm 4 -- --

Reserved -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Emergency stop -- -- 1/16-4/16

58 – 59 Alarm 5 – Alarm 6 -- --

Reserved -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

60 Alarm 7 -- --

Reserved -- -- 13/16-16/16

Magnetic pick-up fault -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

61 Alarm 8 -- --

Auxiliary Input A -- -- 13/16-16/16

Auxiliary Input B -- -- 9/16-12/16

Auxiliary Input C -- -- 5/16-8/16

Auxiliary Input D -- -- 1/16-4/16

62 Alarm 9 -- --

Auxiliary Input E -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

63 – 69 Alarm 10 – Alarm 16 -- --

Reserved -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

70 Reserved -- --

Reserved -- -- 13/16-16/16

Reserved -- -- 9/16-12/16

Reserved -- -- 5/16-8/16

Reserved -- -- 1/16-4/16

71 Input Output Diagnostics -- --

Digital Input A -- -- 16/16

Digital Input B -- -- 15/16

Digital Input C -- -- 14/16

Digital Input D -- -- 13/16

Digital Input E -- -- 12/16

Reserved -- -- 9/16-11/16

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Register Offset

Value Scale Factor


Digital Output A -- -- 8/16

Digital Output B -- -- 7/16

Digital Output C -- -- 6/16

Digital Output D -- -- 5/16

Digital Output E -- -- 4/16

Reserved -- -- 3/16

Unimplemented -- -- 2/16

Unimplemented -- -- 1/16

72– 73 Reserved -- -- Unsigned

Actual value = Observed value on MODBUS interface multiplied with scale factor.

The interpretation of alarm status (registers 54-69 in Table 17) is as shown in Table 18

Table 18 : Interpretation of alarm status results

Value of Register

Interpretation

0 Alarm disabled

1 Alarm not active

2 Warning alarm active

3 Shutdown alarm active

4 Reserved

5 – 14 Reserved

15 Unimplemented

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Notes

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Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice.

SEDEMAC Mechatronics Pvt Ltd Technical Centre

C9-10, C Block, MIDC Bhosari Pune 411026, India

Manufacturing Plant

G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje

Pune 410501, India

Manufacturing Plant Survey No. 64/5, Off Sinhagad Road

Vadgaon Budruk, Narhe Pune 411041, India

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