Gensys Technical Documentation PDF

GENSYS
April 2009
Generator management module

Technical Documentation
CRE Technology believes that all information provided herein is correct and reliable and reserves the right to
update at any time. CRE Technology does not assume any responsibility for its use unless otherwise expressly
undertaken.
CRE Technology
130 Allée Charles-Victor Naudin
Zone des Templiers - Sophia Antipolis
06410 BIOT - FRANCE
Phone: + 33 (0)4.92.38.86.82 - Fax: + 33 (0)4.92.38.86.83
www.cretechnology.com - info@cretechnology.com
SARL au Capital de 300.000 Euros - RCS Antibes: 7488 625 000 15 N°TVA FR54 488 625 583
GENSYS – Documentation technique page 1/1

A40 Z0 9 0020 K-EN Technical documentation
Date Version Comments Par
28-10-2008 J Integration of application notes and general reorganization LB
31-03-2009 K Révision générale et mise à jour JAM
You can download this documentation and the different documentation relating to GENSYS on our
web site: http://www.cretechnology.com/ .
Documentation list on web site:

• GENSYS technical documentation (this manual)
• Complete variable list with label, units and limits
• GENSYS menu help file (HELP windows file)
• Web JAVA machine
• CPA technical documentation
• GCR technical documentation
• C2S/SCR technical documentation
NOTE :
Bureau VERITAS marine approval :
The control and monitoring functions must not be undertaken on the same module. The
engine securities (min oil pressure, over speed and oil absent) must not be handled by
the same module.
NOTE :
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury
and/or property damage.
Contact your CRE dealer for course training.

Table of contents
1 Overview .............................................................................................................. 9
1.1 European Union Directive Compliance CE ............................................................ 9
1.2 Environment .............................................................................................................. 9
1.3 Characteristics .......................................................................................................... 9
2 Description......................................................................................................... 10
2.1 Front panel .............................................................................................................. 10
2.1.1 Display panel ................................................................................................................... 10
2.1.2 Service panel ................................................................................................................... 11
2.1.3 Control Panel ................................................................................................................... 11
2.1.4 Upper Panel ..................................................................................................................... 12
2.2 Rear panel ............................................................................................................... 13
2.2.1 Overview .......................................................................................................................... 13
2.2.2 Inputs/Outputs ................................................................................................................. 13
3 User interface .................................................................................................... 17
3.1 Internal browser description ................................................................................. 17
3.1.1 Navigation Mode .............................................................................................................. 17
3.1.2 Input Mode ....................................................................................................................... 18
3.1.3 Save parameters configuration........................................................................................ 18
3.1.4 Password protection ........................................................................................................ 18
3.2 PC browser .............................................................................................................. 19
3.2.1 Setting up Windows XP ................................................................................................... 20
3.2.2 View Web Pages from the GENSYS Web Server ........................................................... 31
3.2.3 First level screens ............................................................................................................ 31
3.3 Screensaver ............................................................................................................ 32
4 Operating modes ............................................................................................... 34
4.1 Manu mode .............................................................................................................. 34
4.2 Auto mode ............................................................................................................... 34
4.3 Test mode ................................................................................................................ 35
4.4 Semi Auto Mode ..................................................................................................... 35
5 Typical start sequence for fuel engines .......................................................... 36
6 Predefined configurations ................................................................................ 37
6.1 Single generator in change-over mode (without paralleling) ............................. 37
6.2 Generators paralleling with inter GENSYS CANbus ........................................... 39
6.3 Generators paralleling with GENSYS and parallel line modules ....................... 40
6.4 Multiple generators with static paralleling ........................................................... 41
6.4.1 Configuration ................................................................................................................... 41
6.4.2 Sequence:........................................................................................................................ 41
6.5 Single generator paralleled with mains (option 2)............................................... 42
6.5.1 Mains paralleling modes: ................................................................................................. 43
6.6 Power plant paralleled with mains ........................................................................ 44
6.6.1 Interfacing GENSYS with GCR ....................................................................................... 45
6.7 Power plant paralleled with several mains .......................................................... 46
7 Installing and commissioning a GENSYS application ................................... 48
7.1 Wiring diagram ........................................................................................................ 48
7.2 Installation instructions: ........................................................................................ 48
7.2.1 Panel cut-out: ................................................................................................................... 49
7.2.2 Mounting: ......................................................................................................................... 49
7.2.3 Earth grounding: .............................................................................................................. 50
7.2.4 Wiring guidelines:............................................................................................................. 50
7.2.5 Vibrations: ........................................................................................................................ 51
7.2.6 Real time clock battery:.................................................................................................... 51
7.3 Before commissioning (before going on site) ..................................................... 51
7.4 During commissioning ........................................................................................... 52
8 Predefined functions ........................................................................................ 58
8.1 Water preheat / Pre-lubrication / Pre-glow functions .......................................... 58
Auto mode ...................................................................................................................................... 58
Manual mode .................................................................................................................................. 58
8.2 Crank / Fuel / Starter 2 / Starter 3 functions ......................................................... 58
8.3 Air fans..................................................................................................................... 59
Auto mode ...................................................................................................................................... 59
Manu mode..................................................................................................................................... 59
8.4 Fuel filling / Coolant filling / Oil filling................................................................... 59
Auto mode ...................................................................................................................................... 60
Manu mode..................................................................................................................................... 60
8.5 Configurable I/Os functions ................................................................................... 60
8.5.1 Digital input functions ....................................................................................................... 60
8.5.2 Configurable input label ................................................................................................... 60
8.5.3 Validity.............................................................................................................................. 60
8.5.4 Input functions .................................................................................................................. 60
8.5.5 Direction ........................................................................................................................... 63
8.5.6 Dedicated inputs .............................................................................................................. 63
8.6 Digital output functions.......................................................................................... 63
8.6.1 Output functions ............................................................................................................... 63
8.6.2 Polarity ............................................................................................................................. 67
8.7 Use spare analog input for digital input ............................................................... 67
8.7.1 Purpose: ........................................................................................................................... 67
8.7.2 Configuration: ................................................................................................................... 67
8.7.3 Parameters: ..................................................................................................................... 67
9 Special functions .............................................................................................. 69
9.1 Fuel crank relay function ....................................................................................... 69
9.1.1 Introduction ...................................................................................................................... 69
9.1.2 Configuration .................................................................................................................... 69
9.2 Load sharing using a central frequency (de-drooping) ...................................... 70
9.2.1 Introduction ...................................................................................................................... 70
9.2.2 Procedure......................................................................................................................... 70
9.2.3 GCR synchronization & mains paralleling ....................................................................... 71
9.2.4 INTEGRAL INHIBITION ................................................................................................... 71
9.3 Pulse control calibration procedure ..................................................................... 72
9.3.1 Parameters....................................................................................................................... 74
9.4 Operator controlled return of mains ..................................................................... 74
9.5 Mains & Generator electrical fault options ........................................................... 74
9.6 GENSYS with external automatic start module ................................................... 77
9.6.1 Overview .......................................................................................................................... 77

9.7 Remote start upon external pulse ......................................................................... 79
9.7.1 Setting external input ....................................................................................................... 79
9.8 Safety Inhibitions .................................................................................................... 80
9.8.1 Objective .......................................................................................................................... 80
9.8.2 Configuration ................................................................................................................... 80
9.9 GENSYS with 500Hz PWM (Cat/Perkins) .............................................................. 82
9.9.1 Schematic ........................................................................................................................ 82
9.9.2 Configuration ................................................................................................................... 83
9.10 GENSYS with BSM II ........................................................................................... 84
9.10.1 Configuration ................................................................................................................... 84
9.10.2 Standard procedure ......................................................................................................... 84
9.10.3 Custom procedure ........................................................................................................... 85
9.11 GENSYS with Carantec ....................................................................................... 86
9.11.1 Wiring parallel lines:......................................................................................................... 86
9.11.2 Configuration of GENSYS ............................................................................................... 86
9.12 GENSYS with TEM compact ............................................................................... 86
9.13 Under voltage trip coil ........................................................................................ 88
9.14 Level -1 (G59 & counters) ................................................................................... 89
9.15 Scada .................................................................................................................... 89
9.16 How to set a GPID ............................................................................................... 89
9.16.1 Principle ........................................................................................................................... 89
9.16.2 Empirical method settings ............................................................................................... 90
9.17 Automatic load / unload ...................................................................................... 90
10 GENSYS PLC .................................................................................................. 91
10.1 Introduction ......................................................................................................... 91
10.2 File description .................................................................................................... 91
10.3 Parameter definition block ................................................................................. 91
10.4 Label definition block ......................................................................................... 92
10.5 Unit definition block ............................................................................................ 92
10.6 Initialization definition block .............................................................................. 93
10.7 Equation definition block ................................................................................... 93
10.8 End of file ............................................................................................................. 93
10.9 PLC programming language .............................................................................. 94
11 Communication .............................................................................................. 96
11.1 CANBUS GOOD PRACTICES ............................................................................. 96
11.2 COM1: RS232 to PC ............................................................................................ 97
11.3 COM2: CAN bus inter GENSYS .......................................................................... 97
11.3.1 Wiring ............................................................................................................................... 97
11.3.2 CAN bus fault................................................................................................................... 98
11.4 Broadcasting Data between GENSYS units ...................................................... 99
11.4.1 Introduction: ..................................................................................................................... 99
11.4.2 Procedure / Example ....................................................................................................... 99
11.5 Can Bus Inhibition ............................................................................................. 103
11.5.1 How to set theses functions:.......................................................................................... 103
11.6 COM3: CANopen remote I/O ............................................................................. 104

11.6.1 System configuration ..................................................................................................... 106
11.6.2 Read / write I/O .............................................................................................................. 106
11.7 COM3: MDEC (MTU) .......................................................................................... 107
11.7.1 Procedure....................................................................................................................... 107
11.8 COM3: J1939 ...................................................................................................... 111
11.8.1 Configuration .................................................................................................................. 111
11.8.2 J1939 fault...................................................................................................................... 111
11.8.3 Engine Speed ................................................................................................................ 111
11.8.4 Coolant temperature ...................................................................................................... 111
11.8.5 Oil pressure .................................................................................................................... 111
11.8.6 Engine diagnostic........................................................................................................... 112
11.8.7 J1939 Messages ............................................................................................................ 112
11.8.8 Advanced functions........................................................................................................ 115
11.8.9 Engine notes .................................................................................................................. 115
11.9 COM4: MODBUS RTU on serial port RS485 .................................................... 116
12 Troubleshooting........................................................................................... 119
13 Variables ....................................................................................................... 121
14 Precautions .................................................................................................. 122
15 References ................................................................................................... 124
15.1 Options ............................................................................................................... 124
15.2 Accessories ....................................................................................................... 124
16 Company Information .................................................................................. 126

List of illustrations
Figure 1 - Rear panel ............................................................................................................................ 13
Figure 2- Browser link description ......................................................................................................... 18
Figure 3 - Contextual keys for Input Mode ............................................................................................ 18
Figure 4 - Password input mode display ............................................................................................... 18
Figure 5 - Typical menu page................................................................................................................ 19
Figure 6 - Typical configuration page .................................................................................................... 20
Figure 7 - GENSYS Ù PC ................................................................................................................... 20
Figure 8 - Tree menu description .......................................................................................................... 32
Figure 9 - State machine ...................................................................................................................... 35
Figure 10 - Typical start sequence for fuel engines .............................................................................. 36
Figure 11 - Power plant in change over mode without paralleling ........................................................ 37
Figure 12 - Power plant with several generators................................................................................... 39
Figure 13 - Static paralleling with 4 generators coupled together in emergency situation.................... 41
Figure 14 - Example with 4 generators coupled together in emergency situation. ............................... 42
Figure 15- Paralleling with mains .......................................................................................................... 42
Figure 16 - Typical sequence in No Break CO mode............................................................................ 43
Figure 17 - Typical sequence in permanent mode ................................................................................ 44
Figure 18 - Power plant paralleling with mains ..................................................................................... 44
Figure 19 - GCR Ù GENSYS wiring diagram....................................................................................... 45
Figure 20 - Power plant paralleling with several mains ......................................................................... 46
Figure 21 - Power plant paralleling with several mains configuration ................................................... 47
Figure 22 - Panel cut-out ....................................................................................................................... 49
Figure 23 - Mounting kit......................................................................................................................... 49
Figure 24 - Mounting brackets on GENSYS ......................................................................................... 49
Figure 25 - Earth grounding .................................................................................................................. 50
Figure 26 - Interconnection of all battery negatives .............................................................................. 51
Figure 27 - Connecting CAN bus with isolators .................................................................................... 51
Figure 28 - Speed output....................................................................................................................... 53
Figure 29 - Voltage output ..................................................................................................................... 55
Figure 30 - Connections for water preheat, pre lubrication and pre glow ............................................. 58
Figure 31 - Connection for air fans ........................................................................................................ 59
Figure 32 - Connections for filling.......................................................................................................... 59
Figure 33 - Fuel filling diagram .............................................................................................................. 60
Figure 34 - Speed and voltage control with Contact / Pulses (1) .......................................................... 73
Figure 35 - Speed and voltage control with Contact / Pulses (2) .......................................................... 73
Figure 38 - Schematic ........................................................................................................................... 84
Figure 39 - Wiring GENSYS Ù TEM ................................................................................................... 87
Figure 40 - Typical GPID controller ....................................................................................................... 89
Figure 41 - CAN Bus wiring ................................................................................................................... 97
Figure 42 - GENSYS Ù GENSYS ........................................................................................................ 97
Figure 43 - GENSYS Ù GENSYS Ù GENSYS Ù … .......................................................................... 98
Figure 44 - Mobile generator sets ......................................................................................................... 98
Figure 45 - CAN bus inhibition schematic (example) .......................................................................... 103
Figure 46 - Modular remote I/O extension module.............................................................................. 105
Figure 47 - CANopen coupler wiring ................................................................................................... 105
Figure 48 - Wiring diagram for Volvo EMS2........................................................................................ 116
Figure 49 - GENSYS Ù GENSYS ÙGENSYS Ù … (MODBUS) ..................................................... 117
Figure 50 - Several generators warning .............................................................................................. 122
Figure 51 - One generator with mains warning ................................................................................... 122
Figure 52 - Standard cables ................................................................................................................ 125
Figure 53 - Access to CRE Technology in Sophia Antipolis ............................................................... 126

List of tables
Table 1 - GENSYS Front Panel ............................................................................................................. 10
Table 2 - LCD screen characteristics .................................................................................................... 10
Table 3 - Display Panel keys ................................................................................................................. 11
Table 4 - Service Panel keys ................................................................................................................. 11
Table 5 - Control Panel keys ................................................................................................................. 12
Table 6 - Control Panel LEDs ................................................................................................................ 12
Table 7 - Inputs/Outputs description...................................................................................................... 16
Table 8 - User interface ......................................................................................................................... 17
Table 9 - Screensaver description ......................................................................................................... 33
Table 10- Typical change over mode configuration .............................................................................. 37
Table 11 - Typical sequence in change over mode............................................................................... 38
Table 12 - Typical basic multi Generator configuration ......................................................................... 39
Table 13 - Generator paralleling with parallel lines ............................................................................... 40
Table 14 - Typical basic configuration for GENSYS with parallel lines modules .................................. 40
Table 15 - Typical basic mains paralleling configuration ....................................................................... 43
Table 16 - Paralleling with mains configuration ..................................................................................... 45
Table 17 - GENSYS /GCR configuration ............................................................................................... 46
Table 18 - Input functions ...................................................................................................................... 63
Table 19 - Wiring GENSYS Ù Auto Start Module ................................................................................ 78
Table 20 - Wiring GENSYS Ù TEM ...................................................................................................... 87
Table 21 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus ................................... 99
Table 22 - Variables received by BROADCAST DATA via Inter GENSYS CANbus .......................... 100
Table 23 - CAN bus inhibition parameters........................................................................................... 104
Table 24 - CANopen configuration example ....................................................................................... 107
Table 25 - MDEC connection .............................................................................................................. 108
Table 26 - Important parameters ......................................................................................................... 108

1 Overview
1.1 European Union Directive Compliance CE

The EMC Directive (89/336/EEC) deals with electromagnetic emissions and immunity. This product is
tested by applying the standards, in whole or in part, which are documented in the following technical
construction file:
CEM 2004/108/EC, which replaces directive CEM (89/336/EEC) relative to electromagnetic emissions
as from July 20th 2009.
This product is developed to respect harmonized norms:
EN 55099:2009
EN 55099:2010
EN 55088:2008
2006/95/EC (replaced directive 73/23/EEC since January 16th 2007).
SAE J1939/71, /73, /31
Other norms:
EN 61326-1: 2006 (Industrial location)
EN 55011
EN 61000-3-2
EN 61000-3-3
1.2 Environment
Operating temperature
A40Z0 0 to 55°C
A40Z1 -20 to 70°C
A40Z2(GNSS) 0 to 55°C (UL certified)
A40B0,B1, B2, B3, B4, B5 5 to 55 °C (Bureau Veritas Marine agreement)
Storage temperature -30 to +70°C
Humidity 5 to 95%
Tropic-proof circuits for normal operation in humid conditions.
Front panel: IP54 protection.
Back panel: IP20 protection.
Altitude: 2000m
1.3 Characteristics
Size 248x197x57mm (9.76x7.76x2.24in)
Weight 1.9kg (4.2oz)

2 Description
2.1 Front panel
Display Service
Panel Panel
Control
Panel
Table 1 - GENSYS Front Panel

The display panel allows setting up and monitoring of the GENSYS configuration and the power plant
it controls. It provides a large LCD display and a keypad. See "User interface" chapter, for more details
about the functions of LEDs & Keys.
LCD characteristics Value Unit

Viewing area 240x128 dot
114x64 (4.49x2.52) mm (in)
30x16 Characters
Character size (small font) 2.7x3.6 (0.1x0.14) mm (in)
(standard font) 3.6x3.6 (0.14x0.14) mm (in)
9.45x9.45 (0.37x0.37) mm (in)
(large font)
Back light 60 cd/m²
LCD mode STN
Table 2 - LCD screen characteristics

2.1.1 Display panel
Input mode
Key Navigation mode
(during parameter modification)
Navigation bar scroll / select menus and change parameter value
parameters
Enter enter a menu / switch to ‘Input Validate parameter and return to

mode’ ‘Navigation mode’

Shift Used with other keys only (F1, F2, Not used.
I). Shift + I saves all parameters.
F1 Shortcut to special function

Increase speed in manual mode.
Increase voltage when associated
with Shift key in manual mode.
F2 Shortcut to special function
Decrease speed in manual mode.
Decrease voltage when
associated with Shift key in
manual mode.
Esc Return to parent menu Discard parameter changes and
return to ‘Navigation mode’
Table 3 - Display Panel keys

2.1.2 Service panel
The five dedicated keys of the service panel allow you to switch to special menus or functions directly.
See "User interface" chapter for more details about the functions of LEDs & Keys.
Key Function
Buzzer This key will stop the buzzer and turn the associated LED off.
The associated red LED indicates the status of the buzzer output.
Fault Direct access to the Fault menu.

! An associated red LED indicates the Fault status of the generator.
Pressing this key will switch to the associated menu, showing active faults.
Pressing a second time on the same key will switch back to the menu displayed
beforehand.
Direct access to the Alarm menu.

Alarm
! An associated orange LED indicates the Alarm status of the generator.
Pressing this key will switch to the associated menu, showing active alarms.
beforehand.
Info 1. Direct access to global monitoring page (user configurable).
2. Save parameters in flash storage when pressed with SHIFT: this action is called
“SHIFT-I”
Pressing this key will switch to the associated menu, which is custom made and
contains parameters the user wants to monitor easily.
beforehand.
Bulb LED test: pressing this key will turn on all GENSYS LEDs. It is a simple test to
check the LEDs and the keypad.
Table 4 - Service Panel keys

2.1.3 Control Panel
The control panel allows the user to pilot and control the generator. See "User interface" chapter, page
17, for more details about the functions of LEDs & Keys.
Key Function
LED This LED is not associated with any key. It is illuminated when a key is
upper pressed and switched off when all keys are released. This LED also stays on
right during a save parameters command (see SHIFT-I above).

Auto Switches the system to automatic mode. The associated LED is ON when
AUTO mode is activated.
Test Switches the system to test mode. The associated LED is ON when TEST
mode is activated.
Manu Switches the system to manual mode. The associated LED is ON when
MANU mode is activated.
Start Starts the generator (only available in manual mode).
Stop Stops the generator (only in manual mode).
O/I Closes/opens the generator breaker (only in manual mode).
O/I Closes/opens the mains breaker if available (only in manual mode).
Table 5 - Control Panel keys

Led Function
Shows green when engine is running
Engine
Shows green when generator voltage is present
Alternator
Shows green when generator breaker is closed

Genset
breaker
Shows green when mains breaker is closed

Mains
breaker
Shows green when voltage is present at Mains/bus input

Mains /
Bus
voltage
Table 6 - Control Panel LEDs

2.1.4 Upper Panel
The upper panel displays the status of the power supply. See "User interface" chapter for more details
about the functions of LEDs & Keys.

2.2 Rear panel
2.2.1 Overview
Figure 1 - Rear panel

2.2.2 Inputs/Outputs
Terminal
capacity
Pin nb Description Comment
(mm² /
AWG)
Crank relay out 2.5 / 12 Supplied via emergency stop input at battery positive
A1
voltage; 16 Amps.
Fuel relay out 2.5 / 12 Supplied via emergency stop input at battery positive
A2
voltage; 16 Amps.
Emergency stop 2.5 / 12 To battery positive, normally closed; direct supply to
A3
crank and fuel relay outputs.
Generator N 2.5 / 12 Not necessarily connected: if not connected, GENSYS
B1
will calculate a virtual neutral voltage.
B2 Generator L1 2.5 / 12 100 to 480 VAC line to line. Frequency: 50 or 60 Hz.
100 mAmps / 600 VAC fuses.
B3 Generator L2 2.5 / 12
For UL homologation:
Generator L3 2.5 / 12 - 100 to 230VAC line to line
B4 - Fuses must be UL 248-14 listed.
- Surge protection must be UL1449 listed.
B5 Mains L1 2.5 / 12 100 to 480 VAC line to line. Frequency: 50 or 60 Hz.

Mains L3 2.5 / 12 100 mAmps / 600 VAC fuses.
B6 - 100 to 230VAC line to line
- Fuses must be UL 248-14 listed.
- Surge protection must be UL1449 listed.
Output 1 to 5 2.5 / 12 350 mAmp. Over current protected. Reactive load.
C1 to Each output can be configured with a specific function
C5 (see option list in the Z090014.chm file) or
programmed with an equation.
D1 Generator I1- 2.5 / 12 0 to 5 Amps. Maximum rating: 15 Amps during 10s.
1 VA consumption.
D2 Generator I1+ 2.5 / 12
Each phase is isolated from the others and from the
D3 Generator I2- 2.5 / 12 supply voltage.
D4 Generator I2+ 2.5 / 12 External current transformer must be UL506 listed.
D5 Generator I3- 2.5 / 12
D6 Generator I3+ 2.5 / 12
D7 Mains I1- 2.5 / 12 0 to 5 Amps. Maximum rating: 15 Amps during 10s.
1 VA consumption.
Mains I1+ 2.5 / 12
Each phase is isolated from the others and from the
D8 supply voltage.
External current transformer must be UL506 listed.
E1 Mains breaker NC 2.5 / 12 230 VAC, 5 Amps.
Isolated relay contact.
E2 Mains breaker NO 2.5 / 12
E3 Mains common 2.5 / 12
E4 Gen breaker NC 2.5 / 12 230 VAC, 5 Amps.
Isolated relay contact.
E5 Gen breaker NO 2.5 / 12
E6 Gen common 2.5 / 12
F1 Engine meas. 1- 2.5 / 12 0 to 10 kOhms resistive sensors with programmable
gain.
F2 Engine meas. 1+ 2.5 / 12
F3 Engine meas. 2- 2.5 / 12 0 to 10 kOhms resistive sensors with programmable
gain.
F4 Engine meas. 2+ 2.5 / 12
F5 Shield 2.5 / 12
F6 Water temp meas. - 2.5 / 12 0 to 400 Ohms resistive sensors.
F7 Water temp meas. + 2.5 / 12
F8 Oil pressure meas. - 2.5 / 12 0 to 400 Ohms resistive sensors.
F9 Oil pressure meas. + 2.5 / 12
G1 0-20 mA + 2.5 / 12 +/- 10 V (20 kOhms input) or +/- 20 mAmps (50 Ohms
input).
G2 Shield 2.5 / 12
Used as Mains power input with single generator.
0-20 mA - 2.5 / 12 Used as synchronization input from GCR (terminal 42)
G3 when several generators parallel with mains
G4 Parallel. - 2.5 / 12 5V (10KOhms)
Load sharing and power set level (kW only).
G5 Shield 2.5 / 12

Parallel. + 2.5 / 12 Compatibility with GCR (CRE product) and with
analogue load sharing line.
G6 Compatibility with Wheatstone bridge.
Only used with GCR or old ILS
Isolated.
G7 Pickup - 2.5 / 12 50 Hz to 10 kHz. Maximum voltage: 40VAC
Used for speed regulation, crank drop out and over-
Pickup + 2.5 / 12
speed (see precautions in chapter 4.2.8).
G8 If not wired, the speed measurement can be made by
the alternator voltage. But pickup is recommended.
G9 Speed out + 2.5 / 12 G9: +/- 10 V analogue outputs.
G11: +/-10V input from speed governor (ESG)
G10 Shield 2.5 / 12
Compatibility with most of speed regulators.
Speed ref 2.5 / 12 Independent gain and offset software adjustment (see
G11 Z0900014.chm file).
H1 Not connected 2.5 / 12
H2 AVR out + 2.5 / 12 Analogue output.
Automatic voltage regulator (AVR) set level (see
H3 Shield 2.5 / 12
Z0900014.chm file for further explanations).
AVR out - 2.5 / 12 Stanford, AVK and Leroy Somer automatic voltage
H4 regulators already tested. For others, ask your dealer.
Isolated.
Mains breaker in 2.5 / 12 Digital input with 10 kOhms pull-up.
Dedicated input for mains breaker feedback.
J1
Accepts NO or NC contacts to 0V.
Not isolated.
Gen breaker in 2.5 / 12 Digital input with 10 kOhms pull-up.
Dedicated input for generator breaker feed back.
J2
Not isolated.
Remote start/stop 2.5 / 12 Digital input with 10 kOhms pull-up.
Dedicated input for remote start/stop request in Auto
J3 mode.
Not isolated.
Oil pressure 2.5 / 12 Digital input with 10 kOhms pull-up.
Dedicated input for oil pressure fault.
This sensor is needed to start the engine whatever the
J4
mode.
Accept s NO or NC contacts to 0V.
Not isolated.
Water temp 2.5 / 12 Digital input with 10 kOhms pull-up.
Dedicated input for water temperature fault.
J5
Not isolated.
Input 1 to 10 2.5 / 12 Digital inputs with 10 kOhms pull-up.
10 inputs can be configured with a specific function
J6 to (see option list in the Z090014.chm file) or
J15 programmed with PLC equations.
Not isolated.
Reserved 2.5 / 12 Used for 12V power supply backup during crank time.
K1
See A40U200000 documentation for more information.
K2 Power supply + 2.5 / 12 9 to 40 V, 10 Watt consumption (without actuator).

Power supply - 2.5 / 12 Polarity inversion protection.
Note:
The "Power supply -" must be wired from the speed
governor using 4 mm² wires. See "state of the art"
K3
rules wiring diagram.
5 Amps / 40 VDC fuse recommended.
Fuse must be UL 248-14 listed.
K4 Actuator + 2.5 / 12 200 Hz PWM output (6 Amps continuous).
Power supply of actuator.
Actuator - 2.5 / 12
Compatibility with most standard electromagnetic
K5 actuators. (Barber Colman, GAC, SynchroStart)
Needed to activate an OPTION
(To be ordered with the product).
RS232 to PC or Female Straight cable is needed.
modem DB9 19200 bps, 8b, no parity, 1 stop bit.
Communication with a local computer.
Used for configuration, parameters, file downloading
COM1
and uploading.
Uses a TCP/IP protocol to communicate.
Not isolated.
Not to be connected while engine running.
CAN1 to other Male DB9 125 kbaud.
GENSYS Standard CAN© / proprietary protocol.
Used to communicate with other GENSYS units (kW,
COM2
kVAR, dead bus management) and for broadcast data
function.
Not isolated.
CAN2 to options Male DB9 125 kbaud.
Standard CAN© / CANOPEN© protocol.
Used to communicate with remote I/O (WAGO) (see
COM3
remote I/O chapter) or with engine management units
(option 4).
Not isolated.
RS485 / MODBUS RTU Male DB9 4800, 9600 or 19200 bps.
Used to communicate with SCADA.
COM4 MODBUS RTU slave. Read (04 and 03) and write (06)
functions.
2 wires mode.
Table 7 - Inputs/Outputs description

3 User interface
Table 8 - User interface

The user interface can be controlled through two different ways:
• Directly on local browser using front panel LCD screen and keyboard
• Remotely through an internet browser running on a PC
3.1 Internal browser description

GENSYS can be configured and monitored remotely with a Web browser such as Internet Explorer or
Netscape Navigator.
For local usage, GENSYS has an embedded browser which is able to display the same information
pages as the remote Web browser.
The user can navigate through the different menus with the navigation bar and the / keys.
3.1.1 Navigation Mode
The navigation bar provides 5 contextual keys. Depending on the menu displayed, different icons may
appear above these keys, allowing the user to scroll up/down the pages or to select a link to a new
menu or parameter.
When the user selects a parameter and presses the ‘ ’ key, the browser switches to the ‘Input
mode’.
The 5 icons above contextual keys will change appearance depending on the type of parameter to
change (list of choice, label, numerical value, password...).
When in ‘Input mode’, the key will discard the parameter changes and return to the ‘Navigation
mode’. The key will confirm the parameter changes and return to the ‘Navigation mode’.
The browser displays a white pointer in front of each link or parameter of a menu. A black pointer will
indicate the active link or parameter. Figure 2- Browser link description shows these two pointers:

Figure 2- Browser link description
3.1.2 Input Mode
To change a parameter, first select it with contextual keys and press to switch to ‘Input mode’.
New icons will appear above the contextual keys, depending on the kind of parameter selected.
Label modification:
Digital value modification:
List of options modification :
Figure 3 - Contextual keys for Input Mode
When the new parameter value is input, the user must press key to store and confirm the new
value.
3.1.3 Save parameters configuration
All GENSYS parameters used in configuration are stored in a FLASH memory. When a parameter is
changed by the user, the new value is stored in a RAM memory. This new value will be effective as
soon as it is entered, but it will be lost if the GENSYS power supply is cut or too low. To save the new
parameters in FLASH, you must use “SHIFT-I”. The user must press both + keys together.
This will start the backup sequence and store all parameters in the FLASH memory. Now, the new
parameters will be effective even after a power supply failure.
NOTE:
Due to the great number of parameters. The back-up procedure may take a few
seconds. It is thus essential to save parameters when the motor is stopped. To save all
parameters, the user must press at the same time on both + keys on the
GENSYS front panel. Otherwise, the new parameters will be lost when shutting down the
GENSYS.
3.1.4 Password protection

The GENSYS has different password levels, allowing access to more or less critical parameters or
menus. When the password page is shown on the LCD display, the user must first press on the
key (like for other parameters) to switch to the ‘Password Input mode’.
Figure 4 - Password input mode display

Three lines of characters (upper case and lower case letters and ‘0’ to ‘9’ characters) will appear along
with 5 icons above the contextual keys.

The first four contextual keys allow the user to move the cursor up, down left or right onto the desired
character. The last key (OK icon) will validate the selected character and write it in the password line
(a * will appear).
When all characters are entered, another press on the key will validate the password. If it is
correct, the main menu will appear on the LCD display. Otherwise, the password page will be
displayed again.
Default settings for the password are:
• Level 0: no password entered, just press "Enter" key.
• Level 1: 1.
• Level 2: Only for distributors.
The password of your level and those lower can be changed in the system menu.
Note: the menus might differ according to the security level of the password entered.
3.2 PC browser
GENSYS provides an efficient way of configuring your application thanks to its embedded Web server.
It is thus possible to access the different menus with a simple Web browser such as Netscape
Navigator or Internet Explorer. However, it is not recommended to be connected with the PC while the
engine is running.
Before connecting with the GENSYS you have to configure your computer as described in the next
chapter ". The next figure show a typical GENSYS menu accessed from a PC Web browser.
Figure 5 - Typical menu page

In this page, the user can choose from among 6 submenus (Generator electrical meters for example).
It is also possible to scroll up/down the other pages of the menu with the page up << and page down
>> links. The ESC link acts in the same way as the GENSYS ESC key: it will display the parent menu.
The last 3 links are identical to the Fault / Alarm / Information key on the GENSYS front panel.
The next figure shows a typical configuration page. The user can change 5 different parameters (in
this case, two numerical values and three option lists) and send them to the GENSYS using the [Save]
button. Clicking on the [Save] button changes the parameter immediately.

Figure 6 - Typical configuration page
NOTE :
The user must press on both + keys at the same time on the GENSYS front
panel to save the parameters permanently. Otherwise, the new parameters will be lost
when shutting down the GENSYS.
3.2.1 Setting up Windows XP

Connecting a GENSYS with a PC is similar to connecting to Internet with a modem.
GENSYS works as a modem and the integrated software works as an Internet provider.
GENSYS also provides 1 web server. This web server sends HTML pages to your PC, and your PC
browser is used to display it. Live data is refreshed with the JAVA applet.
A40W0
Figure 7 - GENSYS Ù PC
Data transfer takes place through a straight serial cable (with 9 wire DB9 connectors), as shown on
the figure above.
A few steps are required to configure a PC before controlling a GENSYS:
• Install the modem.
• Create a Dial-Up Networking Connection.
• Check the network properties.
• Set-up the internet security properties.
Communication between the GENSYS and the PC is carried out via a Dial-Up Network.

The PC must be configured to communicate with a 19.2K bps modem with TCP/IP networking
enabled.
3.2.1.1 Check the network properties
Click Start, Settings, and Network Connection.
Dial-Up Adapter and TCP/IP -> Dial-Up Adapter protocols must be present in the list. If they are not
there, create a new connection using the new connection wizard.
In the New Connection Wizard, select “connect to the network at my work place”. Then, click “Next”.

Select “Dial-up connection”. Click on “Next”
In the next page, select a 19 200 bps modem. Then, click “Next”.
In the connection name dialog box, in the “Company name” field write “GENSYS”. Click on “Next”
In the “Phone number to dial” dialog box, in the “Phone number” field, write: “123”. Then click “Next”.

The new connection is now installed. Select “Add a shortcut to this connection to my desktop”. Then
click on “Finish”.
3.2.1.2 Install the Modem

Click Start, Settings, and Control Panel.
In the Control Panel, double-click the Modems icon.
In the Modems Properties dialog box, click Add.
Double click on “Add hardware” icon.

Click on “Next”.
Choose the “Modem” icon.
Then, choose “Add a new hardware device”, and click “Next”.
Select “Yes, I have already installed the hardware”, and click “Next”.

Select install the hardware that I manually select from a list (Advanced)”. Then, click “Next”.
The following dialog box will appear: select option “don’t detect my modem; I will select it from a list”.
Then, click “Next”.
In the next dialog box, under Manufacturers, Standard Model Types should be selected. Under
Models, select Standard 19200 bps Modem, then click Next.
In the next dialog box, select the Communications Port where GENSYS is connected as the port, and
then click Next.

After Windows installs the modem, click Finish.
3.2.1.3 Set the Modem Properties

Back in the Modem Properties dialog box, select the new modem (Standard 19200 bps Modem) and
then click Properties.
In the “General” tab, check that the port speed is: 19 200 and the flow control is “hardware”.
In the Advanced parameters, in the “advanced options” tab, ensure that the modem is configured for 8
data bits, no parity, and one stop bit. Then click “OK”.
Click OK until you exit this dialog box.
Create a Dial-Up Networking Connection.
In the Control Panel, select Network Connection.
Double click on the “GENSYS” icon.

In the “Connection to GENSYS dialog box”, click on “Properties”.
In the “General” tab, ensure that the selected modem is the modem installed in the previous step.
In the “Option” tab, in the dialling option, select “Display progress while connecting”.

In the “Security” tab, select “Typical (recommended settings)”.
In the “Networking” tab, select “PPP Windows 95/98/NT4/2000, Internet”. Select “Internet Protocol”.
Click on “Install”.
In the “General” tab, select “Use the following IP address” and write: 192.168.11.2. Then select
“Advanced”.

In the “General” tab, disable every tick box.
In the “DNS” tab, select “Append primary and connection specific DNS suffixes” and “Append parent
suffixes of the primary DNS suffix”.
In the “WINS” tab, select “enable LMHOSTS lookup” and in the NetBIOS setting, select “enable
NetBIOS over TCP/IP. Then, click OK.

Back in the “GENSYS properties dialog box”, click on “Advanced tab. In this tab, ensure that every
option is disabled. Then, click OK.
3.2.1.4 Setting the internet security properties

• In the Control panel, double-click the Add/Remove program icon.
• If present, uninstall the Java sun program. Click OK.
• Run the msjavwu_.exe program provided in the CD Rom.
• Click Start, Settings, and Control Panel.
• In the Control Panel, double-click the Internet Options icon.
• Under the Security tab, select Trusted Sites and click on Add Sites…. Check that Require server
verification (https :) for all sites in the zone is disabled. In the Zone field write "http://GENSYS"
and click on Add. Click OK.
• Under the Security tab, select trusted sites, click on Customize…. In Java (or Java VM for 95, or
Microsoft VM for ME) and Java permissions, select Custom. Click on the Java Custom Settings
button. Under the Edit permissions tab, enable the Access to all Network Addresses in the Run
Unsigned Content part. Click OK. Click OK. If a dialog box appears, click YES.
• In the Connection tab, click on Never establish connection. Select GENSYS modem in the
modem list Click on Settings, Use a proxy server must be disabled. Click OK.
• Under the Advanced tab, in the Java VM field (Microsoft VM for ME); check that Java JIT
enabled is selected. Click OK.
• Close Control panel.
• Copy the file named hosts from the GENSYS CD Rom “C:\WINDOWS\system32\drivers\etc”

3.2.1.5 Connect the GENSYS
Connect one end of a DB-9 serial cable to the COM1 port of the PC. Connect the other end of the
cable to the connector labelled "RS232 to PC or modem" on the GENSYS.
Double-click on the Shortcut to GENSYS icon. In the Connect to dialog box, click CONNECT. Click
close.
If the connection is OK, an icon (2 small computers) in the bottom right of the screen appears.
3.2.2 View Web Pages from the GENSYS Web Server
After the TCP/IP connection has been established with GENSYS, you can view GENSYS menus with
any standard Web browser such as Firefox or Internet Explorer.
Start the web browser (Internet explorer, Firefox …).
In the “Location” or “Address” field of the web browser, enter the URL of the GENSYS: http://gensys
(CAUTION: host file must be present in “C:\WINDOWS\system32\drivers\etc” and must contain a line
such as:
« 192.168.11.1 GENSYS »
The GENSYS password page should appear in the browser window. Enter your password.
You can now browse through the different GENSYS menus.
To close the connection, double-click on the connection icon in the status bar of Windows. In the
Connected to GENSYS dialog box, click Disconnect. Close your web browser.
3.2.3 First level screens
Upon power up, GENSYS displays the genset status (if EMERGENCY STOP not connected) or
WELCOME SCREEN.
The first level menu contains three entries:

• Display
• Configuration
• System
You can access it with next KEY sequence:
=> => =>

You then have access to the top level menu:
=> =>

Figure 8 - Tree menu description
See the Help file for the complete description of the tree menus.
3.3 Screensaver
GENSYS has automatic screensavers. They only appear on the GENSYS LCD screen when you
press "Esc" in the password page or after an adjustable delay (GENSYS variable 1266). There are
four screensavers and the display depends on the mode and state of GENSYS:
Display in Manu
Screensaver Description Display in Auto mode
mode
4 customized lines
Customized
Customer Logo In Wait state (engine stopped). In other cases.
screen
Date and time
KW (in large font)
Voltage (in large font)
Generator When the generator breaker is When the generator
Frequency (in big font)
overview closed. breaker is closed.
Running hours (in large
font)
Crank Relay Output
Fuel Relay Output
Water Temp Digital
Input
Oil Pressure Digital
Input
Engine When you press Start
Emergency Stop In Start state and fault state.
overview or when in fault state.
Remote start
Nb of start attempts
Battery voltage (bar
graph)
Engine speed (bar
graph)
Frequency difference
(bar graph) When the generator is
Synchronization Voltage difference (bar ready and the
In Synchronization state.
column graph) generator breaker is
Phase difference opened.
(column)

Frequency match (OK /
NOK)
Voltage match (OK /
NOK)
Phase match (OK /
NOK)
Table 9 - Screensaver description

4 Operating modes
With the GENSYS unit, three main operating modes and one special mode are available to allow you
to control your generator.
Modes are:
• Manual
• Automatic
• Test Mode
4.1 Manu mode

In manual mode, it is possible to control the generator with the front panel of the GENSYS. All steps
from engine start to paralleling are controlled by pushing keys.
To start the engine push the [Start] key and hold down until the oil pressure fault disappears. On the
front panel, the 2 LEDs above the generator should light up. The left hand LED indicates that a speed
greater than zero is measured, whereas the right hand LED indicates that a voltage other than zero is
measured.
If a speed regulator is connected to GENSYS, it is possible to increase the speed with the F1 key, and
decrease it with the F2 key.
If a voltage regulator is connected to GENSYS, it is possible to increase and decrease the voltage with
the SHIFT+F1 keys and SHIFT+F2 keys.
When the generator is synchronized, it is possible to close the breakers with the 0/I keys.
Important: The internal synch check relay is always active, i.e. it is impossible to close the breaker if
the conditions for closing are not met.
When the breaker is closed the corresponding LED on the front panel should light up.
As soon as the generator breaker is closed, the GENSYS is switched to droop mode for speed and
voltage, i.e. the speed and the voltage will decrease when the load increases.
To stop the engine, push the Stop key.
4.2 Auto mode

Speed and voltage droop are inhibited in this mode, the system is running isochronously, i.e. the
speed and the voltage remain unchanged whatever the load.
This mode has 4 main ways of operating:
One generator with Change Over:
The generator starts with a remote start or in the case of mains failure. When the generator is ready
(voltage, frequency), the mains breaker is opened and the generator breaker is closed. Should the
mains return to normal conditions or remote start is off, after a programmed delay the generator
breaker is opened, the mains breaker is closed and the generator set is stopped.
One generator paralleling with the mains (option 2):

The generator starts with a remote start or if there is a mains failure. Paralleling depends on
configuration: NO CHANGE OVER, CHANGE OVER, NO BREAK CHANGE OVER, or PERMANENT
Load sharing can be on a "base load" or "peak shaving" basis. Depending on the configuration, the
generator will stop either when there is a remote stop or when mains power returns to a stable level.
Power plant with several generators without automatic load/unload:

The generator starts with a remote start signal, and parallels with the bus. If there is a dead bus,
GENSYS will check with the other GENSYS units before closing the bus breaker (this depends on the

validation of the dead bus management). The load sharing is accomplished via the inter GENSYS
CAN© or via the parallel lines. The generators stop with a remote stop signal.
Power plant with several generators with automatic load/unload:

The communication between GENSYS units is via the inter GENSYS CANbus and determines which
generators start or stop. The number of generators used depends on load requirements (all generators
receive the remote start signal but only start if necessary).
4.3 Test mode

This mode tests the Auto mode. When you press the [Test] key, the engine starts as if there was a
remote start, and GENSYS will carry out the standard Auto mode sequence. To exit “TEST MODE”,
push the [AUTO] key.
4.4 Semi Auto Mode

Similar to Auto Mode, except that to pass from one state to another you press a button. The following
illustration shows the various states.
Figure 9 - State machine

5 Typical start sequence for fuel engines
During the start sequence protections are inhibited. This concerns all engine protections. When the
engine reaches the required state (E2057 = 6, see next figure) the protections are activated. A timer
can be added to inhibit protections during the "safety on" delay (E1514). The timer will start when
E2057=6.
Speed
Nominal speed (1080 or 1081)
Idle speed (1079)
Crank drop out
(1325 or 1326 or 1327)
Start Stop
request request
Running timers Prelub Preglow Crank Crank rest Preglow Crank Warm up RPM stab Volt stab Safety on Cooling Rest
1145 1157 1135 1136 1157 1135 1139 1140 1141 1514 1142 1144
Engine state (2057) 0 1 12 2 11 12 2 3 4 5 6 6 8 9 10 0

Engine Gen. ready
ready
Crank relay out (2018)
(Terminal A1)
Fuel relay out (2019)

(Terminal A2)
Warm up (2214)
(Terminal J6 to J15)
Validation protection (2192)
Figure 10 - Typical start sequence for fuel engines

6 Predefined configurations
6.1 Single generator in change-over mode (without paralleling)
GENSET
GENSET
Power
Power
t t
MAINS
Power
OU
MAINS
Power
t
t
LOAD
Conso
LOAD
Conso
t
t
GENSYS
Functions:
- Manual mode
- Auto mode
- RMS reasurements
- Test mode (three or single phase) Start/stop
- Nb of running hours - Electrical protections
Analog / logical inputs : (>V,<V,>f,<f,>Q, Alarms ... LV
>P,>I, ...) or
- Oil Pressure HV
- Water temp (100-
- remote start 480Vac)
- Emergency stop
- Genset breaker aux
- Mains breaker aux
- Pickup frequency
- Spares ...
Logical outputs:
Mains
- Crank
- Fuel solenoid LV
- Mains breaker or
HV
- Genset breaker
(100-
- Spares 480Vac)
Analog output:
Breakers
- analog signal to speed regulator management
Utility
Figure 11 - Power plant in change over mode without paralleling
Variable number Variable label Variable value

1179 Gen. number 1
1147 Nb of gen. 1
1148 Mains parallel ChangeOver
1153 Mains regul X
1158 ILS compatible No
1177 Synchro mode Dynamic
1515 Deadbus manag. X
1258 Load/Unl. mode Inhibited

1846 Break Ma Fault Mains
1841 Fault start Yes
Table 10- Typical change over mode configuration

In Change over mode, as shown in Table 10- Typical change over mode configuration, the generator
starts and takes the load when a mains electrical fault occurs. When mains power returns, the
generator breaker is opened and the mains breaker is closed after a pre-set delay.
For the generator to start when mains failure occurs, either a protection (mains or other) or a digital
input has to be configured as a "Mains electrical fault".
If remote start is on when mains are present the generator starts, GENSYS opens the mains breaker,
then closes the generator breaker and takes the load.
E0022 Mains voltage
400 V
triggered by a protection or
digital input set as "Mains
E2201 Mains electrical fault electrical fault"
Fastest mains
electrical fault
E1085
Mains back
Remote start on timer
E2002
terminal J3
Genset ready
E0003 Genset voltage
400 V
E1142 E1142
Cool E1459 Cool
Switchover
E2001 Generator CB down Switchover down
delay
E1459 delay
E1459
E1459
E2000 Mains CB Swithover
Swithover delay
delay
Second black
First black
First black
Second black
There are 2 blacks There are 2 blacks
START FOR EMERGENCY START FOR TEST

will only start if a mains protection or a digital input is programmed as or switch load from mains to genset
"Mains electrical Fault".
Table 11 - Typical sequence in change over mode

Note: in "No change over" mode (1148) GENSYS only starts upon a remote start demand and
doesn't manage the mains breaker.

6.2 Generators paralleling with inter GENSYS CANbus
KW, KVAR, COS (f), ... CAN Bus
GENSYS 1 GENSYS 2 GENSYS n
Utility
Figure 12 - Power plant with several generators
Variable
Variable number Variable label
value
1179 Gen. number 1 to n
1147 Nb of gen. N (>=2)
1148 Mains parallel No ch.over
1153 Mains regul X
1515 Deadbus manag. Yes
1258 Load/Unl. mode X
1020 MA kW <-> 20mA 0
1021 MA 0kW setting 0
Table 12 - Typical basic multi Generator configuration

6.3 Generators paralleling with GENSYS and parallel line modules
Analog load sharing lines
KW, KVAR, COS (f), ... CAN Bus
ILS PowRcon
GENSYS 1 GENSYS 2 GENSYS n
Utility
Table 13 - Generator paralleling with parallel lines

1147 Nb of gen. n (>=2)
1153 Mains regul X
1158 ILS compatible Yes
Deadbus
1515 No
manag.
Table 14 - Typical basic configuration for GENSYS with parallel lines modules
When GENSYS is in ILS compatible mode, the active power sharing is handled via the parallel lines.
You have to disconnect the AVR output (H2-H4) and have an external device control the reactive
power (CT droop...).

6.4 Multiple generators with static paralleling
This mode is useful as it allows:
• Gradual magnetization of the step-up transformers (no transient short-circuit).
• Full plant availability in less than 10 seconds.
6.4.1 Configuration
• One GENSYS per genset.
• CAN bus must be connected between GENSYS units.
• An "Excitation" output (e.g. exit C1) must be configured on each GENSYS unit.
• GE breaker must be powered by 24VDC (so as to close without AC).
• In the Setup menu / plant overview / sync mode. E1177 must be set as "A stop".
• The value of the maximum excitation rpm is set with E1896 (default: 97%).
• The alternators must be identical.
• Each GENSYS must be equipped with a speed sensor (magnetic sensor / Pick-up).
Figure 13 - Static paralleling with 4 generators coupled together in emergency situation

6.4.2 Sequence:
• Loss of voltage -> Dead Busbar
• Each GENSYS is ordered to start (Terminal J3).
• CB1, CB2, CB3 & CB4 close as ordered by the GENSYS units.
• DG1, DG2, DG 3, and DG4 start.
• All generators reach the speed defined by the E1896 setting (CANBUS synchronization).
• All C1outputs close simultaneously to activate excitation (after dialogue between GENSYS
units).
• Alternator voltages increase gradually at the same time.
• The plant is available to take up required load.
• Breakers are closed when engine is stopped.
• There is a residual voltage of 80V.

Speed
1500tr/min
Voltage
400V
80V
Time
9
Figure 14 - Example with 4 generators coupled together in emergency situation.
6.5 Single generator paralleled with mains (option 2)
GENSYS
Mains
CPA2
Utility
Figure 15- Paralleling with mains

In permanent mode (1148) and peak shaving mode (1153), a mains power measurement is required.
Internal via D7-D8 inputs (Mains I1) or external via G1-G3 inputs (0-20 mA).

1179 Gen. number 1
1147 Nb of gen. 1
1148 Mains parallel NoBreak CO / Permanent
1153 Mains regul Base load / Peak shav.

Deadbus
1515 X
manag.
Table 15 - Typical basic mains paralleling configuration

In all mains paralleling modes, if a "mains electrical fault" is set (via protections or digital inputs), the
generator starts and takes the entire load upon mains loss even if the remote start is off. In all cases,
you have to set a mains protection in order to determine the behaviour of your generator when mains
power disappears.
6.5.1 Mains paralleling modes:
Choice of mains paralleling mode is configured through parameter E1178.
No Break CO (No break change over):

When remote start is on, the generator starts, synchronizes and parallels with the mains, then takes
the load (ramps up). Once the mains are unloaded, GENSYS opens the mains breaker. When remote
start is off, the mains takes the load in the same way as the generator did previously. If the generator
started for a mains failure, when mains power returns the GENSYS synchronizes the load transfer
(ramps down), opens the breaker and then stops the generator.
E0022 Mains voltage
400 V
Triggered by
fastest "Mains
Remote start on
E2002
terminal J3
E0003 Genset voltage

400 V
E1142
E1142
Cool
GE ready
GE ready
Cool
down
E2001 Generator CB down
E1152 E1151 E1152

E1459 E1085 Unload Load ramp Unload
E2000 Mains CB Swithover Mains back ramp ramp
delay timer
Short transfert from GE
First Black
Short transfert from GE

Synchro back
Short transfert from
Synchro back
Synchro
mains to GE
to Mains
to mains
There is only 1 black No black

START FOR EMERGENCY START FOR TEST
will only start if a mains protection or a digital input is programmed as or to transfert load from mains to GE.
Figure 16 - Typical sequence in No Break CO mode
Permanent:
When the remote start is on, GENSYS starts the generator, synchronizes and parallels with the mains,
then ramps up load until it reaches its set point. In base load mode (E1153), the generator has a
constant load and the mains take the utility load variations. If the utility load is less than the generator

set point, mains are in reverse power. In the peak shaving mode (E1153), the mains have a constant
load and the generator takes the utility load variations.
E0022 Mains voltage
400 V
Triggered by
fastest "Mains
Remote start on
E2002
terminal J3
Cool
E0003 Genset voltage down
400 V
E1142 E1152
Cool Unload
GE ready
GE ready
E2001 Generator CB down ramp
E1152
E1459 E1085 Unload
ramp E1151
E2000 Mains CB Swithover Mains back Load ramp
delay timer
Transfert load from GE
Base load or peak

Synchro
shaving (CHP for

First Black
Load ramp
Unload ramp
Synchro back
example)
to Mains
There is only one black No black. Mains CB is always closed
START FOR EMERGENCY START FOR PRODUCTION /

will only start if a mains protection or a digital input is programmed as base load or peak shaving
Figure 17 - Typical sequence in permanent mode
6.6 Power plant paralleled with mains

Synchronization bus
KW, KVAR, COS (phi), ...

CAN bus
GENSYS 1 GENSYS 2 GENSYS n GCR
Réseau
PLC
Mains kW
CPA2
Utility
Figure 18 - Power plant paralleling with mains

In this configuration, base load or peak shaving regulation can be selected, depending on GCR
configuration. In base load mode, GCR doesn't need CPA.

1147 Nb of gen. n (>=2)
1153 Mains regul X
1515 Deadbus manag. Yes

1020 MA kW <-> 20mA 18000

1461 Ext kW measure +/- 10V
Table 16 - Paralleling with mains configuration

To allow Power Factor regulation, the "Mains breaker in" (J1) information to GENSYS must be wired.
Power Factor regulation is not an option.
6.6.1 Interfacing GENSYS with GCR
Figure 19 - GCR Ù GENSYS wiring diagram

• GCR (39-40) – GENSYS (G4-G6): parallel lines (0-3V) to control active power.

• GCR (42-43) – GENSYS (G1-G3): mains synchronization bus (+/- 3V).
• GENSYS (K3): -VBat from speed governor.
1464 Mains kW Meas. External
1461 Ext kW measure +/- 10V
1020 MA kW <-> 20mA 20000
Table 17 - GENSYS /GCR configuration
6.7 Power plant paralleled with several mains

Synchronization bus
KW
KVAR
COS (f) CAN bus
...
GENSYS 1 GENSYS 2 GENSYS n GCR 1 PLC
Mains 1
kW
CPA
GCR 2
Mains 2
CPA
Utility 1
CPA
GCR n
CPA Mains n
Utility 2
CPA
CPA
Utility n
Figure 20 - Power plant paralleling with several mains

For further information concerning managing several mains using GCR, refer to the GCR technical
documentation.

1147 Nb of gen. n (>=2)
1153 Mains regul X
Deadbus
1515 Yes
manag.
Figure 21 - Power plant paralleling with several mains configuration

7 Installing and commissioning a GENSYS application
7.1 Wiring diagram
7.2 Installation instructions:

The GENSYS module has been designed for front panel mounting.
Indoor or outdoor installation is possible as long as the following requirements are met:
• The chosen cabinet must meet the standard safety rules of the workplace.

• The chosen cabinet must be closed during normal use to prevent the user from coming into
contact with power cables.
• Only the front panel must be accessible during normal use.
• In accordance with the Bureau VERITAS marine agreement, the module must not be installed in
areas which are exposed to the weather.
7.2.1 Panel cut-out:
177 mm /
6.97 in
228 mm /
8.98 in
Figure 22 - Panel cut-out
Note: Cut-out must be cleaned of any metal dust before mounting.
7.2.2 Mounting:
To secure the GENSYS onto the panel, use the special kit provided with the module. The kit contains
4 screws, 2 brackets and 1 mounting tool.
Figure 23 - Mounting kit

1. Remove the connectors.
2. Pass the module through the panel cut-out. Ensure that the gasket is properly positioned on
the panel and that it is flat.
3. On the rear side of the module, insert the first bracket into the two holes on the upper edge of
the module and push it to the left.
Figure 24 - Mounting brackets on GENSYS

4. Use the tool which is provided to screw the bracket gently onto the panel (just to hold the
module in place)
5. Insert the second bracket into the two holes on the lower edge of the module and push it to
the right.
6. Use the tool to screw the bracket gently onto the panel.
7. Tighten brackets gradually until the module is firmly secured.
8. Plug in the connectors.

7.2.3 Earth grounding:
Earth grounding of the GENSYS must be made with two M5 screws & fan washers. Use a short 4mm²
cable to connect the unit to earth (see below).
Figure 25 - Earth grounding

For UL homologation, the screw must be hexagonal with green head.
7.2.4 Wiring guidelines:
The power cable must be kept separate from the communication cable. The communication cable can
be installed in the same conduit as the low level DC I/O lines (under 10 volts).
If power and communication cables have to cross, they should do so at right angles.
Correct grounding is essential to minimise noise from electromagnetic interference (EMI) and is a
safety measure in electrical installations. To avoid EMI, shield communication and ground cables
appropriately.
If several GENSYS are used, all the power supply 0V (pin K3) must connected together with mini
10mm².
WARNING :
Please read the following recommendations to avoid any hardware damage to the
GENSYS CANBUS Driver (not isolated).
Power supply to circuit breaker

Terminal K3 (0V) should never be disconnected. The battery circuit should only be opened using a
breaker placed between the battery's positive terminal and the K2 terminal (Power supply +).
Note: If the K3 (0V) terminal is disconnected and the bus bar voltage is applied to the GENSYS,
there is the risk of getting AC voltage on the CANBUS terminals.

Interconnection of all battery negatives
Figure 26 - Interconnection of all battery negatives

Rental fleet & HV generating sets
CANBUS isolators are recommended for generating sets used for rental fleet, Marine, or High Voltage
switchboards.
Figure 27 - Connecting CAN bus with isolators

Note: These isolators are fitted to prevent any damage due to a disconnection of any K3
terminal from the inter-negative connection.
These isolators can be supplied by CRE Technology with the reference A40M0.
7.2.5 Vibrations:
In case of excessive vibration, the module must be mounted on suitable anti-vibration mountings.
7.2.6 Real time clock battery:
If the battery is disconnected, remove the rear panel and connect a 3V battery to the ST1 jumper
(+battery: ST1 up; -battery: ST1 down).
Battery maintenance must be provided separately from the GENSYS unit.
7.3 Before commissioning (before going on site)

Schematics check
How?
• Be sure you have the latest power plant schematics.
Why?
• To be sure the wires will be present on site (Can bus connector, shielded wires...).
What?
• 0 Volt wiring
• Shields
• Speed governor / GENSYS Interface
• Automatic Voltage Regulator / GENSYS Interface (droop current transformer must be removed)
• CAN Bus
• GCR
Check the list of input/output
How?
• Check if the required function is present in the list of preset functions.
• If any doubt check with distributor.
Why?
• To evaluate if an input/output needs an extra equation.
• To evaluate / quote development time.
• To evaluate necessary password clearance: Level 1 (consumer), Level 2 (Distributor), or Level 3
(CRE Technology only).
7.4 During commissioning

Start with safe condition
How?
• Disconnect the GENSYS connector labelled as “E” (breaker control).
• Disconnect the wires between GENSYS and the speed governor (G9 / G11).
• Disconnect the wires between GENSYS and the AVR (H2 / H4).
• Check important GENSYS parameters (See chapter 4.2).
• Ask the technician who wired the power plant to lock the generator breaker open.
Why?
• So as to be sure not to cause a false paralleling during commissioning.
Download the text file from the GENSYS.

How?
• With a PC and Internet explorer.
Why?
• To store all parameters before starting the commissioning.
Check speed detection.

How?
• Press on manual key.
• Lock the fuel closed.
• Access the information menu.
• Press and hold the start button during 5 sec.
• While the starter turns over, check that GENSYS RPM is close to 200RPM.
Why?
• To be sure that the GENSYS will release the starter motor at the correct speed (around
400RPM).
• To have over speed protection.
Start the generator, check speed detection.

How?
• Set the speed governor potentiometer to its minimal value.
• In [Manu] mode, press and hold [Start] button for 10s.
• Adjust the speed to 1500 RPM (using speed governor potentiometer).
• In the information menu check that Frequency= 50.00 when RPM=1500RPM. You may have to
adjust the number of teeth on the gear where the measure is taken (for example).
• Press [Stop] to stop the generator.

Check the 5 minimum protections before carrying out any other
tests:
• Over speed
• Over voltage
• Emergency stop
• Oil Pressure
• Temp
How?
• Short-circuit the sensors.
• For over speed and over voltage, set the thresholds to 101%.
GENSYS / Speed governor Interface

How?
• Connect only the reference wire.
• Set the recommended gain and offset (if not in the list, contact CRE technology).
• Start the generator at 1500RPM to obtain exactly 50.00 Hz (60.00 Hz if applicable).
• Measure the voltage between Ref and remote voltage input on the speed regulator side.
• Adjust GENSYS output voltage (G11 G9) using the offset.
• Connect the control wire.
• Check the maximum speed range in manual mode with F1 and F2.
• This range must be near +/- 3Hz.
Deviation ESG amplitude

(1076)
+ G9 Speed out
ESG offset (1077) +
G11 Speed
ref
Figure 28 - Speed output

• The ESG offset adjustment (E1077) can be set between -10V and +10V, and is added to the
external speed reference (G11). The values in % are % of 10V. E.g. 51%=5.1 volts.
• The Speed ref (G11) doesn't need to be connected if there is no voltage reference available.
• 0V must be wired with 4 mm² as follows: battery Ö speed regulator Ö GENSYS
ESG ESG
Terminal Terminal
Manufacturer Model Amplitude offset Remark
G9 (out) G11 (ref)
(1076) (1077)
E6 10% 0% B3
KG6 / System
E6 -25.00% 46.50% E3 NC
HEINZMANN
Voltage converter
PANDAROS to isolate the
24%
DC6 26% B3 A3 signal on the line.
(DC/DC) (advise)

ECM pour
10 (Barber
QSK23 / QSK40
Colman 06 (5
/ QSK45 / 1.00% 00.00%
Frequency Volts)
QSX15 / QSK
CUMMINS bias input)
60
EFC 2% 0% 8 9
ECM (QST30) 1.00% -3.00% 18 15(7,75v)
All models with
5% -1.65% ILS input 4v
analog input
10% -1.05% ILS signal 2,5V
BARBER
COLMAN Digital
DPG 2201 1.6% -27% ILS signal supply
(+5V)
1.6% 25% ILS signal BAT-
- 2301A/D Shunt 14-16
25.00% 25.00% 10 11
ILS+speed
Shunt 26 (com) to
90.00% 0% 25 26
- (w/o U & I) 0V
G11 connected to
2301D 25.00% 00.00% 15 16
0v
WOODWARD
2301A Speed 16 connected to
99.00% -1.00% 15 16
only 0V
Pro-act / Pro-act Aux- connected to
25.00% 00.00% Aux + Aux -
II 0V
8290-189 /
25.00% 30.00% 11 NC 11-12 open
8290-184
-
MTU MDEC 25.00% 8 31 (5v) Programmable
20.00%
- 24 / conn. 25 / conn.
EDC 4 15.00%
VOLVO 25.50% F F
EDC III 20.00% 25,00% Pot signal NC
-
PERKINS ECM 25.00% 30 3 (5v)
25.00%
+/- 1.5 Hz not to
8.00% to -
EMR 24 25 reach EMR
13.50% 26.20%
Deutz overspeed
See application
TEM compact -- -- -- --
note A40Z090200
GAC All ESD -20% -63.8% N P
Ghana Control PWC 2000 75.5% -25% J G
16 ltr full
SCANIA electronic 20% -36% 54 28
engine
-2Hz and +0,8Hz
EMCPII - (although the
CATERPILLAR 5% 2 1
interface 13.10% GENSYS output
still increase)

38% 23.80% G2(speed D2(sensor
input line) return)914
Two different
JOHN DEERE 915
ECU wirings for the
LEVEL III
same governor.
5V(ref
34% -15% G2 speed) 999
GENSYS / Auto Voltage Regulator Interface

To set AVR control correctly:
Start engine (MANU Mode), then set gain E1103:= 0 and Offset E1104:=0 on GENSYS.
Set the AVR system to 400 VAC using its potentiometer.
Gain and Offset adjustment: Enter maximum correction (E2038 = + 7000) with Shift and “F1” buttons.
From the following table, choose the best values for Gain and offset to obtain 430VAC ±5V:
GAIN OFFSET
0 0
255 0
255 255
0 255
If necessary, modify Gain and then Offset to obtain 430VAC ±5.

Enter minimum correction (E2038 = - 7000) with Shift and “F2” buttons, then check that you have
370VAC ±5
Set to no correction (E2038 = 0) and check that you have 400VAC.
Gain and Offset adjustment if you cannot obtain 400V on the AVR: Adjust the maximum voltage with
the AVR potentiometer, which is normally below 400VAC. Choose the best values for Gain and offset
to obtain the maximum deviation.
Deviation AVR gain (1103) H2 AVR out +
47R
AVR offset
(1104)
H4 AVR out -
Figure 29 - Voltage output

• AVR gain and AVR offset settings:
000 -> 0 kOhms
255 -> 10 kOhms
• AVR gain is set to 255 for an output between -5V and +5V.
• See table below for predefined settings. For specific setting contact your dealer.
AVR AVR
Terminal Terminal
Manufacturer Model gain offset Remark
H2 H4
(1103) (1104)
Trim pot of AVR
STAMFORD MX321 255 0 A2 (+) A1 (-)
fully CW
Trim pot of AVR
SX440 155 0 A2 (+) A1 (-)
fully CW
AEC63-7
AVC63-4
AVC63-4A
240 240 6 7 Remove the shunt
APR63-5
APR125-5
SSR63-12
DECS32-15-
BASLER
xxx
DECS63-15- Use VAR control
xxx - - - - included in the
DECS125- DECS.
15-xxx
DECS300
VR63-4 240 240 VAR+ VAR- Remove the shunt
Aux input Aux input
DVR2010 100 0
MARATHON A B
ELECTRIC Replace with SE350
DVR2000 - - - -
or DVR2000E
Cosimat N+ 255 0 Pot + Pot -
AVK
MA329 155 0 A2(+) A1(-)
Remove the shunt
M8B 240 240 P Q
PQ
470nF capacitor
between 8 and M.
M8B400 0 0 8 6
Don’t connect
MarelliMotori
shield.
470nF capacitor
between 6 and M.
M405A640 0 0 6 8
Don’t connect
shield.
Jumpers have to be
K65-12B 2 3
KATO 255 0 removed.
K125-10B Or 4 Or 7
Available soon
50kOhms in serial
MECC ALTE SPA UVR6 250 200 Pot + Pot -
with H2
Pot input
R449 253 255 Pot input - Remove the shunt
+
Pot input
+
LEROY SOMER
Pot input Pot input – Remove the shunt.
R221 100 241
+(6) (7) Pot ineffective
Pot input
+
DVR
130 210 7 45
KVAR/PF
CATERPILLAR 1.5kOhms in serial
VR6 130 245
with H2
CDVR 255 100 P12.6 P12.3

Check the control of the breaker on dead bus
How?
• Be sure there is no critical load connected to bus bar
• Connect the “E” connector
• Start the engine in manual mode
• Press the generator breaker 0/I key.
• The breaker must close (control OK) and the GENSYS front face led must light up (feedback
position OK).
• Press the generator breaker 0/I Key.
• The breaker must open and the led must go out.
Check mains / bus ref L1 and L3

How?
• Start the generator
• Close the breaker
• Enter the Synchronization menu to check that phase difference is 0°.
Check synchronization
How?
Unplug “E” connector

• Check voltage on bus bar
• Set the “Fail to synchronize” parameter at 500s.
• Start the generator in auto mode.
• Check that you are now in synchronization mode using the information screen key [i].
• Adjust the phase and frequency PID.
• When the difference between phases is stable and near to 0°, measure the voltages (L1 L2 and
L3) directly on the circuit breaker between generator and bus bar.
• When you are sure there is no wiring problem, stop the generator
• Set the “Fail to synchronize” parameter according to the customer's request.
• Connect the “E” connector
• Start in automatic mode.
• The generator must be paralleled in less than 10s.
Load sharing / kW regulation
• For this application, check the stability of KW and kVAR regulation.

8 Predefined functions
Inputs/outputs are associated with functions. Some of these I/Os are dedicated, others are
programmable via parameters.
8.1 Water preheat / Pre-lubrication / Pre-glow functions
GENSYS
J6: Input 1: Preheating (2273)
J7: Input 2: Manual water preheat request (2224)

Pre heat
J8: Input 3: Manual oil prelub. request (2225) Output 1: C1 relay
J9: Input 4: Manual preglow request (2226) Output 2: C2 Pre lubrication
relay
J10: Input 5: Manual start request (2227) Output 3: C3 Pre glow
relay
F6 / F7 F8 / F9
Water Oil pressure Output 1 function (1260) = Water preheats (2083)

temperature sensor Output 2 function (1261) = Pre lubrication (2084)
sensor Output 3 function (1262) = Pre glow (2085)
Figure 30 - Connections for water preheat, pre lubrication and pre glow
Auto mode
Pre-heat is activated if J6 is closed and if temperature is under the pre-set threshold (E0030 < E1154).
Note: The water temperature sensor is required in this instance.
Pre-lubrication will be activated when engine is in pre-start (E2057 = 1) if pressure is under the
threshold (E0029 < E1155). If the threshold (E1155) is 0, then pre-lubrication is active while the engine
is in pre-start (E2057 = 1). In the last case the oil pressure sensor isn’t required.
Pre glow is active when engine state is pre glow or start (E2057 = 12 or 2).
Manual mode
Preheat will be activated when J7 is closed. The water temperature sensor isn’t required.
Pre lubrication will be activated when J8 is closed. The oil pressure sensor isn’t required.
Pre glow will be activated when J9 is closed, when you push GENSYS start button, or when J10 is
closed.
8.2 Crank / Fuel / Starter 2 / Starter 3 functions

If there is an external crank relay, you can use the crank function (E2018) on digital output. The
behaviour will be exactly the same as the crank relay output (terminal A1).
If there is an external fuel relay, you can use the fuel function (E2019) on a digital output. The
behaviour will be exactly the same as the fuel relay output (terminal A2).
For multiple starters (E1138 = 2 or 3), the outputs can be configured with the Starter 2 (E2267) and
Starter 3 (E2268) functions. The number of attempts (E1134) is the global number and not the number
of attempts per starter. For example:
• the number of attempts (E1134) is 4
• the default starter (E1602) is 2
• the number of starters (E1138) is 3
• output 1 (terminal C1) is configured as Starter 2 (E1260 = 2267)
• output 2 (terminal C2) is configured as Starter 3 (E1261 = 2268)

Note: Should the engine refuse to start, the sequence will be:
C1 activated, crank rest, C2 activated, crank rest, A1 activated, crank rest, C1 activated,
start failure.
8.3 Air fans
GENSYS
J5: water temp input Output 1: C1 Air fan relay
F6 / F7
Water temperature Output 1 function (1260) = Air fan (2215)

sensor
Figure 31 - Connection for air fans

In all cases, the air fans will be activated when J5 is activated or when the “max water temp” protection
(F6/F7 analogue input) is configured and triggers.
Auto mode
This output is activated if temperature is over the pre-set threshold (E1178) and de-activated when
water temperature is lower than 80% of the threshold. AIR FAN is not activated if engine is stopped
(E2057=0).
Manu mode
This output activated when the speed is other than 0.
8.4 Fuel filling / Coolant filling / Oil filling
GENSYS
J6: Input 1: Fuel low level (2230)

J7: Input 2: Fuel high level (2231)
J8: Input 3: Manu fuel fill (2252) Fuel fill relay
J9: Input 4: Coolant low level (2243)
J10: Input 5: Coolant high level (2244)
J11: Input 6: Man cool fill (2253) Output 1: C1
Output 2: C2 Coolant fill relay
J12: Input 7: oil low level (2246)
J13: Input 8: oil high level (2247) Output 3: C3
J14: Input 9: Manu oil fill (2254)
Oil fill relay
F1/F2 F3/F4
Output 1 function (1260) = Fuel filling (2229)

Level sensor Level sensor Output 2 function (1261) = Coolant filling (2242)
Output 3 function (1262) = Oil filling (2245)
Figure 32 - Connections for filling

The 3 filling features all have exactly the same behaviour. Fuel filling will be described below. For the
other functions, fuel is to be replaced by coolant or oil and the variable number by the values shown in
the figure above.

Auto mode
Fuel filling
(2229)
Fuel high level

(2231)
Fuel low level

(2230)
Figure 33 - Fuel filling diagram

Note: If the tank is fitted with a fuel level sender that can be connected to an analogue input
(F1/F2 or F3/F4), it is possible to calculate the fuel low/high limits using equations (see
application note Z090203). In this case, J6 and J7 connections are not needed.
Manu mode
Output is only activated when J8 is closed.
8.5 Configurable I/Os functions

8.5.1 Digital input functions
The digital input functions are distinguished between dedicated and configurable inputs.
For Digital inputs 1 to 10 [E2006,E2007,E2008,E2009,E2010,E2011,E2012,E2013,E2014,E2015] :
• Label
• Validity
• Direction
• Function
have to be defined. For dedicated inputs, only polarity is to be defined.
Input variables numbers: [E2000, E2001, E2002, E2003, E2004]
8.5.2 Configurable input label
This is the name you give to the input. The name will be displayed in the info, alarm, and fault screens
if so programmed.
8.5.3 Validity
Input validity variable numbers [E1287 to 1296] can be set as:
• Never: [E2329]: never active: should be selected if you do not use the input.
• Always: [E2330]: always active: input will be monitored as long as GENSYS has power.
• Post-Starting: [E2331] input will be monitored at the end of the "safety on" timer.
• Stabilized: input will be monitored when genset frequency and voltage have become stable.
• Spare scenario: [E2332]: input will be monitored as programmed in equations.
8.5.4 Input functions
Input function variable numbers: [E1267 to 1286] can be set as indicated in next table.
Unused [0] Should be selected if you do not use the input.

Used by equations [1] if the effect of input activation is not listed below, choose
"used by equations"
Manual water preheat request [E2224] Can be chosen if a coolant pre heating system is installed;
can be used in conjunction with digital transistor output. Will
only work in manual mode.

Manual oil prelub. request [E2225] Can be chosen if a pre lubrication pump is installed on the
engine; can be used in conjunction with digital transistor
output. Will only work in manual mode.
Manual preglow request [E2226] Can be chosen if pre heating plugs are installed on the
engine; can be used in conjunction with digital transistor
output. Will only work in manual mode.
Fault reset request [E2205] If an external reset is wired to the input, choose fault reset
request. This will have the same effect as pressing the reset
key on the GENSYS front panel on Faults and Alarms
displays.
Manual start request [E2227] To be selected if a remote start command in manual mode is
to be installed.
Manual stop request [E2228] To be selected if a remote stop command in manual mode is
to be installed - different from emergency stop.
Manual +f request [E2233] To be selected if a remote frequency increasing command is
to be installed.
Manual -f request [E2234] To be selected if a remote frequency decreasing command is
to be installed.
Manual +U request [E2235] To be selected if a remote voltage increasing command is to
be installed.
Manual -U request [E2236] To be selected if a remote voltage decreasing command is to
be installed.
Fuel high level [E2231] To be selected for a max level sensor or a calculation; can
be used in conjunction with digital transistor output.
Fuel low level [E2230] To be selected for a min level sensor or a calculation; can be
used in conjunction with digital transistor output.
Coolant high level [2244] To be selected for a max level sensor or a calculation; can
Coolant low level [E2243] To be selected for a min level sensor or a calculation; can be
Oil high level [E2247] To be selected for a max level sensor or a calculation; can
Oil low level [E2246] To be selected for a min level sensor or a calculation; can be
Securities inhibition [E2197] Will inhibit all protections. These alarms and faults remain
listed in the faults and alarm logging.
No cranking [E2198] To be selected to prevent engine from starting.
Ext. secu.(Hard shut down) [E2210] If external protections are installed, for immediate stop of the
engine. See recommendation in Directions paragraph.
Ext. fault(Soft shut down) [E2209] If external protections are installed, for immediate opening of
Genset breaker and stop of the engine after cooling down
timer has expired. See recommendation in Directions
paragraph.
External alarm [E2208] If external protections are installed, to report an alarm. See
recommendation in Directions paragraph.
Generator electrical fault [E2217] If external protections are installed, protection will open
genset breaker and try to synchronize again. See

Mains electrical fault [E2218] If external protections are installed, protection will open
mains breaker and try to synchronize again. See
Non essential trip alarm [E2681] Remote non essential load.
HELP + FAULT ( Soft shut down) To be selected to stop the engine after cool down. The
[E2736] GENSYS will ask another engine to start before stopping
itself
HELP + Gen Electrical Fault [E2737] To be selected to activate the "gen electrical fault" action.
The GENSYS will ask another engine to start before
stopping itself
Remote stop horn [E2655] To be selected to stop the external Horn. Useful if one output
is set as "Horn". To be used in conjunction with digital
outputs
Gen. breaker Close manual [E2336] To be selected if manual remote close button for genset
breaker is programmed.
Gen. breaker Open manual [E2337] To be selected if manual remote open button for genset
breaker is programmed
Mains breaker Close manual [E2338] To be selected if manual remote close button for mains
Mains breaker Open manual [E2339] To be selected if manual remote open button for mains
Generator breaker Aux [E2001] To be selected if a different input for the generator breaker
position is required.
Mains breaker Aux [E2000] To be selected if a different input for the mains breaker is
required.
Remote start [E2002] To be selected if a different input for remote start is required.
Oil pressure fault [E2003] To be selected if a different input for oil pressure fault is
required.
Water temperature fault [2004] To be selected if a different input for water temperature fault
is required.
Priority generator [E2241] To be selected if load/unload features depend on a priority
genset; see Configuration -> load / unload menu
Synchronization forced [E2257] Will force GENSYS to synchronize the output with the
governing system. AVR will act so as to synchronize the
genset. The “Power mode” (E2088) is forced to
Synchronization (1).
Fixed kW forced [E2258] Will force GENSYS to give constant power delivery. The
output governing system will maintain a fixed power output
from the genset. The “Power mode” (E2088) is forced to
Fixed kW (4).
kVAR sharing forced [E2259] The output to AVR will share reactive load with other
gensets, using the inter GENSYS CANbus. (E.g. to be used
in manual mode). The “AVR cont. mode” (E2090) is forced to
kVAR sharing (5).
Voltage Droop forced [E2656] Will force the GENSYS to apply Droop to the AVR command.
Set with [E1105]. The “AVR cont. mode” (E2090) is forced to
Voltage droop (1).

No manu mode [E2260] Will inhibit the "Manu" key on the GENSYS front panel.
GENSYS will never be in Manu mode even if you press the
GENSYS Manu key.
External manu mode request [E2261] Will put GENSYS into Manual mode. Will have the same
effect as the GENSYS "Manu" key.
Running with breaker open [E2661] Allow the engine to run in Auto mode without paralleling or
closing its breaker.
Select speed 2 [E2279] Will select the second speed set point.
Select volt 2 [E2280] Will select the second voltage set point.
Select KW 2 [E2281] Will select the second power output set point.
Select PNom 2 [E2513] Will select the second nominal power (active and reactive).
Preheating [E2273] Can be chosen if a coolant pre heating system is installed;
can be used in conjunction with a digital transistor output.
Will work in auto mode.
Manu fuel fill [E2252] To be selected for a manual fuel refill; to be used in
conjunction with digital outputs.
Man cool fill [E2253] To be selected for a manual coolant refill; to be used in
Manu oil fill [E2254] To be selected for a manual lubricant refill; to be used in
Heavy consumer request [E2766] To be selected to activate the "Heavy consumer control"
special sequence.
Table 18 - Input functions

8.5.5 Direction
Input direction variable numbers: [E1297 to 1306]
For each of the ten inputs, two options are possible:
• NO: [0] normally open; should be selected unless the input is used for protection.
• NC: [1] normally closed; should be selected if the input is normally connected to 0V and opens
when active.
8.5.6 Dedicated inputs
In the menu list, each input is named after its pin number on the wiring of GENSYS. Polarity can be
normally open or normally closed. Program this according to the wiring you will have on site.
As a reminder:
• J1 is the Mains breaker position
• J2 is the Genset breaker position
• J3 is the remote start input
• J4 is the oil pressure switch
• J5 is the coolant temperature switch.
[E2000, E2001, E2002, E2003, E2004]
8.6 Digital output functions

Outputs 1 to 5: [E1260,E1261,E1262,E1262,E1264], function and polarity have to be defined.
The "Crank" and "Fuel" relay outputs can be set up for other functions. The initial settings are for
"Crank" and "Fuel". Polarity cannot be changed for these relay outputs. "Crank" output function can be
set with [E1989]; Fuel output function is set with [E1916].
8.6.1 Output functions
Unused [0] To be selected if output is not wired.
Used by equations [1] To be selected if output is used by equations.
Water preheat [E2083] Can be used for coolant pre heat system.
Pre lubrication [E2084] Can be used for pre lubrication pump.
Pre glow [E2085] Can be used for cylinder pre heating plugs
Crank [E2018] Can be used for external crank relay
Fuel [E2019] Can be used for external fuel relay
Excitation [E2211] Can be used to activate an external AVR in a static
synchronizing configuration [see Configuration -> power
plant overview]
Will activate an external excitation relay when engine state
[E2057] is: engine ready [5]; generator ready [6]; wait after
stop request [7]; cool down [8]. In the case of dynamic
paralleling [E1177 = 0], the output will also be activated in
the start [2], warm up [3], and nominal speed [4] states.
Fuel (energize to stop) [E2212] Can be used for an external relay if fuel solenoid has to be
energized to stop the engine. Will activate an external fuel
relay [Energize to stop] when engine is running [E0033 > 0]
and if there is an engine fault [E2046] or a stop request. In
Manual mode the stop request will be the “Stop key” [E2047]
or the “Manual stop request” [E2228] or no fuel [E2019 off].
Generator breaker order [E2016] Can be used to open or close genset breaker.
Mains breaker order [E2017] The outputs configured with this function will have exactly the
same behaviour as the outputs for the Generator breaker [E4
to E6].
Alarms summary [E2202] Faults summary: will activate an output when there is at least
Faults summary [E2203] one “alarm” / “security” / “fault” / “gen. elec. fault” / “mains
Securities summary [E2204] elec. fault” triggered by GENSYS.
Gen. electrical faults summary [E2200]
Mains elec. faults summary [E2201] Output will be activated whenever a protection triggers a
mains electrical fault.
Trip out 1 [E2724] Output activated by the protection in "Non essential
consumer trip" sequence. This is the first trip; Non Essential
consumer trip
consumer trip" sequence. This is the 2nd trip activated
[E1894] sec after the previous one. Non Essential consumer
trip
consumer trip" sequence. This is the 3rd trip activated
trip
consumer trip" sequence. This is the 4th trip activated
trip
consumer trip" sequence. This is the 5th trip activated
trip
Trip out direct [E2774] Output activated by the protection in "Non essential
consumer trip" sequence. This one is activated directly. Non
Essential consumer trip

Smoke limiter [E2213] Output to be used if external speed controller has smoke
limit input. Will activate an output upon start. In Manu mode,
when GENSYS start button is pressed or with a manual start
request. In Auto mode, when engine state [E2057] is “Start”
[2], “Warm up” [3] and “Nominal speed” [4].
Warm up [E2214] This output will activate when engine is warming up. Will
activate an output upon start. In Manu mode, when GENSYS
start button is pressed or with a manual start request and
while the warm up timer [E2061] is different from 0. In Auto
mode, when engine state [E2057] is “Start” [2] and “Warm
up” [3].
Horn [E2206] Can be used for external horn or flashing light relay; output
will activate whenever a protection triggers. The output will
have the same behaviour as the GENSYS front face LED. It
will be activated when a generator electrical fault [E2200],
mains electrical fault [E2201], alarm [E2202], fault [E2203] or
security [E2204] triggers, and while the GENSYS horn button
is pressed.
Air fans [E2215] To be wired to fan relay.

Generator breaker Close [E2219] Can be used to close genset breaker [100 ms pulse]
Generator breaker Open [E2221] Can be used to open genset breaker
Mains breaker Close [E2220] Can be used to close mains breaker.
Mains breaker Open [E2222] Can be used to open mains breaker.
Generates a 100ms pulse on the output, when
Generator/Mains breaker [E2016/E2017] wants to
close/open
Fuel filling [E2229] Can be used for an external fuel pump in conjunction with
"Fuel low level" and "Fuel high level" or "Manu fuel fill"
functions of spare digital inputs.
Coolant filling [E2242] Can be used for a compressor in conjunction with "Coolant
high level" and "Coolant low level" or "Manu air fill" functions
of spare digital inputs.
Oil filling [2245] Can be used for oil level filling in conjunction with "Oil high
level" and "Oil low level" or "Manu oil fill" functions attributed
to spare digital inputs.
+f [E2341] The behaviour will change according to the mode. In Manual
-f [E2342] mode, if you program the +f function, the output will be
+U [E2343] activated when you press the GENSYS [+] key or if there is a
-U [E2344] “Manual +f request” [E2233]. Likewise for the other functions;
-f activates with [-] key or “Manual –f request [E2234]; -f
activates with [+]+SHIFT keys or “Manual +U request
[E2235]; -f activates with [-]+SHIFT keys or “Manual –U
request [E2236]. In Auto mode, these functions will control a
speed / voltage regulator requiring +/- contacts. You can
configure the no action range for the speed [E1598] and for
the voltage [E1599], the impulsion delay for the speed
[E1600] and for the voltage [E1601].
Damper [E2223] Will activate in stop sequence to stop the engine when
damping flap is fitted. Will be activated when there is an
engine fault [2046].
Light test [E2232] This will activate the output whenever the light test key is
pressed on the front panel of GENSYS, or an input
programmed for light test is active

Generator ready [E2331] Output will be active when start sequence is completed and
voltage is present on the generator. In Auto mode, the output
will be activated when the engine state [E2057] is “Gen
ready” [6]. In Manu mode the output will be activated when
the speed [E0033] is positive.
Generator stopped [E2240] Output will be active when genset is at rest. In Auto mode,
the output will be activated when the engine state [E2057] is
“Waiting” [0]. In Manu mode the output will be activated when
there is no speed [E0033].
F1 key [E2262] These keys are useful in Manu mode to control the speed
Shift + F1 keys [E2263] and the voltage.
F2 key [E2264]
Shift + F2 keys [E2265]
Manu mode [E2056] Output will be active when GENSYS is in manual mode.
Starter 2 [E2267] Will be active when a second engine starting system is
present and programmed in Configuration -> Start sequence
menu.
Starter 3 [E2268] Will be active when a third engine starting system is present
and programmed in Configuration -> Start sequence menu.
Ana1 threshold [E2269] Output will be active when the measurement of analogue
input 1 [oil pressure] is under the set value; it will not de-
activate until measurement is over [set value + hysteresis
value]. To be programmed and used with the following
parameters: “Oil threshold” [E1175], “Oil hysteresis” [E1176].
input 2 [water temperature] is over the set value; it will not
de-activate until measurement is under [set value minus
hysteresis value]. To be programmed and used with the
following parameters, “Wat temp thresh” [E1426], “Wat temp
hyst.” [E1427]
input 3 [1st spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 1 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 1 thresh.” [E1428], “Meas 1 hyst.” [E1429].
input 4 [2nd spare measure] is over or under the set value; it
will not de-activate until measurement is under or over [set
value +/- hysteresis value]. To choose the direction of the
protection, see Configuration -> engine/battery settings [SS
measure 2 min or max thresh.].
To be programmed and used with the following parameters:
“Meas 2 thresh.” [E1430] and “Meas 2 hyst.” [E1431].
Available in Auto [E2525] Will activate when the genset has completed its start
sequence in auto mode - can be used for external logic. The
output will be activated when GENSYS is in Auto mode and
the power state [E2071] is not in fault [40, 100 or 255].
Heavy consumer authorization [E2767] Output activated when the heavy consumer starting is
allowed in the "Heavy consumer control" sequence.
8.6.2

Polarity
For each of the five outputs, two options are possible:
• NE: normally energized; the output will de-energize when required, according to its function.
• ND: normally de-energized; the output will energize when required.
8.7 Use spare analog input for digital input

8.7.1 Purpose:
Use spare analog inputs (spare 1 & 2, connections F1-F2 and F3-F4) as digital inputs.
In this case, GENSYS will have 12 digital inputs.
8.7.2 Configuration:
Spare analogue input calibration table should be set as shown below to mimic digital input.
For « Normally closed » or « normally opened » inputs, wiring will be similar, only the software
requires modification.
GENSYS
F1 F2
-BAT
8.7.3 Parameters:
Calibration table for a normally closed input:
V1210 0 N Spare1 calib1 -32768 +32767
V1211 1 N Spare1 calib2 -32768 +32767
V1212 1 N Spare1 calib3 -32768 +32767
V1213 1 N Spare1 calib4 -32768 +32767
V1214 1 N Spare1 calib5 -32768 +32767
V1215 1 N Spare1 calib6 -32768 +32767
V1216 1 N Spare1 calib7 -32768 +32767
V1217 1 N Spare1 calib8 -32768 +32767
V1218 1 N Spare1 calib9 -32768 +32767
V1219 1 N Spare1 calib10 -32768 +32767
V1220 1 N Spare1 calib11 -32768 +32767
V1221 0 N Spare1 res1 +00000 +10000

V1222 1000 N Spare1 res2 +00000 +65535
V1223 2000 N Spare1 res3 +00000 +65535
V1224 3000 N Spare1 res4 +00000 +65535
V1225 4000 N Spare1 res5 +00000 +65535
V1226 5000 N Spare1 res6 +00000 +65535
V1227 6000 N Spare1 res7 +00000 +65535
V1228 7000 N Spare1 res8 +00000 +65535
V1229 8000 N Spare1 res9 +00000 +65535
V1230 9000 N Spare1 res10 +00000 +65535
V1231 10000 N Spare1 res11 +00000 +10000
Then write these equations, to switch to virtual input :
@*********************************;
@analog input to DI/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1 ;
@*********************************;
E2283:= E0031 ;
For normaly opened input, calibration table is similar, you must only
change equation by :
@*********************************;
@entree analogique en TOR/spare 1 ;
@*********************************;
@E0031 analog input spare 1;
@E2283 virtual input 1;
@*********************************;
E2283:= !E0031 ;
NB: See files:

• test_ana_NF.txt
• test_ana_NO.txt

9 Special functions
9.1 Fuel crank relay function

9.1.1 Introduction
With software version 2.09d and later (3.03a for the Crank) it is possible to change this function and
create specific equations for the Fuel and Crank Relays.
This section describes the Custom behaviour of the Fuel and Crank Relays.
9.1.2 Configuration
For Fuel:
If E1916:= 0: The standard function applies, with E2019 to the A2 (fuel) output.
If E1916 := 2xxx: One can create a new equation and switch to the A2 (fuel) output. For this function,
write equations for the variable E2xxx.
For Crank:
If E1989:= 0: The standard function applies, with E2018 to the A1 (crank) output.
If E1989 := 2xxx: One can create a new equation and switch to the A1 (crank) output. For this function,
write equations for the variable E2xxx.
Example 1:
Use the Crank Output to indicate an engine fault.
E1989:= E2217
Example 2:
Create a pulse to the A2 output (fuel)
E1710 is the time of the pulse (100 = 10 seconds)
E1916:= 2440;
BLOC
@example to create a pulse to the output A2 (fuel) pulse ;
TEST E2450 EQ 0 THEN
TEST E2019 EQ 1 THEN E2450 := 1 TEND
ELIF E2450 EQ 1 THEN
TEST E2451 GT E1710 THEN
E2450 := 2
ELSE INC E2451
TEND
BLOC
E2451 :=0;
TEST E2019 EQ 0 THEN E2450 :=0 TEND
BEND
TEND;
E2440 := E2450 EQ 1
BEND

9.2 Load sharing using a central frequency (de-drooping)
9.2.1 Introduction
This section describes the GENSYS’ new load sharing function.
This modification appears in versions 2.09 and later.
It allows perfect load sharing at the right frequency even if the generators are not the same.
When several generators are on the bus bar, one takes a central role with a fixed frequency of 50Hz.
The other generators determine load sharing using an integral so that each one has a perfect share.
The set point of the central frequency is the parameter E1080 (or E1081 if selected).
When the GENSYS starts, one genset is elected to be the master (the first one on the bus). The
master determines the central frequency and load sharing is without an integral. The other gensets
determine the load sharing with an integral, but without using the central frequency.
When you are in state E2071=29 (several generators paralleled with mains), the central frequency is
disabled.
9.2.2 Procedure
1. Download firmware 2.09 or later.
2. In manual mode, using F1 and F2, adjust the speed control output (G9-G11) to obtain the desired
frequency +/-2Hz from each genset.
3. Test that load sharing is working properly (default values inhibit the integral).
4. Activation of frequency centre with genset 1:
In Configuration/modification by variable number adjust E1476 to 2.
In Configuration/Active power regulation menu:
kW sharing GPI
G = 50 %(E1102)
P = 5 %( E1900)
I = 2 %(E1901)
Central Hz gain
G = 25% (E1902)
5. Adjust genset speed to 49Hz on speed governor (GENSYS in manual mode without load).
6. Switch to TEST mode. When the breaker is closed speed should go back to 50.00Hz within 5
seconds. Adjust the Hz central gain (E1902) to adjust the time if needed.
7. Repeat step 6 for all gensets.
8. Test the load sharing by changing the nominal frequency of one generator to 49Hz.
-> bus frequency should remain at 50 Hz and kW load sharing within 2% of that desired. The stability
of load sharing is adjusted with kW sharing GPI / I (E1901)
Remarks:
E1902 = stability of de-drooping (only activated in the master GENSYS, e.g. the one which closes its
breaker first). Adjust to recover 1Hz within 5 sec.
E1476 = 0 Ù Inhibition of central frequency; factory setting.
E1476 = with a high value, response time will be slower (recommended default value =2)
E1901 = Load sharing integral, is only active on the slave GENSYS units.
E1102 = Global gain of load sharing is obtained by multiplying the PI and the central Hz gain.
E2739 = 1 Ù I am the master (I control the frequency).
E2739 = 0 Ù I am a slave (I share load using the integral)

9.2.3 GCR synchronization & mains paralleling
The following equations should be added in level 1 or 2 if the synchronization bus is used (terminal 42
of GCR, terminals G1 & G3 of GENSYS):
@ ******************************************************;
@ digital input 1 is closed during mains synchronization;
@ mains breaker feedback is connected to terminal J1 ;
@ Don’t forget to allow parameter E1476 and E1020 to be ;
@ modifiable by modbus and equations ;
@*******************************************************;
TEST (E2006 EQ 1) AND (E2000 EQ 0) EQ 1 THEN
BLOC
E1476:=0;
E1020:=20000
BEND
ELSE
BLOC
E1476:=2;
E1020:=0
BEND
TEND;
9.2.4 INTEGRAL INHIBITION
To disable this type of load sharing and return to the factory setting, apply the “Disable value” from the
table below.
The variables involved in this new load sharing are:
De-
Variable Disable
Label Description droop
number value
value
V1900 Load sharing P Parameter to set the Proportional gain. 5 1
V1901 Load sharing I Parameter to set the Integral gain. 2 0
Parameter to control the central frequency, acting

V1902 Hz centre gain 25 0
as a frequency standard
V1476 XXXXXX 2 0
not not
V2739 Master gen. Nb If 1 this GENSYS is the master.
used used
Warning:
When the CAN bus is not used, you have to disable load sharing (see table above).
In the case of a CAN bus failure where E1259 is not set at 6 (load sharing in droop
disabled), you also have to disable load sharing.

9.3 Pulse control calibration procedure
Procedure for calibrating the +Hz and –Hz outputs on the GENSYS in order to have good frequency
droop compensation and load sharing.
1. Enter the following parameter in the information screen: E2058.
2. Set the external speed potentiometer to its centre position.
3. Set the following parameters:
• E1598 on “50” which is about 1 percent load sharing difference (dead band on E2058)
• E1600 on “2” which is 200 msec. pulse time
• E1874 on 2,0 sec which is the pulse pause time for frequency/voltage compensation
• E1873 on 0,1 sec which is the pulse length for frequency/voltage compensation.
• E1309 on 0 which is the phase Integral gain.
• E1113 on 0 which is Frequency Integral gain.
NB: For best results in sync it's important to set the GPID synch values high (80 to 200).
4. Start the engine with GENSYS in manual mode.
5. Engine should run near the nominal speed with deviation due to mechanical droop.
6. Put engine in Automatic mode. In this case the GENSYS should control the output until it
is running at the nominal speed, if a difference is present.
7. Set the frequency compensation for a recovery time of 10 sec for 0,5 Hz compensation
(E1874).
8. If the generator is changing the speed but over- or undershoots the nominal speed the
length of the E1873 pulse is too long. Make it a little bit shorter.
9. If it takes too long to reach the nominal speed the E1874 period is too long. Make this a
little bit shorter.
10. If you are not able to get the right compensation than the following needs to be checked:
- Does the potentiometer still turn if the GENSYS is sending an output signal.
- If not, the potentiometer is not able to control a sufficient speed range.
11. If each pulse causes overshooting it can be caused by the potentiometer motor running
on, even when the pulse is off. A shunt resistor over the motor input could solve this
problem.
12. Load the generator in island operation and the GENSYS in automatic mode, if possible
with full load.
13. Check if it still compensates the frequency according to the above specification (0,5 Hz in
10 sec).
14. If this is OK the Frequency compensation is set. (Repeat for all available engines)
15. Switch on one engine in auto mode and load it at 100 percent.
16. Disconnect the output to close the generator breaker of the next engine.
17. Start this engine in auto mode and wait until it shows in the information screen that it is
synchronizing. Simulate on the Generator aux input that the breaker is closed.
18. In the information screen you should see that the unit is in Load sharing mode.
19. Check the value of E2058: this should read as follows:
a. For the engine which is supplying the load, the value should be about – 6000.
b. For the engine which is not supplying the load, the value should be about + 6000.
20. If this value is lower than + 6000 or higher than – 6000 you have to increase the Load
sharing Gain.
21. If this value is higher than + 6000 or lower than – 6000 you have to decrease the Load
sharing Gain.
22. If you are still not able to reach this value you can do the following:
• Reduce the value of the load sharing 3 times.
• Set parameter E1473 to “1” instead of “3”, which makes the value of the Load sharing Gain 3
times stronger.
Repeat from step 19.
The same procedure has to be used for the calibration of the voltage control.
• E1599 No action window +U/-U (in %), default value = 50
• E1601 Impulsion delay +U/-U, default value = 2 (200ms)
• E1874 on 2 sec which is the pulse pause time for frequency/voltage compensation, this
parameter was adjusted for the speed control, do not modify.
• E1873 on 0,1 sec which is the pulse length for frequency/voltage compensation, this
parameter was adjusted for the speed control, do not modify.
E2058 Load sharing / Synchro pulses only
GENSYS wants the genset to go faster
Maxi(+Hz) = +7000
E1598 = DEADBAND
Maxi( –Hz) = -7000

GENSYS wants the genset to go slower
E2342 E1600
= pulse -Hz
E2341 T=700/E2058 seconds

= pulse +Hz
Frequency center pulses only

Frequency Hz=E0020
GENSYS wants the genset to go slower
DEADBAND=0.1Hz
GENSYS wants the

genset to go faster
E2342 E1873
= pulse -Hz
E1874
E2341 E1873
= pulse +Hz
E1874
Somation of both signals
E2342 E1873
= pulse -Hz
E1874
E2341 E1873
= pulse +Hz
Figure 34 - Speed and voltage control with Contact / Pulses (1)
GENSYS
K1 K2 K3 K4
C1 C2 C3 C4
K1 K2 K3 K4
Lower Volt
Raise Volt
Lower Hz
Raise Hz
Figure 35 - Speed and voltage control with Contact / Pulses (2)

9.3.1 Parameters
Parameter Value Description Menu
E1260 +f [E2341] Output C1 Configuration/Transistor digital outputs
E1261 -f [E2342] Output C2 Configuration/Transistor digital outputs
E1262 +U [2343] Output C3 Configuration/Transistor digital outputs
E1263 -U [2344] Output C4 Configuration/Transistor digital outputs
9.4 Operator controlled return of mains

Explanation:
Normal operation: In the case of mains failure, the engine starts and takes the load. When the mains
voltage returns, the engine resynchronizes with the mains and automatically gives back the load.
The “Operator controlled return to mains” special function (set with the parameter E1620 = 1) allows
the operator to control the moment the engine will return the load to the mains.
The GENSYS waits for E2584 = 1 (Virtual input 40) before re-synchronizing the engine to the mains.
How to set this function:

The E1620 variable must be set to 1.
The Virtual Input 40 must be set as “used by equations” (E1699=1)
This virtual input can be associated to:
• a digital input: Ex: E2584= E2006;

• a Wago deported digital input : Ex: E2584:= E0158;
• an equation result:
E2584 := ( E2440 GT 1000) AND ( E2006 EQ 1)
Summary:
• E1620 = 1.
• E2854 = Virtual Input 40 to allow the genset to return the load to the mains.
• E1699 = 1 : (E2584 ( VI 40) is “used by the equations)
Variables used
E1620 Inhibition of Variable 13= Operator return Mains ( + E2584)

E2584 Virtual input Spare 40
E1699 Virtual Input 40 associated function.
9.5 Mains & Generator electrical fault options

Mains electrical fault management
Parameters (default value in bold):
E1846: Open breaker: selects the breaker that will be opened upon a "Mains electrical fault". Choose
between the "Mains" breaker or the "Generator" breaker or "both".
E1841: Fault start: allows the engine to start upon a "Mains electrical fault". You can select "Yes" to
start the engine or "No".
E1840: Start delay (0.0): is the delay between the "Mains electrical fault" and the engine start. It will
delay a digital or virtual input. In the case of an internal detection, this delay bypasses the delay of the
protection.
E1842: No load delay (60.0): is the time for which the engine runs without load when the generator
breaker is opened. If the delay is 0, the generator will never stop.

Default configuration
Start on fault and open generator on fault
This parameter is useful in permanent mains paralleling mode with "open generator breaker on mains
failure". It can be used if the generator nominal power is not high enough to take the load in island
mode.
In this case, the generator will provide power, but if there is a mains failure the generator will not take
the load alone, and opens its breaker.
In case the setup of the unit does not generate an engine start upon mains failure, it will run with no
load and stop after a preset time (E1842).
Generator electrical fault

Parameters (default value in bold):
E1843: TM re-synch. (30.0): the delay before the generator tries to re-synchronize with the Mains after
a "Generator electrical fault".
E1844: Nb re-synch. (3): number of attempts to re-synchronize.
In the case of a generator electrical fault, the generator breaker is opened and the GENSYS is in state
40. In this state, the alternator is de-excited (if wired) during a timer (E1265). After this timer, if the fault
is still present, there is a hard shutdown. Otherwise GENSYS will try to re-synchronize.
Configuration : Change over with one digital input programmed

in "Mains electrical fault"
When Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Voltage bus
presence E2054
Start sequence
Timer before start on Mains back timer
Mains electrical fault
Production
request E2072

Configuration : permanent mains paralleling with one digital
input programmed in "Mains electrical fault"
Breaker openned on Mains electrical fault is Mains
Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back Synchronization

timer
Production
request E2072

Breaker openned on Mains electrical fault is Generator
Start on Mains electrical fault is No
Remote start is always On
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back Synchronization No load Mains back timer

timer running timer
Production
request E2072

Breaker openned on Mains electrical fault is Generator
Start on Mains electrical fault is Yes
Generator CB
E2001
Mains CB
E2000
Mains electrical
fault E2201
Bus voltage
presence E2054
Mains back Synchronization No load Mains back timer

timer running timer
Production
request E2072
Permanent Mains paralleling and

generator electrical fault
Power state
E2071 ParalleledFaultSync Paralleled Fault Sync ParalleledFault Sync ParalleledFault Sync ParalleledFault Stop
Generator CB
E2001
Generator electrical
fault E2200
Delay before re- Delay before re- Delay before re- Delay before re-
synchronization synchronization synchronization synchronization
Number of re-
synchronization
attempt = 3 Delay before reset of the
number of re-synchronization
attempt
0 1 0 1 2 3 4 0
NOTE :
Never use “No start on fault” in conjunction with "open mains on fault" in permanent
mode or no break change over mode.
Always use “No start on fault” when "generator breaker" or "both breakers" to open is
selected.
9.6 GENSYS with external automatic start module

9.6.1 Overview
This chapter describes how to interface the GENSYS with an engine which has got its own automatic
start module. The start sequence is redundant in the system. The following diagram shows the main
functions of each device:

Remote start
Auto Start GENSYS

Module
Start request Synchronisation
Start sequence Electrical protections
Engine GE breaker control
protections Generator ready PF control Mains/Bus voltage
Engine alarm kW control
Engine fault Monitoring
Oil pressure
Crank Water temp
Pickup
Governor AVR 3*U 3*I
Engine
M
Figure 36 - Wiring GENSYS with Auto Start Module
Signal description Direction Auto Start Module (ASM) GENSYS
Start request GENSYS->ASM Remote start input C5
Genset ready ASM->GENSYS Digital output J15
Engine Alarm ASM->GENSYS Digital output J7
Engine Fault ASM->GENSYS Digital output J6
Table 19 - Wiring GENSYS Ù Auto Start Module

GENSYS does not need oil pressure and water temp digital inputs. This table is shown as an example
only and can be customized as needed.
Specific parameters & equations to enter into the GENSYS:

1. To inhibit the auto start sequence of the GENSYS you need to set 1608 = 1. You will also find this
parameter in the example of text file:
V1608 1 Inhibit var 1 +00000 +65535
2. To accept the “Generator OK” input you need to add the following equation in level 1.
E2515 := E2015;
If your Auto Start Module only has an “Engine start” output (activated when crank disconnect set point
is reached), add an external delay timer or enter the following equation:
E2515 := E2015 AND ((E0033 GT (E1080*95/100)) OR E2515);
E0033 is the speed and E1080 is the “Speed setpoint 1”.
3. To set output C5 as a “Start request” you need to add the following equation in level 1:
E2024 := (!E2005) AND (!E2046) AND ((E2056 AND (E2045 OR E2227 OR
E2024) AND (!E2047) AND (!E2228)) OR (E2055 AND E2059));
4. To display the Engine Fault set the GENSYS' digital input 2 as an alarm.
5. To open the breaker upon an engine fault, set GENSYS digital input 1 as a hard shut down.
The following text file is the text file of an application tested on site:
Power plant example:
One single genset (1800 RPM) in parallel with mains in base load mode.
Emergency start.
Manual breaker on the mains side.
Motorized breaker on generator side.
Auto Start Module has a generator ready output.
Copy the following text and paste it in a new text file only.
You can download it to a GENSYS (level 1) as a starting point before commissioning.
CAUTION: this file is only a guide and is not enough to start a new application.
{PARAMETERS}
V1080 1800 Speed 1 +00000 +65535

V1081 1800 Speed 2 +00000 +65535
V1608 1 Inhibit var 1 +00000 +65535
{INIT L1}
@ WARNING : if section empty or missing, existing equations will be lost.
{EQUATIONS L1(every 100ms)}
@ WARNING : if section empty or missing, existing equations will be lost.

PROG 1
BLOC
E2515 := E2015;
E2024 := (!E2005) AND (!E2046) AND ((E2056 AND (E2045 OR E2227
OR E2024) AND (!E2047) AND (!E2228)) OR (E2055 AND E2059))
BEND
.
{END OF FILE}
9.7 Remote start upon external pulse

To set the GENSYS to start upon an external pulse input, 2 solutions can be used:
-Use a relay
-Set an external input
9.7.1 Setting external input
This variable E2514 (Virtual Start) must be maintained at « 1 » after the first rising edge and
go to 0 after the second rising edge.
Example is for the J10 input:
@ WARNING : if section empty or missing, existing equations will be lost;

PROG 1
BLOC
@@@@ PULSE ON REMOTE START FROM EXTERNAL @@@@;
@ E2585 = Value of the E2015 with one cycle less to detect a pulse;
@ ( E2015 EQ 1) AND (E2585 EQ 0) Detection of a top pulse;
@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@;
E2585:=E2015;
E2514:=((E2514 OR ((E2015 EQ 1) AND (E2585 EQ 0))) AND ((E2514 AND
((E2015 EQ 1) AND (E2585 EQ 0))) EQ 0))
BEND
.
Don’t forget to set the input
V1276 1 N DI10 function +00000 +02999
Here the variable E2585 detects a rising edge on E2815.
The cycle or the variable E2815 goes from 0 to 1. The variable E2585 stays at 0 a cycle longer in
order to see E2815 =1 and detect the rising edge.
You can also detect the falling edge by changing the equation:
(E2815 EQ 1) AND (E2585 EQ 0) to (E2815 EQ 0) AND (E2585 EQ 1).
9.8 Safety Inhibitions

9.8.1 Objective
Safety inhibitions are mandatory on certain types of application, particularly in safety generators used
in public spaces (norm NF E 37-312).
The aim is to inhibit the oil pressure and water temperature safeties on the GENSYS. Thus, in the
case of a fault, the generator remains in operation. Other protections (over speed, overload, etc...) are
still active if set.
9.8.2 Configuration
Note: If E2197 is active, there will never be a Generator electrical fault (E2046).
Hardware:
Contacts for oil pressure and water temperature are no longer connected to J4 and J5 but to spare
configurable inputs.
In this example, the oil pressure and water temperature contacts are on J13 and J14.
Software:
The following equations must be downloaded to level 1 or 2
BLOC
@***************************************************************;
@Inhibition de la pression d'huile et de la temp eau ;
@***************************************************************;
@E2011 Entree logique 6 GENSYS inhibition securite ;
@E2012 entree spare 8 J13 pression d huile ;
@E2013 entree spare 9 J14 temperature eau ;
@E1274 fct entree spare 8 ;
@E1275 fct entree spare 9 ;
@E0033 vitesse ;
@E1712 param utilisateur: seuil de vitesse demarrage ;
@E1714 param utilisateur: seuil de vitesse arret ;
@E1456 Sens pression dhuile ;
@E1457 Sens temperature eau ;
@E2283 entree virtuelle 1 alarme inhibition ;
@***************************************************************;

BLOC
E1457:=0;
E2283:=1;
E1275:=2208;
TEST E0033 GT E1712 THEN E1456:=0
ELIF E0033 LE E1714 THEN E1456:=1
TEND;
E1274:=2208
BEND
ELSE
BLOC
E1456:=E2012;
E1457:=!E2013;
E2283:=0;
E1274:=1;
E1275:=1
BEND
TEND
BEND

9.9 GENSYS with 500Hz PWM (Cat/Perkins)
9.9.1 Schematic
See note 4
Pickup input
See note 1
power supply
isolated from
Chassis
G8 G7
Pickup +
Pickup -
-Alim
G10
Shield
K3
power supply -
-
Battery
K4
Actuator +
OR
F
Power supply +
K2
+
regulator
Speed
Actuator -
K5
F
Emergency
A3
stop
See note 5
H2 H4 H3
AVR out +
G
AVR
CRANK Crank
A1
relais out AVR out -
+Alim
Shield 1
diverter
Surge
Fuel
A2
FUEL relay out
100 - 480 V
F
Gen L1
B2 B3 B4 B1
L1
F
L2
Gen L2
F
Gen L3
L3
C1 Output 1
Gen N
N S1
P1
1-5A
D6
Gen I3+
Output 2
C2
D5
Gen 3-
S2
P2 S1
P1
Output 3
D4
Gen I2+
C3
D3
Gen I2-
S2
P2 S1
Output 4
C4
Not required
Always present
P1
D2
Gen I1+
+Alim
Output 5
C5
Gen I1- D1
S2
P2- Alim
Shield
F5
E6
Gen common
Oil pressure meas. -

F8
E5
Gen Breaker NO
Oil pressure meas. +
F9
E4
Gen Breaker NC
Water temp meas. -

F6
Utility
Water temp meas +
F7
Engine meas. 1 -
F1
E3
Mains common
Engine meas. +
F2
E2
Mains Breaker NO
Engine meas. 2 -
F3
- Alim P1
E1
Mains Breaker NC
Engine meas. 2 +
F4
S1
See note 2
D8
Mains I1 +
Mains power for single

GENSYS
D7
Mains I1 -
from GCR for several
Synchronisation input
G2 G3
generator Shield
S2
P2
100 - 480 V
generators
0-20mA - Mains L3
B6 B5
L3
F
See note 7
See note 2
+/- 20mA or +/- 10V Mains L1

L1
several generators
bus bar when
Connected to the
diverter
Surge
G1
0-20mA +
G5 G6
Shield
Mains
GCR or BC analog
Parallel lines to
Parallel +
load sharing
See note 6
Mains breaker IN
J1
G4
Parallel -
Gen Breaker IN
J2
Remote start/stop
J3
See note 3
MODBUS
DB9 male
Oil pressure
9 - 0V
8 - NC
7 - NC
6 - A (+)
5 - B (-)
4 - 0V
3 - 0V
2 - NC
1 - NC
J4
RS 485
Water temp
J5
- Alim
Input 1
J6
other GENSYS
See note 6
DB9 male
9 - NC
8 - NC
7 - CANH
6 - 0V
5 - 0V
4 - NC
3 - 0V
2 - CANL
1 - NC
CAN1 to
Input 2
CAN 1
J7
Input 3
J8
Input 4
J9
DB9 male
CAN 2 to
9 - NC
8 - NC
7 - CANH
6 - 0V
5 - 0V
4 - NC
3 - 0V
2 - CANL
1 - NC
CAN 2
options
J10
Input 5
J11
Input 6
J12
Input 7
RS232 to PC or
DB9 female
RS 232
7 - RTS
6 - DSR
5 - 0V
4 - DTR
3 - Rx
2 - Tx
1 - NC
9 - RI
8 - CTS
modem
J13
Input 8
J14
Input 9
J15
Input 10
Note 1: If a speed governor is used, connect the battery negative to the speed governor and connect
“Power supply –“(K3) to the speed governor. Otherwise, connect directly to the battery. Always use
4mm² wires.
Note 2: For a peak shaving application, a mains power measurement is required. This can be done
internally via the Mains current input (D7/D8), or externally, if you use an external power measurement
such as a CPA connected to the “0-20 mA input” (G1/G3). You have to choose one of the two
measurements and you can disconnect the other.
Note 3: “Mains breaker in” (J1) is useless in the following cases:
- Several generators with no voltage regulator.
- Generator alone on the utility.
- In “No change over” mode.
Note 4: If the speed measurement is taken from a magnetic pick up, then “Pickup-“ (G7), “Pickup+”
(G8) and “Shield” (G2, G5 or G10) are required. You can also measure the speed from the alternator
frequency, but magnetic pick-up is recommended.
Note 5: Only if an AVR is used for kVAR sharing and cosφ regulation, but not necessary.
Note 6: For load sharing communication lines are necessary. If you use only GENSYS, the COM2 is
required. If there is another module using analogue load sharing, parallel lines (G4/G6) are required.
Note 7: In several generators mode, an external synchronization module (such as GCR) is necessary
for synchronization with mains.
9.9.2 Configuration
The GENSYS has to be ordered with the modification number A40M090.
Variable number Label Value Description

Activates the speed control with 500Hz PWM. In this mode
E1639 500 Hz ACT 1
the analogue speed output (G9 / G11) is unavailable.
Is the PWM for nominal frequency. If 50.00% is set, the PWM
E1077 ESG offset 70%
will be 50%.
ESG Is the range of PWM. For example, if you have set 20.0%, the
E1076 30%
amplitude PWM will vary +/- 10%.
PWM (%)
Offset = 70%
Amplitude = 30% 100
85
70
55
Min correction 0 Max correction Deviation

(E2058)
Figure 37 – PWM dynamic diagram

GENSYS with BSM II
Schematic
BSM II
GENSYS 5 CANH ; 7 CAN L
CAN2(COM3) + R 120Ohms
A40W2
Figure 38 - Schematic
Note 1: An A40W2 cable (a CRE product) is recommended to connect GENSYS to BSM II.
Connect “CAN H” (terminal 5) of BSM II to the Blue/white striped wire and connect “CAN
L“(terminal 7) of BSM II to White/Blue striped wire.
Note 2: If BSM II is at the end of the CAN bus, add one 120Ω resistor in parallel with terminals 5
and 7.
9.9.3 Configuration
The communication between GENSYS and BSM II uses CANopen protocol. BSM II is a slave unit and
GENSYS is a master unit.
GENSYS can be connected to several devices by its COM3 port: BSM II (Max 2), Wago© coupler
(Max 32).
Only one of the two BSM II must be set to archive data from GENSYS (limited by the number of
message sent from GENSYS).
9.9.4 Standard procedure
This example allows you to log the most significant variables of your application when an alarm
occurs.
See also the application note “A43Z090100A” to configure the BSM II logging.
• Download the text file (level 1 equation) “Z090211a_1.txt” to the GENSYS.
• Download the text file (level 1 equation) “A43Z090100a_1.txt” to the BSM II.
Archiving of data begins immediately.
Variables are stored in the BSM II when an alarm occurs:
• 1 sample per second
• 5 samples before the alarm
• 1 sample when alarm occurs
• 5 samples after the alarm
See the application note “A43Z090100A” to retrieve archives from the BSM II.
Note 1: in this configuration, the BSM II node ID is equal to 1. Be careful that any other device on
the CAN bus has the same node ID.
Note 2: Variable transmitted
AO Var. AO Var. AO Var. AO Var. AO Var. AO Var.
Alarm kW GE V1 I2 kW3
1 5 9 13 17 21 Free
E0516 E0018 E0000 E0007 E0011
kW PwrMngt
Hz GE V2 I3
2 mains 6 10 14 18 Status 22 Free
E0020 E0001 E0008
E0036 E2071
Hz cosϕ Engine
V3 kW1
3 mains 7 GE 11 15 19 Status 23 Free
E0002 E0009
E0023 E0021 E2057
4 U13 8 Sum 12 I1 16 kW2 20 free 24 Free

mains Digital E0006 E0010
E0022
Sum Digital = each digital variable is equal to one bit.
• Bit0 = breaker in mains (E2000)
• Bit1 = breaker in GE (E2001)
• Bit2 Æ Bit14 : free
• Bit15: forbidden
9.9.5 Custom procedure
This procedure shows you how to customize equations to send your own variables to the BSM II.
See also the application note “A43Z090101A” to customize the BSM II archiving.
Download the text file (level 1 equation) “Z090211a_1.txt” to the GENSYS.
Download the text file (level 1 equation) “A43Z090100a_1.txt” to the BSM II.
Customisation: see notes below.

Note1: Change the Node ID of BSM II
See BSM II user's manual to choose the node ID in the BSM II.
Then change this Node ID in the settings of the GENSYS (default ID equal 1):
-Go to CANopen menu: configuration / << / CANopen
-In each input/output message used, change "Mod. ID" to the correct value.
Note2: Delete message
If you do not need to send all variables set in default equations, you can delete output
messages.
Go to CANopen menu: configuration / << / CANopen / Output message
Change “Typ. Out mess” to UNUSED to remove the message
Change “Mod. ID” to 0
Note3: Add message
Each message sends a maximum of 4 Analogue values to BSM II.
Go to CANopen menu: configuration / << / CANopen / Output message
Set "Mod. ID" to the correct Node ID of the BSM II.
Set “Typ. Out mess” to ANALOG
Set “Nb of Outputs” (Max 4)
Add equations as described below:
All variables are transferred as analogue outputs from GENSYS to BSM II.
Analogue output GENSYS Variable
AO1 Æ AO8 E2432 Æ E2439
AO9 Æ AO16 E2682 Æ E2689
AO17 Æ AO32 E2708 Æ E2723
All variables are transferred as analogue inputs from BSM II to GENSYS.
Analogue input GENSYS Variable
AI1 Æ AI44 E0285 Æ E0328

To transfer a variable from GENSYS to BSM II, write the equation below in level 1:
Example:
@ Allocate AO1 (E2432) to the measure of kW (E0018)

E2432:=E0018;
Transfer several digital variables (max 15) in one analogue output.

Each bit of the AO is equal to a digital variable.
Example:
@ allocate AO8 to digital outputs

@Breaker mains(b6) + 6 Digital Outputs(DO6=b5 -> DO1=b0);
E2439:= 0;
E2439:= X2439 + (64*E2000) + (32*E2445) + (16*E2444) + (8*E2443) +
(4*E2442) + (2*E2441) + E2440;
Note: In the PLC equation, variables are considered as signed integers. This means that bit 31
is the sign and cannot be used.
9.10 GENSYS with Carantec

9.10.1 Wiring parallel lines:
Gensys Carantec
Parrallel lines + G6 13 Parrallel lines +
Parrallel lines - G4 44 Parrallel lines -
9.10.2 Configuration of GENSYS

Change the next parameter in the PLANT/CONFIGURATION menu:
Compatible ILS 1158= YES (0)
Gest Dead bus 1515= NON (1)
9.11 GENSYS with TEM compact

This chapter describes how to interface the GENSYS with the TEM compact from Deutz Engines.
The association of the TEM and the GENSYS is an excellent solution to parallel a generator set with a
Deutz Engine prime mover.
Some functions are redundant: the kW regulation and the start sequence. The following diagram
shows the main function of each device:

Remote start
Actual
TEM kW GENSYS
Remote
Start sequence I/O Can Synchronisation
Engine kW Electrical protections
Open
protections demand kW measurement
2* 0-20mA
KW control outputs GE breaker control Mains voltage
Gaz protections PF control
Start request
+ Hz
-Hz
Generator ready
Engine alarmt
Engine fault
AVR 3*U 3*I

Deutz gaz
engine
M
Figure 39 - Wiring GENSYS Ù TEM
Signal Remark Direction TEM Compact GENSYS / Wago

description
Start request used only if the kW set GENSYS->TEM X141-4 X142-4 C5
point is in the TEM
kW demand Used to start/stop and to GENSYS/Wago Wago output 2
0-20mA fix the kW set point. ->TEM
Genset ready TEM->GENSYS X31-5 J15
X31-6
TEM Alarm Relay TEM->GENSYS X31-1 J7
X31-2
TEM Fault Relay TEM->GENSYS X31-3 J6
X31-4
+ Hz Digital signal GENSYS->TEM X141-6 C1
X142-6
- Hz Digital signal GENSYS->TEM X141-7 C2
X142-7
Pickup G7 – G8
Analog AVR AVR=MX321 GENSYS->AVR H2 – H4
signal
Actual kW GENSYS -> TEM Wago output 1
0-20mA
Table 20 - Wiring GENSYS Ù TEM

The following text file is the text file of an application tested on site:
Power plant:
• One single genset in parallel with mains in base load mode.
• No emergency start.
• Manual breaker on the mains side.
• Motorized breaker on generator side.

Generator set:
Engine:
• DEUTZ TBG 616V12K,
• 450/525kW 1800RPM.
• TEM COMPACT engine management system
Generator:
• Newage/Stanford 1800RPM,
• 480/277V, 910kVA
• AVR MX321
Power management:
• GENSYS (CRE), Soft V1.25
• Remote analog I/O 0-20mA (Wago)
Copy the downloadable text file from the website and paste it in a new text only file. You can download
it to a GENSYS as a starting point before commissioning. This file is only a guide and is not enough to
start a new application.
9.12 Under voltage trip coil

Equation for under voltage trip coil:
Example (two different ways):
@***************************************************************;
@Bobine à manque ;
@***************************************************************;
@E2020 Digital output ;
@E2016 Command Output breaker GE ;
@E2001 Gen breaker in ;
@***************************************************************;
BLOC
TEST (E2001) AND (E2016) EQ 1 THEN E2470:=1 TEND
BEND
BLOC
TEST E2016 EQ 0 THEN E2470:=2 TEND
BEND
BLOC
TEST E2001 EQ 0 THEN E2470:=0 TEND
BEND
TEND;
E2020:=!(E2470 EQ 2);
Or:
E2020:=!((!E2016) AND E2001);

9.13 Level -1 (G59 & counters)
The end user can access limited parameters without using the level 1 password.
To activate the level 1 password menu, you have to connect in level 2, enter the “System” menu, and
then go to “level-1 password menu”.
Then set 1610 to the menu you want (None, G59 or Meter Pres).
Press [ENTER]
Don’t forget to save the settings on the GENSYS by pressing [SHIFT] + [ i ]
In this menu, you can also change the custom password. The default password is “CustMenu”.
Now, you can only access the specific menu and its parameters by inserting the custom password in
the password menu.
Specific applications
Meters preset
With this option you can set all the counters, and not only reset them.
Don’t forget to save the settings on the GENSYS [SHIFT] + [ i ].
G59 option
G59 is a protection norm widely used in the UK.
You can set and lock the following protections:
Mains Under / Over frequency
Mains Under / Over voltage
Vector surge
ROCOF (df/dt)
When the protections are locked, thresholds, timers and controls are also locked.
You can also change the custom password to an official application.
Don’t forget to save the settings on the GENSYS [SHIFT] + [ i ]
9.14 Scada
GENSYS communication uses industrial standards. This product is versatile, and can be used with
Modbus, for example to be controlled by a SCADA system.
CRE Technology offers different solutions for such applications (remote display, remote control, event
and alarm management …). Contact us for more information.
9.15 How to set a GPID

9.15.1 Principle
A GPID allows the control of any system in a simple way. Figure 38 shows a typical GPID.
P
+
Set Deviation
point
G I
-
D
Measure
G: global gain
P: proportional gain
I: integral gain
D: derivative gain
Figure 40 - Typical GPID controller

The G parameter acts as sensitivity adjustment for the other parameters.
The P parameter adjusts the rise time (time needed for the system to reach its set point for the first
time). By increasing P, the rise time will decrease. However, overshoot will increase and may also
render the system unstable (fast hunting). Using only the P factor will always leave a difference
between the set point and the actual value (this difference is also called droop).
The I parameter reduces the difference between the set point and the actual value. By increasing I,
the rise time will decrease. However, overshoot will increase and may also render the system unstable
(slow hunting).
The D parameter increases the stability and minimizes the overshoot phenomena. By increasing D,
overshoot will decrease but the system may still be unstable, particularly if the measured signal is
disturbed (sensor signal not filtered).
9.15.2 Empirical method settings
First set G to 50%.
Set the parameters P, I and D to zero.
Increase the value of P until the system becomes unstable. From this position, decrease the value of P
to 60% of the previous value.
Set I in the same way.
Increase D if the system is unstable upon fast load variation.
If stability cannot be achieved, restart the settings and reduce (system unstable) or increase (system
too slow) G.
9.16 Automatic load / unload

This function automatically controls the start and stopping of several generators of a power plant
depending on the load request, whether paralleling with the mains or not. Coordination with the other
GENSYS units is via the CAN bus (COM2).
Required configuration to allow automatic load / unload:

-All the remote start inputs must be on, on each GENSYS (connected to 0V).
-At least 2 generators must have GENSYS units.
-The "Load/Unl. Mode" (E1258) variable should be set to "Hours run" or "Digital in", which sets the
priority generator.
-If remote start is off, the generator never starts.
A generator can run in "Forced running" mode using a digital input. Select a digital input with the
function "Priority generator". Activate this input. The generator starts, synchronizes, closes its breaker
and stays on the bus bar until "Remote start/stop" is de-activated.
If there are no generators in "Forced running" mode, the priority generator with "remote start" always
starts and closes its breaker on the bus bar, even if there is no load.
When all generators are stopped and have "remote start" activated, upon start-up the "Forced
running"" generators stay on the bus bar while the others coordinate stopping one by one.
How to determine the priority generator (which starts/stops) by using the variable "Load/Unl. mode"
(E1258):
-"Hours run" selected: the generator which has the least running hours has the priority to start, the
generator which has the most running hours has the priority to stop.
-"Digital in" selected: the generators start following a logical sequence ("Gen. number": E1179),
starting from the generator which is in "Forced running" mode (as shown below).
Note:
To force the start of a generator in load / unload mode, during commissioning for example, remote
start and digital input (in "Priority generator" mode) must be activated.
In "Hour run" mode, if a generator starts and goes past the hours run by a generator which is stopped,
the first one does not immediately stop and the second one immediately start. Coordination between
generators is activated only during a load or unload request, i.e. in the next start/stop on load request.
During a load request, only the stopped and available generators coordinate (auto mode selected; no
hard fault).
During an unload request, only the started generators coordinate.
GENSYS units in manual mode do not take part in start or load sequence.

10 GENSYS PLC
10.1 Introduction
The core system of the GENSYS is based on a list of predefined variables.
The file named “40 Z0 9 0030.xls” gives an explanation of each of them.
The variable number always uses the same format.
The first digit is the type of variable:
• 0 Measurement or real time value (Ex: Voltage phase 1, CAN Bus Fault …)
• 1 Parameter to be stored in non-volatile memory (Ex: Genset number, Nominal power …)
• 2 General purpose variable (Ex: Alarms, PLC variables …)
•
The next 3 digits are the number of the variable.
All the parameters (Variable from 1000 to 1999) of the GENSYS are stored in a non-volatile FLASH
memory in the module. It is possible to download or upload these parameters with a computer allowing
the user to save, modify and reuse these parameters later.
All these values are stored in a text file. The following chapter describes the layout of that file.
10.2 File description

The text file is composed of 5 parts:
• Parameter definitions
• Label definitions
• Unit definitions
• Initialization definitions
• Equation definitions
10.3 Parameter definition block

The starting point of this block is designated by a "{PARAMETERS}" statement.
Each parameter (1xxx or 4xxx variable) can be found as an input in this block. The structure of the
input is as follows:
The variable parameter number preceded by the letter V (Ex: V1006)

The value (Ex: 320)
R/W attribute (for MODBUS and PLC equations) (Ex: Y)
The label (only for clarification) (Ex: Gen Nominal KW)
The minimal value (only for clarification) (Ex: +00000)
The maximal value (only for clarification) (Ex: +65535)
Ex:
{PARAMETERS}
V1006 320 Gen nominal kW +00000 +65535
V1007 1.00 Gen PT ratio +00000 +65535
It is possible to modify the values directly in the text file before uploading it into the GENSYS. The user
must be sure that the modified value is within the minimum / maximum range. Failure to do so will lead
to an error message during uploading (Compilation result: VARIABLE).
It is also possible to write an incomplete parameter block (not all parameters are displayed in the list).
When uploaded, such a file will only modify the parameters which have been entered, the others
remain unchanged. This procedure can be used to upload an old text file into a newer GENSYS or to
activate special features independently.

10.4 Label definition block
The starting point of this bloc is designated by a "{LABELS}" statement.
Only the 2 spare analogue inputs, the 10 digital inputs, the 40 virtual digital inputs, the 10 maintenance
cycles and the 4 lines in the Logo Page can have an input in this bloc (see file Z090030.xls for variable
number).
The structure of the input is as follows:
The variable number preceded by the letter L (Ex: L1130)
The text (14 characters maximum) (Ex: Sample Label)
Ex:
{LABELS}
L1130 Sample label
Note: The label is language sensitive, i.e. a text file uploaded with PC language set to French will
modify only the French labels. The English or Italian labels will remain unchanged. For the
same reason, a text file uploaded with PC language set to French will display only French
labels.
10.5 Unit definition block

The starting point of this bloc is designated by a "{UNITS}" statement.
Only the 4 analogue inputs have an input in this bloc (see file Z090030.xls for variable number).
The structure of the input is as follows:
The variable number preceded by the letter U (Ex: U1130)
The digital code of the unit (Ex: 14)
List of valid units:
• 00 : No unit
• 01 : V
• 02 : kV
• 03 : mA
• 04 : A
• 05 : kA
• 06 : Hz
• 07 : kW
• 08 : kWh
• 09 : kVAR
• 10 : kVARh
• 11 : rpm
• 12 : %
• 13 : Bar
• 14 : mBar
• 15 : kPa
• 16 : PSI
• 17 : °
• 18 : °C
• 19 : °F
• 20 : L
• 21 : Gal
• 22 : s
• 23 : h
• 24 : days
• 25 : Hz/s
• 26 : m3/h
• 27 : Gal/h
• 28 : L/h
Ex:
{UNITS}
U00029 14
Note: Only the 4 analogue inputs can be present in this bloc, but the associated parameters, like
thresholds for example, are modified automatically.
10.6 Initialization definition block

The beginning of these blocks is shown by the statements "{INIT1}" or "{INIT2}" depending on the level
of access (1st or 2nd level password).
A user connected in level 0 (no password) cannot read equations from, or transfer equations to, the
GENSYS.
A user connected in level 2 will get access to INIT1 and INIT2 blocks.
A user connected in level 1 will only get access to the INIT1 block.
INIT equations are only run by the PLC when the power supply of the module is turned ON. They
won’t be run again until power supply is turned OFF and then ON again. The purpose of these blocks
is to provide custom equations to the user. They are run during the power up stage.
INIT blocks are typically used to set the initialization values of outputs, timers or counters associated
to custom equations or custom parameters.
For further details on the programming language see the "PLC" chapter.
10.7 Equation definition block

The beginning of this these blocks is shown by the statements "{EQUATIONS L1}", "{EQUATIONS
L2}", depending on the level of access (1st level password or 2nd level password).
A user connected in level 0 (no password) cannot read equations from or transfer equations to the
GENSYS.
A user connected in level 2 will get access to EQUATIONS L1 and EQUATIONS L2 blocks.
A user connected in level 1 will only get access to EQUATIONS L1 block.
The purpose of these blocks is to provide custom equations to the user which are run cyclically. These
equations are run every 100ms (PLC cycle time).
Non standard equations can be entered here to handle user defined features like thresholds,
Input/Output expansions, PID controls …
For further details on the programming language see the "PLC" chapter.
10.8 End of file

Every text file must end with the "{END OF FILE}" statement.
GENSYS will not try to read data following that statement, so you can place your own comments here.
Note: It is strongly recommended not to add too many comments after the" End of File"
statement because the size of the file must not exceed 62Kbytes.
NOTE:
This file is a text ONLY file. Do not use word processors (like Microsoft© Word) to edit
this file: it would include layout information and corrupt the file. Use text editors only
(Notepad for example).
The file should not exceed 62Kbytes. If you try to transmit a bigger file to a GENSYS, it
will be rejected.
CAUTION :
When you download or upload a file, you must disconnect all connectors, except power
supply.

10.9 PLC programming language
It is strongly advised that you follow training before using custom PLC equations on a power plant.
Contact your local dealer for details on training sessions.
The PLC equations use a simple language with a small number of commands. The code is intrinsically
linear, each equation being executed one after the other (without any loop). Level 1 equations are
executed first, followed by level 2 equations. This way, level 2 equation results can overwrite any
conflicting level 1 equation.
The "INIT" part is only executed upon start-up, and the "PROG" part is executed every 100 ms.
All the GENSYS variables can be used in the equations in the way defined below:
-E0xxx parameters are read only as measurements. They can’t be changed by equations.
-E1xxx parameters can be read by equations. If allowed, they can also be modified using MODBUS or
equations downloaded via the text file (see {PARAMETERS} section of the text file chapter).
E2xxx parameters are PLC outputs. They can be read and written by custom equations.
Note:
-Variables E1xxx/E4xxx are parameters stored in FLASH (non volatile memory). In level 2
and above, the user can allow the parameters to be written by PLC equations or via
MODBUS.
-Be very careful when modifying a parameter through equations, as unexpected behaviour
(due to an error in your equations for example) may damage your generator.
-It is advisable to include tests in the equations to verify that the engine is stopped prior to
changing a parameter. Otherwise, make modifications in the "INIT" block if possible.
These parameter modifications will not be saved in FLASH memory, i.e. parameters will
be reset to their previous value if power supply is turned OFF and then ON again, unless
the user saves them manually.
-Use document A53 Z0 9 0030 to get a complete list of all GENSYS variables.
-Variables E2xxx/E5xxx are outputs from the PLC; they can be read and written by PLC
equations without restrictions.
Each instruction is terminated by a semicolon (;) except before reserved words (BEND, ELIF, ELSE,
TEND). Init and program blocs are terminated by a dot (.).
Program PROG Starting point of PLC
INIT equations
. Starting point of INIT
equations
End of equations
Blocs BLOC Starting and ending points of
BEND a block of equations
Logical operators AND Logical operation used on a
OR whole variable (i.e. these are
XOR not bit to bit operators)
Unary operators ! Bit to bit complement
- Sign change
> Right shift
< Left shift
INC Increment
DEC Decrement
$ Hex value
Arithmetical operators + Addition
- Subtraction
* Multiplication
/ Division
Bit operators ^ Rotation right
| Access one bit
# Bits mask
Affectation := Affectation
Comparison operators EQ Equal
NE Not Equal
GT Greater Than
LT Less Than
GE Greater or Equal
LE Less or Equal
Array [...] Array element
Tests TEST
THEN
ELIF
ELSE TEND
Comments @
The PLC equations only use 16 bit signed integer values. This means that all variables and data
should be between -32768 and +32767. This is an important point to keep in mind when comparing
values or doing calculations. For example, 20000*10 will produce a calculation overflow. For the same
reason, variables displayed with decimal digits are treated in the equations as if the decimal point
wasn’t there. For example, a power supply voltage of “24.5 V” will be treated as “245” in the equations.
Be careful when entering values which have digits after the decimal point. If you have one digit after
the dot, you have to multiply the number by 10. If you have two digits, multiply by 100.
For instance, the battery voltage measure (variable E0041), is from 0.0 to 6553.5, so you have one
digit after the dot. If you want to compare the battery voltage to 25.0 volts, you have to write:
TEST E0041 GT 250 THEN...
To know the number of digits after the dot, look in the “A53 Z0 9 0030-x.xls” file. In the 'Mini' / 'Maxi'
columns, the number of digits after dot appears.
Test examples:
TEST condition THEN instruction TEND;
TEST condition THEN BLOC instruction; instruction;…;instruction BEND TEND;
TEST condition THEN BLOC instruction; instruction;…;instruction BEND

ELIF condition THEN BLOC instruction; instruction;…;instruction BEND
ELIF condition THEN BLOC instruction; instruction;…;instruction BEND
ELSE BLOC instruction; instruction;…;instruction BEND
TEND;
Calculation / instruction examples:
E2680:=(E2000+E2001+E2002+E2003)/4;
E2000:=2; E2680[E2000+1]:=10;
E2680:=(E0030 GT 1450) AND ((E0030 GT 1500) OR E2680);
Condition examples:
TEST E2050 EQ 1 THEN ...
TEST E0030 GT 1500 THEN ...
TEST (!E2046) AND E2055 AND ((E2071 EQ 14) OR (E2071 EQ 15)) EQ 1 THEN …
Variable use:
There are two ways of accessing the 2xxx variables for reading. With E2xxx you access the value
locked at the start of program loop. With X2xxx you access the very last value modified by the
program executed previously.
It is strongly recommended that you use the E2xxx Eyyyy syntax. X2xxxyyyy can only be used for
special purpose and only by advanced, "High GENSYS Knowledge" users.

11 Communication
11.1 CANBUS GOOD PRACTICES

This chapter explains and describes good practices used to ensure a good reliable CAN
communication. This advice is true for all CAN bus connections and should be applied to both
GENSYS units for inter GENSYS bus, and for second CAN communication port.
Here is the standard pin out of a DB9 CAN connector compared with a GENSYS implementation:
GENSYS Standard
SHIELD GROUND
PIN 1 NC Cable Drain
PIN 2 CAN-L CAN-L
PIN 3 GROUND-1 CAN GND
PIN 4 NC free
PIN 5 GROUND-2 +24V POWER
PIN 6 GROUND-1 free
PIN 7 CAN-H CAN-H
PIN 8 NC free
PIN 9 NC 0V POWER
Note: GROUND-1 and GROUND-2 are each protected with a 47 ohms resistor.
CAN-BUS cable:
The CAN bus-BUS cable must be able to carry the CAN signals (CAN-L and CAN-H). These 2 signal
wires should be a 120 Ohm twisted pair (Ex: Belden's 3105A, 3082A-3087A (www.belden.com), LAPP
CABLE Unitronic bus DeviceNet or CAN (www.lappcable.com) or equivalent).
The CAN bus-BUS cable must be shielded, and must have a drain wire connected to the cable shield.
This drain connects to pin 1 of each connector. The connector housing must be connected to the
cable shield, and metallic shells should be used if possible.
For better results, a common GROUND should be used for all connected devices (this can be verified
easily with an ohmmeter, for example).
The total length of the cable must not exceed 250m for a CAN communication speed of 250kb/s. This
length may decrease with lower quality cables.
The last node on the CAN-BUS must have a 120-Ohm termination resistor plugged into its CAN
connector.

IMPORTANT:
Warning:
Never plug or unplug CAN-BUS bus connectors with power on. This may cause internal
damage or cause internal CAN -BUS transceivers to burn.
11.2 COM1: RS232 to PC

This communication port has been described previously in the browser chapter. This is a standard
RS232 communication port. This port can be used for:
- Manufacturing flash memory programming
- Manufacturing process calibration
- Manufacturing quality control
- On site configuration (with standard web browser)
- On site firmware update (with special utility)
11.3 COM2: CAN bus inter GENSYS

This bus will allow synchronization, load sharing (active and reactive), dead bus management and
automatic load/unload. GENSYS uses a proprietary protocol implemented on standard CAN bus
hardware.
11.3.1 Wiring
The figure below shows the connections between each GENSYS.
2 2 2
3 3 3
R 4 4 4 R
5 5 5
7 7 7
9 9 9
GENSYS A GENSYS GENSYS
Figure 41 - CAN Bus wiring

Terminals 2 and 7: 1 twisted pair cable.
Terminals 3 and 5: 1 twisted pair cable.
R: 120 Ohms termination resistor
The CANbus wire is a wire to wire cable, with 1 termination resistor on each extremity. The wires are
connected to a female DB9.
You can also use CRE accessories as shown below to connect several GENSYS units together.
= 2 GE
G G
GENSYS1 GENSYS2
CAN1(COM2) CAN1(COM2)
A40W1
7m
Figure 42 - GENSYS Ù GENSYS

> 2 GE
G G G G
A40W2 A40W4 A40W2
GENSYS1 GENSYS2 GENSYS3 GENSYS4

CAN1(COM2) CAN1(COM2) CAN1(COM2) CAN1(COM2)
7m 7m
A40W3
Figure 43 - GENSYS Ù GENSYS Ù GENSYS Ù …

The next figure shows the wiring for rental generators.
GENSYS1 GENSYS2 GENSYS3

CAN1(COM2) CAN1(COM2) CAN1(COM2)
G G G
2 GE
A40W8
A40W5 A40W5
A40W6
+3 GE A40W8 A40W8
A40W5 A40W5
7m 7m A40W3
Figure 44 - Mobile generator sets

11.3.2 CAN bus fault
If this fault occurs, a GENSYS is missing or there are too many GENSYS units on the CAN bus
compared to the number of generators (E1147). This fault can only be RESET if the right number of
generators is present on the CAN bus.
The kind of alarm/fault generated depends on the "bus CAN fault control" variable (E1259).
• E1259 = 0: no action
• E1259 = 1: generator electrical fault
• E1259 = 2: mains electrical fault
• E1259 = 3: alarm
• E1259 = 4: soft shut down
• E1259 = 5: hard shut down
• E1259 = 6: droop mode, generates an alarm (default setting)
This fault only affects the working of a power plant with several GENSYS units (E1147 > 1).
In Auto mode, if there is a remote start and a CAN bus fault, the GENSYS starts and closes its
breaker after a delay that depends on the generator number (E1179), but only if the dead Bus
management is on (E1515 = 0) and there is no voltage on the bus bar.
Otherwise it will try to synchronize with the bus bar.
If the generator is paralleled to the Mains when a CAN bus fault occurs, and error control variable
E1259 is set to 6 (Droop mode + Alarm), speed control will be switched to droop and volt control will
be switched to power factor regulation. If the mains are not connected, both speed and voltage droop
is applied.

Note: If you need to disconnect a GENSYS from the inter GENSYS CAN bus, you must change
the number of generators (parameter E1147) on all other GENSYS units of the power
plant.
When the power plant is set to load/unload mode (Parameter E1258 set to "Hours run" or "Digital in"),
all generators will start using droop mode if a CAN bus error occurs.
11.4 Broadcasting Data between GENSYS units

11.4.1 Introduction:
This section describes the Broadcast Data by Inter GENSYS CANbus.
This application is only available in versions 2.09 and later.
It is possible to exchange up to 10 digital variables and 2 analogue variables between GENSYS units
with the Inter GENSYS CAN (Com 2).
It’s necessary to use a computer to create the “Broadcast Data by Inter GENSYS CAN bus” equations.
NOTE: When you assign a variable to broadcast data (ex: E2752:=...) remove the “E” from in front of
the variable name: this is the number of the variable you assign, not the variable itself.
11.4.2 Procedure / Example
In this configuration there will be one GENSYS (GENSYS1) which sends variables and the other
GENSYS units (GENSYS 2) which receive variables.
Variables which are sent on the Broadcast Data by Inter GENSYS CANbus:
Variable Description GENSYS

number
E2752 VarDigCAN01 1 or 2
E2762 VarAnaCAN01 1 or 2
E2763 VarAnaCAN02 1 or 2
Table 21 - Variables sent by BROADCAST DATA via Inter GENSYS CANbus

Variable number Description GENSYS
E0536 to E0545 Can bus extension digital input 1 to 10 – GE1 1
E0546 to E0547 Can bus extension analog input 1 to 2 – GE1 1

Table 22 - Variables received by BROADCAST DATA via Inter GENSYS CANbus

Example: Broadcast analogue and digital data
DIGITAL Values:
GENSYS
Input 1 (E2006) N° 1
J6
E2006 E2752
E0552
CAN inter
GENSYS
GENSYS
N° 2
Input 1 (E2006) J6
E2006 E2752
E0536
To other GENSYS
ANALOGUE Values:
GENSYS
Magnetic pick-up (E0033) N° 1
G7-8
E0033 E2762
E0562
CAN inter
GENSYS
GENSYS
N° 2
Magnetic pick-up (E0033) G7-8
E0033 E2762
E0546
To other GENSYS

To send value from GENSYS #1 to GENSYS #2, write this equation in GENSYS #1:
BLOC
@example to send digital input or analog input to each gensys oil pressure
input and speed;
E2752:=2006;
E2762:=33
BEND
In GENSYS #2, to read these two values, use these variables:

E0536 is the value of the GENSYS #1 J6 input (E2006).
E0546 is the value of the GENSYS #1 engine speed (E0033).
To send value from GENSYS #2 to GENSYS #1, write this equation in GENSYS #2:
BLOC
@example to send digital input or analogue input to each gensys oil
pressure input and speed;
E2752:=2006;
E2762:=33
BEND
In GENSYS #1, to read these two values, use these variables:

E0552 is the value of the GENSYS #2 J6 input (E2006).
E0562 is the value of the GENSYS #2 engine speed (E0033).
Example 2 (Application example):
If you don’t want to use the “remote start” inputs on each GENSYS, you can enter it on the first
GENSYS and send it to the others via the CAN.(Example with 3 GENSYS).
GENSYS #1:
@example to send digital input or analog input to each gensys;
E2752:=2002
BEND
GENSYS #2:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
GENSYS #3:
@example to receive digital input to each gensys;
E2514:=E0536
BEND
Important: Even if CAN bus inhibition is activated between GENSYS units (see below), broadcast data
is always sent and received on the inter GENSYS CAN bus.
NB: When you assign a variable to broadcast data
(ex: E2752:=….) remove the “E” in front of the variable name.
11.5 Can Bus Inhibition

The CAN bus is mainly used by GENSYS modules to send power management data to each other.
CAN bus inhibition is used to prevent one GENSYS from taking into account data coming from one or
more GENSYS units. This is especially useful when tie breakers are used to change the configuration
of the power plant (for example from a 6 generator power plant to two power plants with 3 generators
each).
Variables E2691 to E2706 are used to decide with which modules the GENSYS should communicate
power management data.
CANBUS inter-GENSYS
DG1 DG2 DG3 DG4
CB1 CB2 CB3 CB4
Tie breaker
Figure 45 - CAN bus inhibition schematic (example)

The example above shows a power plant made up of 4 generators that can be split into two power
plants of two generators each. GENSYS units are connected together with a CAN bus on COM1. If it
is necessary to split a complete plant with a tie breaker, for example in a security application, it is
necessary to modify normal functioning:
In normal functioning, the tie breaker is closed, each GENSYS communicates with the others by CAN.
When the tie breaker is open, all GENSYS units need to know that they have to consider the power
plant differently, with two separate bus bars.
To allow this, we will use CAN bus inhibition.
When the tie breaker is closed, all four GENSYS units should communicate with each other for power
management, so variables E2691 to E2694 should be set to 0 (zero) on every GENSYS unit (no CAN
inhibition).
When the tie breaker is open, generators DG1 and DG2 should communicate but ignore data from
DG3 and DG4. In the same way, generators DG3 and DG4 should communicate but ignore data from
DG1 and DG2. To do so, inhibition variables should be set as follows:
E2693 and E2694 set to 1 on generators DG1 and DG2.

E2691 and E2692 set to 1 on generators DG3 and DG4.
Feedback from the tie breaker can be connected to a GENSYS digital input and then used in custom
PLC equations to set or reset these inhibition variables.
11.5.1 How to set theses functions:
Special variables can be used to inhibit CAN bus variable use.

Each GENSYS is able to ignore (inhibit) all the others, depending to the state of the inhibition can
variable.
Note that this does not affect “BROADCAST DATA”, but only genset related functions.
The following table describes these variables.

To take effect (inhibition active), the variable must be set at 1.
Remark: In the GENSYS, control of inhibition is often associated with feedback from the Tie
breaker.
E2691 Inhibition variable of the GE 1 on CAN bus
Table 23 - CAN bus inhibition parameters
11.6 COM3: CANopen remote I/O

Industrial CANopen extension modules can be used to increase the number of digital/analogue inputs
and outputs of GENSYS. This is CAN bus hardware using CANopen protocol and application support
to transfer data between nodes.

Figure 46 - Modular remote I/O extension module
Modular remote I/O (750-337) can be added to GENSYS using a CANOPEN© protocol, on serial port
COM3 with a DB9 male connector. It allows the extension of the number of GENSYS inputs / outputs.
The refresh time of this remote I/O is 100ms.
The GENSYS DB9 wiring is the same as for the CANbus inter GENSYS with a termination resistor.
For the remote I/O see the figure below.
7 - CAN H
A40W2
Shield - Drain
GENSYS 120 Ohms
CAN2(COM3) 2 - CAN L
5 - GND
WAGO
Figure 47 - CANopen coupler wiring

• CAN L must be connected to pin 2 of the DB9.
• CAN H must be connected to pin 7 of the DB9.
• CAN GND must be connected to pin 5 of the DB9.
• Drain must be connected to the shield of the DB9.
• A termination resistor of 120 Ω must be connected to each end of the cable between CANH and
CANL.
• GENSYS can be connected with up to 3 couplers.
• Each coupler can have up to 32 remote I/O terminals.
•
The remote I/O terminals available are the following:
• Digital input and output
• Up/down counter input
• Peak time counter input
• Frequency counter 0.1-10kHz input
• Intruder detection input
• Solid state output
• Relay output
• 0-20mA input and output
• 4-20mA input and output
• +/-10V input and output
• 0-10V input and output
• PT100 input
• PT1000 input
• Thermocouple input
• 10R-1k2 input
• 10R-5k0 input
• Ni 100 input
• Ni 1000 input
•
This list in indicative and non exhaustive, consult your WAGO© dealer for further information, or go to
http://www.wago.com.
11.6.1 System configuration
The system is configured by messages. A total of 13 messages for inputs and 13 messages for
outputs are available.
Each message is determined by:
• The identifier of the module (configurable on the coupler using switches)
• The type of message: analogue or digital for input or output.
• The number of channels in the message
Note: A maximum of 4 analogue inputs/outputs or 64 digital inputs/outputs can be sent by

message
The total number of input/output available is:

• 44 analogue inputs.
• 128 digital inputs.
• 8 analogue outputs.
• 64 digital outputs.
Note: When configuring inputs or outputs, analogue I/O should be programmed first, then digital
I/O.
Note: For a given CANopen module, always group the maximum number of data of the same type
in one message.
For example, it is better to set up one message with 50 digital inputs than 2 messages with
25 digital inputs each.
Note: Always group messages to/from one CANopen module. For example, do not use output
messages 1 and 3 with CANopen module number 1 and message 2 with CANopen
module number 2. It is preferable to use messages 1 and 2 with module number 1 and
message 3 with module number 2.
11.6.2 Read / write I/O
With the Info screen (view by pressing the info key), you can see the remote I/O:
• Digital inputs from 0157 to 0284
• Analogue inputs from 0285 to 0328
• Digital outputs from 2368 to 2431
• Analogue outputs from 2432 to 2439
To have the right variable associated to an input output, follow this rule: the lower variable number is
associated to the lower message number and the I/O nearest to the coupler.
Variable
Configuration Message number
number
First module: 0285

2 0-20 mAmp analogue inputs 1: 0286
ID = 1 ; type analog ;
Second module: nb of Input = 4 0287
Coupler
number 1 2 PT100analogue inputs 0288
2: 0157
Third module:
ID = 1 ; type digital ;
2 digital inputs 0158
nb of Input = 2
4: 0291
Coupler First module:
number 2 2 thermocouple analogue inputs 0292
nb of Input = 2
0159
5: 0160
Second module :
ID = 2 ; type digital ;
4 digital inputs 0161
nb of Input = 4
0162
3: 0289
Coupler 1 module with 2 +/- 10V analogue
number 3 inputs 0290
nb of Input = 2
Table 24 - CANopen configuration example
11.7 COM3: MDEC (MTU)

11.7.1 Procedure
To correctly communicate with GENSYS, MDEC internal variables have to be configured. The MDEC
should be configured as follows to activate the CAN communication:
• 200 set to 450.

• 201.01 set to 32.
• 201.05 set to 201.
For more information on MDEC configuration contact your MTU dealer.
Option 4 has to be ordered to activate the CAN connection.

Download the custom language. MDEC has labels and codes or numbers which correspond to the
MDEC variables:
• Z090210_2_vxxx.txt corresponds to the English version.
• Z090210_3_vxxx.txt corresponds to the French version.
Note: vxxx is the corresponding software version of your GENSYS.
Download the text file that will configure your GENSYS for this application:
• Z090210i_1.txt.
GENSYS to MDEC wiring:
C1 25 h
26 g
0V
C2 43 N
44 M
GENSYS MDEC
0V
COM3 / 7 49 G
COM3 / 2 50 F
COM3 / 5 51 E
G9 8 AA
G11 36 q
X003
connector
GENSYS MDEC X1 X003
Label
terminal connector connector
Digital output to stop request and h 25
C1
emergency stop g to ground 26 to ground
Digital output to start request C2 N 43
M 44 to ground
CAN High COM 3 pin 7 G 49
CAN Low COM 3 pin 2 F 50
CAN ground COM 3 pin 5 E 51
Analogue speed command G9 AA 8
Analogue speed reference G11 q 36
Table 25 - MDEC connection
Variable
Label Value Description
number
V1076 ESG amplitude 50.0 Speed output amplitude to have a trip frequency of +/-3Hz.
V1077 ESG offset 0.00 Offset to obtain nominal frequency.
Custom language selected for MDEC labels on the GENSYS
V1156 Local language 3
screen.
V1311 PC language 3 Custom language selected for MDEC labels on your PC.
V1710 User param 001 10 Time to stop request on digital output C1 (1.0 sec. here)
V1711 User param 002 1500 Nominal speed for MDEC through CAN bus.
Delay (*100ms) before triggering an MTU CAN bus error. (30
V1712 User param 003 300
seconds here).
The Analogue oil pressure that comes from the MTU CAN bus
V1852 Branch P-oil 352
will be used. (*)
The Analogue water temperature that comes from the MTU
V1853 Branch T-water 400
CAN bus will be used. (*)
The Speed measure that comes from the MTU CAN bus will
V1854 Branch Speed 331
be used. (*)
V1855 Opt4 protocol 1 To choose the MTU MDEC CAN bus protocol on COM2.
MTU CANbus Each device on the MTU CAN bus has a node number.
V1856 6
Node GENSYS uses have the number 6.
MTUPV110003
V1857 0 Protection control for over speed from MDEC (E0332). (**)
CT
MTUPV110010 Protection control for combined alarm yellow from MDEC
V1858 3
CT (E0339). (**)
MTUPV110014 Protection control for combined alarm red from MDEC
V1859 5
CT (E0343). (**)
MTUPV110029
V1860 0 Protection control for low oil pressure from MDEC (E0355). (**)
CT
MTUPV110030 Protection control for very low oil pressure from MDEC
V1861 0
CT (E0356). (**)
MTUPV110047 Protection control for low fuel pressure from MDEC (E0358).
V1862 0
CT (**)
MTUPV110048 Protection control for very low fuel pressure from MDEC
V1863 0
CT (E0359). (**)
MTUPV110055 Protection control for low coolant level from MDEC (E0363).
V1864 0
CT (**)
MTUPV110099 Protection control for low coolant level, charge air, from MDEC
V1865 0
CT (E0386). (**)
MTUPV110129 Protection control for high coolant temperature from MDEC
V1866 0
CT (E0403). (**)
MTUPV110130 Protection control for very high coolant temperature from
V1867 0
CT MDEC (E0404). (**)
MTUPV110133 Protection control for high charge air temperature from MDEC
V1868 0
CT (E0407). (**)
MTUPV110143 Protection control for high oil temperature from MDEC
V1869 0
CT (E0414). (**)
MTUPV110168 Protection control for low charge air temperature from MDEC
V1870 0
CT (E0422). (**)
MTUPV110177 Protection control for low engine speed from MDEC (E0426).
V1871 0
CT (**)
Table 26 - Important parameters

(*) the standard sensors required for oil pressure, water temperature and engine speed don’t need to
be connected to GENSYS. The value of these 3 analogue inputs (E0029, E0030, E0033)
will be taken from the MTU CAN bus.
(**) control can take the following values:
• 0: Disable.
• 1: Generator electrical fault.
• 2: Mains electrical fault.
• 3: Alarm.
• 4: Fault (soft shut down).
• 5: Security (hard shut down).
MDEC variables:
The following variables are used to communicate with MTU MDEC devices:
-E0330 to E0484 as input variables (MDEC to GENSYS).
-E2662 to E2677 as output variables (GENSYS to MDEC).
The variables from MDEC can be seen from E0330 to E0484.
The variables than can be written in MDEC are available from E2662 to E2677.
The table in the annexes lists all the variables with correspondences between MDEC and GENSYS.
Specific screens for MDEC:

In the “Display\Engine meters” menu you will find:
Variables
from MDEC
Additional information

In the standard configuration GENSYS can display all the MDEC variables available on the CAN bus
thanks to the screen seen above. These variables are displayed ‘as is’ without any further processing,
except for certain faults. If you need additional functions related to these variables you will have to
program your own PLC equations.
It is also possible to monitor and manage MDEC variables remotely through MODBUS
communication.
Alarms.
The following example will show you how to handle predefined alarms (listed is an example of the
predefined alarm seen above):
E1857 is dedicated to over speed protection from MDEC (E0332). The equation is the following:
TEST (E0332 EQ 1) AND (E1857 NE 0) EQ 1 THEN E2199[E1857]:=1 TEND;
E0332 is the over speed alarm from MDEC.
E1857 is the control.
If you set E1857 as security (E1857=5) and E0332 is set to 1, then E2204 (hard shut down) will also
be set to 1 and trigger the hard shutdown process.
If you want to use an MDEC alarm that is not handled directly by GENSYS, you can use a virtual input
as described in the following example:
For example, if you want to handle an MDEC alarm for “SS Power Reduction Active” (E0338), you can
use the virtual input 2 (E2284). In the “Enhanced / Configuration\>>\Virtual input” menu, set virtual
input 2 with the function (E1329). Choose “External alarm”, and load the following equation in a text
file:
E2284:=E0338;
You can also change the label of the virtual input to be displayed on screen when the alarm occurs.

Fault code numbers.
Combined yellow / red alarms are global warnings. They can be triggered by one of several faults
provided on the CAN bus (see list below). Apart from these predefined errors, additional alarm sources
are available and can be detected using MDEC fault code numbers.
The MDEC fault code is read by GENSYS and stored in MDEC (GENSYS variable E0372). If several
failures happen together, the fault code variable will be refreshed every second.
This will help you find which alarm is activated in case of a combined alarm.
11.8 COM3: J1939

This section describes J1939 configuration for the GENSYS. There are common settings and a
specific file to download in the GENSYS depending on the engine brand.
11.8.1 Configuration
The GENSYS must be configured with "option 4 CAN Engine Communication" enabled. Contact your
CRE dealer for key code & procedure. This option is installable on site. It is not possible to mix J1939
and CANopen applications because they do not use the same protocol.
• Set parameter E1855 to 2, to select standard J1939 protocol.
• Set parameter E1856 to 17, to set the address of the GENSYS (17 is the default value).
• Press SHIFT + I to save the configuration into the FLASH memory.
• Connect the engine CAN bus to COM3 of the GENSYS with an A40W2 cable or equivalent.

Note: connect: ‐CAN Hi to terminal 2 of GENSYS COM3 connector.
‐CAN Lo to terminal 7 of GENSYS COM3 connector.
‐GND to terminal 5 of GENSYS COM3 connector.

• Switch the power supply OFF then ON to reset the system.
In order to display understandable texts in the display menus, all the following custom language files
must be downloaded:
• J1939_0.txt
• J1939_1.txt
• J1939_2.txt,
• J1939_3.txt,
• J1939_4.txt.
Whatever the engine make, these 5 files must be downloaded.
Note: Communication speed is 250 Kbits, non modifiable.
11.8.2 J1939 fault
Variable E2511 is used to detect a J1939 reception error. If E2511 equals 1, it means that no CAN
frames have been received from the ECU for more than 2 seconds. This error is not latched and
resets to 0 (zero) as soon as a new CAN frame is received.
11.8.3 Engine Speed
Variable E0330 contains the engine speed value read from J1939 (in RPM, from 0 to 8031).
To use this J1939 speed value instead of the GENSYS internal speed measurement, set E1854
variable to 330.
To use GENSYS internal speed measurement set E1854 to 33 (default value).
11.8.4 Coolant temperature
Variable E0333 contains coolant temperature value read from J1939 (in °C, from -40 to +210).
To use this J1939 coolant temperature value instead of the GENSYS internal measurement, set
variable E1853 to 333.
To use GENSYS internal temperature measurement set E1853 to 30 (default value).
11.8.5 Oil pressure
Variable E0331 contains oil pressure value read from J1939 (in Bars, from 0.00 to 10.00).
To use this J1939 oil pressure value instead of the GENSYS internal measurement, set variable
E1852 to 331.
To use GENSYS internal oil pressure measurement set E1852 to 29 (default value).

11.8.6 Engine diagnostic
The GENSYS is able to monitor diagnostic messages (DM1) from the J1939 engine ECU. Only
relevant diagnostic messages are taken into account and used in the GENSYS fault/alarm system.
GENSYS is able to understand and interpret messages for display, process, and protection.
RESET message (DM3) is sent to the engine when internal GENSYS RESET is activated (RESET
button or internal variable).
If the diagnostic message is not sent by the J1939 ECU for more than 3 seconds, the corresponding
fault/alarm is automatically reset to OFF.
11.8.7 J1939 Messages
Red "lamp"
This message is used to relay trouble code information that is of a severe enough condition that it
warrants stopping the engine. Variable E0403 contains the "Red lamp" value read from J1939. 0
means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Red lamp" message from the engine,
variable E1866 must be set (hard Shutdown is the default value).
-0: Disable
-1: Generator electrical fault
-2: Mains electrical fault
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown (default value)
-7: Help + Fault (Soft shut down)
-8: Help + Gen. Electrical fault
Amber "lamp"
This message is used to relay trouble code information that is reporting a problem with the engine
system where the engine need not be immediately stopped. Variable E0386 contains the "Amber
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Amber lamp" message from the engine,
variable E1865 must be set (disabled is the default value).
-0: Disable (default value)

-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Protect "lamp"
This message is used to relay trouble code information that is reporting a problem with an engine
system that is most probably not electronic subsystem related. For instance, engine coolant
temperature is exceeding its prescribed temperature range. Variable E0363 contains the "Protect
lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Protect lamp" message from the engine,
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Malfunction "lamp"
A message used to relay only emissions-related trouble code information. This message is only
illuminated when there is an emission-related trouble code active. Variable E0359 contains the
"Malfunction lamp" value read from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Malfunction lamp" message from the engine,
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Very high engine speed

This message is used to relay that the engine speed is above the most severe high level threshold set
for the engine. Variable E0358 contains the "Very high engine speed" value read from J1939. Value of
0 means Not Activated. Value of 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Very high engine speed" message from the
engine, variable E1862 must be set to:
-0: Disable
-3: Alarm
-4: Soft Shutdown
High engine speed

This message is used to relay that the engine speed is above the least severe high level threshold set
for the engine. Variable E0332 contains the "High engine speed" value read from J1939. 0 means Not
Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "High engine speed" message from the
engine, variable E1857 must be set (disabled is the default value).
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Very high coolant temperature

This message is used to relay that the coolant temperature is above the most severe high level
threshold set for the engine. Variable E0356 contains the "very high coolant temperature" value read
from J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "Very high coolant temperature" message
from the engine, variable E1861 must be set (soft Shutdown is the default value).
-0: Disable
-3: Alarm
-4: Soft Shutdown (default value)
-5: Hard Shutdown

High coolant temperature

This message is used to relay that the coolant temperature is above the least severe high level
threshold set for the engine. Variable E0343 contains the "High coolant temperature" value read from
J1939. 0 means Not Activated. 1 means Activated.
To set the behaviour of the GENSYS when receiving the "High coolant temperature" message from
the engine, variable E1859 must be set (disabled is the default value).
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Very low oil pressure

This message is used to relay that the oil pressure is below the most severe low level threshold set for
the engine. Variable E0355 contains the "Very low oil pressure" value read from J1939. 0 means Not
To set the behaviour of the GENSYS when receiving the "Very low oil pressure" message from the
engine, variable E1860 must be set (Hard Shutdown is the default value).
-0: Disable
-3: Alarm
-4: Soft Shutdown
Low oil pressure

This message is used to relay that the oil pressure is below the least severe low level threshold set for
the engine. Variable E0339 contains the "Low oil pressure" value read from J1939. 0 means Not
To set the behaviour of the GENSYS when receiving the "Low oil pressure" message from the engine,
-3: Alarm
-4: Soft Shutdown
-5: Hard Shutdown
Note: All the parameters are available in web pages in the System / Serial port / COM3 menu.

11.8.8 Advanced functions
Custom Rx Frames
If you need to get more values from the J1939 device than those available in the basic operations, the
system is able to read raw data from 5 different frames you can set to fit your needs.
The following variables are used to define those 5 custom Rx messages: E2675, E2676, E2677,
E2678, and E2679 define the ID of the frames to be monitored. The IDs are those defined by the
J1939/71 standards.
The raw data is available as 8 bytes in variables E0410-E0417, E0420-E0427, E0430-E0437, E0440-
E0447 and E0450-E0457.
Custom RX Frame ID Frame Raw data

frame variable variables
1 E2675 E0410 to E0417
2 E2676 E0420 to E0427
3 E2677 E0430 to E0437
4 E2678 E0440 to E0447
5 E2679 E0450 to E0457
Please refer to J1939/71 standards to find the frame ID that fits your needs.
Note that there are no additional web pages to configure these custom RX frames. Please use custom
PLC equations to access custom RX variables. The variables are only accessible by equations.
Custom Tx Frame
If it is needed, a custom frame can be sent every 100ms by the system.
The Variable E2662 defines the size of the frame (from 0 to 8 bytes). A value of -1 switches off custom
TX frame transmission.
The Variables E2663, E2664, E2665, E2666 define the ID of the frame to be send sent (E2663 being
the least significant byte; E2666 is the most significant byte).
The Variables E2667 to E2674 contain the raw data to be sent (E2667 contains data byte 1).
Note that there are no additional web pages to configure the custom TX frame. Please use custom
PLC equations to access custom TX variables.
There are no additional web pages to configure this system; the variables are only accessible via
equations.
11.8.9 Engine notes
PERKINS (Engine series 2800)
The following text file must be loaded into the GENSYS with level 2 access: J1939_perkins.txt
SCANIA
Set variable E1917 to 1 to set the J1939 refresh time to 25ms. (Only available with V2.10b and later)
The following text file must be loaded into the GENSYS with level 2 access:
J1939_SCANIA.txt
This txt file contains LEVEL 2 equation and contains START STOP and SPEED management.
VOLVO EMS2
This electronic control unit has no other means of control than J1939 CAN bus.
Note:
Do not use CIU module with GENSYS.
J1939 High
7 1
2 120 J1939 Low
2
3
GENSYS 1N4007
Batt Switched
4 EMS2
A2
Emergency
5
A3
Stop 6
7
8
+V Batt 8 poles
connector
Figure 48 - Wiring diagram for Volvo EMS2

The following text file must be loaded into the GENSYS with level 2 access:
J1939_VOLVO.txt
IVECO:
Oil pressure value from Iveco engines is never sent by J1939 CAN bus. Additional sensor should be
connected to GENSYS to get an analogue measurement used in association with an analogue input
program like VDO.
The Fuel relay is used to supply power to the control unit.
A different Crank output sequence must be used because the crank signal command must be given
after the control unit is powered up. GENSYS output supply: The C1 output1 sends the crank signal 2
seconds after the normal Crank output.
The following signals can be recovered from the control unit:

-Digital oil pressure.
-Analogue oil pressure.
-Digital water temperature.
Download the text file

J1939_cme.txt
11.9 COM4: MODBUS RTU on serial port RS485

All GENSYS internal variables (Measurements, parameters, PLC outputs…) can be monitored
remotely through an RS486 communication bus using a MODBUS RTU protocol, GENSYS being a
MODBUS slave. It is also possible to enter parameters into the GENSYS. All digital and analogue
input/output values and all other parameters which appear in the GENSYS menus can be obtained by
the serial port RS485, DB9 male COM4. If allowed, variables (2xxx) and parameters (1xxx) can be
written via MODBUS.
Warning:
Be careful when modifying a parameter while the engine is running as unexpected
behaviour while functioning may damage your generator. It is always advised to change
parameters when generator is stopped.

Wiring on the serial port can be achieved using 2 wires, in point to point mode (1 master and 1 slave)
or in multi-drop mode (1 master and several slaves).
The following figure shows the wiring between the GENSYS and modem.
G G A40W4
G A40W4
G A40W4
A40W2
GENSYS1 GENSYS2 GENSYS3 GENSYS4

RS485(COM4) RS485(COM4) RS485(COM4) RS485(COM4) Modem A40W7
7m A40W3 7m A40W3 3 5 6
4 5 6 7 8
GND TD TD/ RD RD/
Figure 49 - GENSYS Ù GENSYS ÙGENSYS Ù … (MODBUS)

MODBUS RTU is supported by GENSYS when within the following fields:
Communication speed: 4800, 9600 and 19200 (pre-setting: 4800).
Number of bits by character: 8
Number of parity bits: 0
Number of stop bits: 1
RTU address: 1 to 254 (addresses 0 and 255 are reserved). This can be modified by variable 1634,
which is only accessible in the "Modification by variable nb" menu.
Supported functions:
04 Analogue reading
03 Register reading
The RTU address of the variables is the same as their number plus 1, converted into hexadecimal. For
example, variable 2000 (Mains break in) has for RTU address 07D1h (2001). See the Z090030.xls file
to locate the variable number.
Example: Here are two MODBUS RTU frames (request from a remote device and answer from
GENSYS). In this case GENSYS slave address is 5, and the request is to read variables E0000,
E0001 and E0002. The result is a function 04 request starting at address 1 (variable E000) and ending
at address 3 (variable E0002).
Request:
Fields Value (hex)
Slave address 05
Function 04
MSB start address 00
LSB start address 01
MSB number of registers 00
LSB number of registers 03
CRC16 --
Response:
Field Value (hex)
Slave address 05
Function 04
Number of bytes 06 (3 registers * 2 bytes per register)
1st byte (MSB of 1st reg.) xx
2nd byte (LSB of 1st reg.) xx
3rd byte (MSB of 2nd reg.) xx
4th byte (LSB of 2nd reg.) xx
5th byte (MSB of 3rd reg.) xx
6th byte (LSB of 3rd reg.) xx
CRC16 --

12 Troubleshooting
GENSYS displays a « sensor lost » fault at the time of start:
Check voltage AC on terminal (B1 to B4).
Check the speed increases until 1500 RPM
If you don’t have these values and engine stops:

Increase the "sensor lost" timer (default value 4 sec.)
You can increase this timer with variable E1458 in Configuration/Speed control setting.
During starting, GENSYS display oil pressure fault or not ready:

If you are in manual mode, you must push and hold start or GENSYS will display this fault.
If you are in automatic mode, check that your J4 input activates and deactivates correctly. Change the
timing of security inhibitions at start-up.
If you use an analogue input for the oil pressure, check Variable E1155: oil pressure threshold.
GENSYS is powered and LED blinks:

Calibration lost, the GENSYS must be returned to CRE Technology to be re-calibrated.
GENSYS displays a "GENSYS CAN Bus" fault:

If the flaw appears during parameter backup, check the connection between GENSYS units.
Check the number of the set and number of sets is correct; this is in Power plant overview menu.
Check the connection between GENSYS.
The fault appears when you backup the parameters
The GENSYS displays "breaker failure":

Check that control switch is in manual mode.
Check that J2 (back breaker) is activated. If this entry did not have time to activate, you can increase
the E1149 variable delay.
This fault can occur if the opening of the circuit breaker has not been controlled by the GENSYS. See
if another module is able to control the circuit breaker.
When you power up the GENSYS, the display does not work:
Check the bootstrap button on the back of GENSYS is off. Remove the power and change the position
of the bootstrap.
If there is no change, the module is defective and needs to be returned to CRE Technology.
During the test of speed or tension:

Check the connection of 0V.
The engine starts but runs above/ below Rated speed.

Adjust ESG offset or trim speed pot
This output (G9-G11) is used to interface with the speed governor. The main objective being to bias
the speed/fuel rack for synchronizing, Load sharing, ramping Load on and off. This output only alters
the Power (KW) it can be set by parameters E 1077 ESG Offset and E1076 ESG Amplitude (span).
When connecting this output you must know the details of the input you are using. For example a
Woodward 2301A uses ± 2.5 Volts input.
Thus the span to achieve the required span (± 2.5Hz) is ± 2.5 Volts, therefore the settings are
E1076=25% and E1077=25%. If you start the engine with output connected the speed may not be at
rated, if so adjust the speed to be back at rated. N.B. On some electronic engines the input may need
configuring with the manufacturers software. In some case it may be turned off and may not respond.
Only the engine manufacturer can tell you this information.
Below describes how to set the gain and offset if you do not have previously tried settings.
• The ESG offset adjustment (E1077) is settable between -10V and +10V, and it’s added to the
external speed reference (G11) (see figure 47).
• The Speed ref (G11) doesn’t need to be connected if there is no voltage reference available.
• 0V must be wired with 4 mm² as follows: battery - speed regulator - GENSYS
• Connect only the ref wire.
• Set the gain and offset .You need to know what the ref voltage is and the span
For instance the ref voltage may be 5V and have a span of 2.3 to 2.7 volts, you are trying to achieve
the centre of the voltage span (2.5V) using the setting of E1077 in percent. So 10volts =100%, thus
2.5 equals 25%. So set -25% in E1077. Next you need the span setting in E1076, again 2.3 = 23%
and 2.7 =27%. You need 2% span therefore from the nominal (25%) so set E1076 at 2%.
• Start the generator, set rated speed. Stop generator.

• Connect the control wire.
• Start the generator. Measure the rated Frequency.
• If required adjust GENSYS output voltage a small amount (E1077) thus adjusting the offset to
get back to rated.
• Check the maximum range of speed in manual mode with [+] and [-].
• This range must be near +/- 3Hz.

13 Variables
The list of all GENSYS variables is an EXCEL Workbook, with all defined parameters, labels, and in all
languages. This EXCEL Workbook is downloadable from our website. It contains around 2500
parameters, defined in 5 different languages. This folder also contains a worksheet with a history of all
different version of GENSYS firmware.
This excel file can be found in the folder at this URL:
http://www.cretechnology.com/soft/

14 Precautions
Change over and paralleling with mains:
For safety reasons, breakers must be equipped with an independent paralleling safety
relay to prevent failure of the automatic sequence, as shown in Figure 48 and Figure 49.
+24V +24V
G1 G2
SYN SYN
GENSYS GENSYS
E5-E6 Gen. SYNCH E5-E6 Gen. SYNCH
ref CHECK ref CHECK
volt RELAY volt RELAY
Bus Bus
ref ref
volt volt
Figure 50 - Several generators warning
Mains
G
+24V +24V
GENSYS Mains Gen. GENSYS

SYNCH
E2-E3 ref ref E5-E6
CHECK
volt RELAY volt
Generator
Mains breaker
breaker NC
SYN SYN NC feedback
feedback
Figure 51 - One generator with mains warning
Warning:
When you use the virtual digital input in this way: "Generator electrical fault", "Mains
electrical Fault", "External alarm", "External fault (Soft shut down)" or "External security
(Hard shut down)", NEVER use the "Normally Open" or "Normally Close" directions but
ALWAYS "Normally Open Wired Or" or "Normally Close Wired Or".
Warning:
Manual breaker opening.
When an external security device opens the breaker, the order has to be latched.
GENSYS needs the feedback.
Warning:
When a power plant has several generators, even if only one generator has a GENSYS,
the number of generators (E1147) must be equal or above 2. If it is 1, you may seriously
damage your generator.
Warning:
The engine, turbine, or other type of prime mover should be equipped with an over speed
(over temperature, or overpressure, where applicable) shutdown device that operates
independently from the prime mover control device.
CAUTION:
When a power plant has several generators, each GENSYS must have a different
number ("Genset number" variable: E1179). If two have the same number, there is no
conflict but there will be some operating problems.
Note:
To close the generator breaker the following conditions have to be met:
• Voltage must be in a window of 70% (parameter E1432) to 130% (parameter E1433) of the
nominal voltage (parameter E1107 or E1108)
• Speed must be in a window of 70% (parameter E1434) to 130% (parameter E1435) of the
nominal speed (parameter E1080 or E1081)
If the bus bar voltage is more than 10% of the nominal voltage, the generator has to be synchronizing
with the bus bar.

15 References
• A40Z0 Standard environment range
• A40Z1 Extended environment range
• A40Bx Bureau VERITAS marine approval
15.1 Options
Each of the following options can be selected and is password activated: contact your dealer for
procedure.
OPT1 PWM 500Hz for CATERPILLAR engine
OPT2 Mains paralleling option for single generator paralleled with the mains.
The most important paralleling functions are:
Phase shift
ROCOF
power management
OPT4 This option connects GENSYS to MTU MDEC by CANBUS.

Special characteristics include:
- MTU Friedrichshafen certified connection
- Oil pressure, engine speed, water temp, & high temp faults
- MDEC sensors are displayed by GENSYS
- GENSYS displays MTU PV number alarms
A complete application note for easy start-up of the CAN© connection option and
communication with engine is supplied. Requires technical specification from consumer and
commercial agreement to allow specific software development.
OPT5 Disable the paralleling function.
OPT6 Enable the paralleling function.
OPT7 Inhibit start sequence.
15.2 Accessories
• A40W0 GENSYS to PC cable - DB9/DB9 - 3m.
• A40W1 CAN© inter GENSYS cable for 2 generators - DB9/DB9 - 120 Ohm termination resistor
included on both ends - 7m.
• A40W2 CAN© inter GENSYS cable for more than 2 generators or CANopen© I/O modules -
DB9/free wires - 120 Ohm termination resistor included on DB9 side - 7m.
• A40W3 DB9/Terminals connector to be used with more than 2 generators for double connection
(with screws).
• A40W4 Communication cable (RS485, CAN, RS232) - Price per meter.
• A40W5 DB9 termination resistor connector.
• A40W6 modem adaptor.
• A40W7 RS485 modem.
• A40X0 manual GENSYS test bench.
• A09Tx GCR: digital mains commander (x=0 for 100 VAC, x=1 for 230 VAC, x=2 for 400 VAC).
• A24Zx CPA : active power converter (x=0 for 100 VAC / 5 A, x=1 for 230 VAC / 5 A, x=2 for
400 VAC / 5 A, x=3 for 100 VAC / 1 A, x=4 for 230 VAC / 1 A, x=5 for 400 VAC / 1 A).

Figure 52 - Standard cables

16 Company Information
CRE TECHNOLOGY
130, Allée Victor Naudin
Zone des Templiers
Sophia-Antipolis
06410 Biot
FRANCE
Phone: +33 (0)4 92 38 86 82

Fax: +33 (0)4 92 38 86 83
Web: www.cretechnology.com
info@cretechnology.com
Figure 53 - Access to CRE Technology in Sophia Antipolis


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GENSYS

Generator management module

GENSYS – Documentation technique page 1/1

Documentation list on web site:

GENSYS – Documentation technique page 2/2

GENSYS – Documentation technique page 4/4

GENSYS – Documentation technique page 5/5

GENSYS – Documentation technique page 6/6

GENSYS – Documentation technique page 7/7

GENSYS – Documentation technique page 8/8

1.1 European Union Directive Compliance CE

GENSYS – Documentation technique page 9/9

2.1 Front panel

Table 1 - GENSYS Front Panel

LCD characteristics Value Unit

Table 2 - LCD screen characteristics

Enter enter a menu / switch to ‘Input Validate parameter and return to

GENSYS – Documentation technique page 10/10

F1 Shortcut to special function

Table 3 - Display Panel keys

Fault Direct access to the Fault menu.

Direct access to the Alarm menu.

Table 4 - Service Panel keys

GENSYS – Documentation technique page 11/11

Start Starts the generator (only available in manual mode).

Stop Stops the generator (only in manual mode).

O/I Closes/opens the generator breaker (only in manual mode).

O/I Closes/opens the mains breaker if available (only in manual mode).

Table 5 - Control Panel keys

Shows green when generator voltage is present

Shows green when generator breaker is closed

Shows green when mains breaker is closed

Shows green when voltage is present at Mains/bus input

Table 6 - Control Panel LEDs

GENSYS – Documentation technique page 12/12

Figure 1 - Rear panel

GENSYS – Documentation technique page 13/13

GENSYS – Documentation technique page 14/14

GENSYS – Documentation technique page 15/15

Table 7 - Inputs/Outputs description

GENSYS – Documentation technique page 16/16

Table 8 - User interface

3.1 Internal browser description

GENSYS – Documentation technique page 17/17

Digital value modification:

List of options modification :

Figure 3 - Contextual keys for Input Mode

3.1.4 Password protection

Figure 4 - Password input mode display

GENSYS – Documentation technique page 18/18

Figure 5 - Typical menu page

GENSYS – Documentation technique page 19/19

3.2.1 Setting up Windows XP

GENSYS – Documentation technique page 20/20

Click Start, Settings, and Network Connection.

GENSYS – Documentation technique page 21/21

GENSYS – Documentation technique page 22/22

3.2.1.2 Install the Modem

Double click on “Add hardware” icon.

GENSYS – Documentation technique page 23/23

Choose the “Modem” icon.

Then, choose “Add a new hardware device”, and click “Next”.

GENSYS – Documentation technique page 24/24