Application note
Subject | Migration GCR to MASTER Compact |
Product | MASTER Compact |
Version | 2.40. and above |
The CRE Technology team would like to thank you for trusting our expertise and investing in a product developed in France.
We have created this application note to help you during the migration of your GCR module to Master Compact.
The GCR is used together with analog load-sharing/synchro modules, in order to get the best efficiency of the replacement controller it is recommended to replace also genset controllers with GENSYS Compact Prime.
Rewiring table
GCR A09T0/T1/T2 | Master Compact | |||||
| Terminal |
| Note | Terminal | Default config | Comments |
EXTERNAL GENSET POWER SET 5K | 1 |
J6
| Analog Input | J6-COMMON | Default Config is providing 5 MW for 500Ohms and 0kW for 0 Ohms, must be calibrated according to the potentiometer value, additional resistor in parallel must be added if potentiometer is >500 Ohms. For existing 5k Pot, install 500Ohms resistor in // | If potentiometer is used for Genset power setpoint |
2 |
| Shield | ||||
3 | Analog Input 1 | J6-Input 1 | ||||
4 |
| NC | ||||
EXTERNAL COMMERCIAL POWER SET 5K | 5 | Analog Input | J6-COMMON | Default Config is providing 5 MW for 500Ohms and 0kW for 0 Ohms, must be calibrated according to the potentiometer value, additional resistor in parallel must be added if potentiometer is >500 Ohms. For existing 5k Pot, install 500Ohms resistor in // | If potentiometer is used for Mains power setpoint, | |
6 |
| Shield | ||||
7 | Analog Input 2 | J6-Input 2 | ||||
8 |
| NC | ||||
MANUAL SYNCHRONIZING 5k | 9 | Not used on MASTER Compact, manual synchro is not available | ||||
10 | ||||||
11 | ||||||
12 | ||||||
FORWARD POWER RELAY | 13 |
J1 | Digital Output 1 (to connect on Relay) | J1 - 4 | Configured as “Max kW level 1” protection, protection has to be configured. | +VCC Transistor Output 2A Max – to connect to a relay. |
14 | ||||||
REVERSE POWER RELAY | 15 | Digital Output 2 (to connect on Relay) | J1 - 5 | Configured as “Reverse kW level 1” protection, protection has to be configured. | +VCC Transistor Output 2A Max – to connect to a relay. | |
16 | ||||||
Synchro ON/OFF | 19 | Digital input 1 | J1-10 | Configured as “Remote start on load” to initiate Synchro when not in // with mains | Digital input | |
Synchro/Load sharing | 20 | Digital input 2 | J1-11 | Configured as “Bus Breaker IN”, must include Mains circuit breaker feedback closed in serial, to make sure Genset is in parallel with Mains | Digital input, must include MCB position closed in serial. | |
Load ramps | 21 | Digital input 3 | J1-12 | If input is inactive GEN power remains in low limit, when input is active GEN power goes to GE fix kW setpoint. | Digital input | |
Systeme 1 or 2 | 22 | Digital input 4 | J1-13 | Alternative selection 1, | Digital input | |
Power set Selection MSB/LSB | 24 | Digital input 5
| J1-14 | For GEN (System 1) In 5 = 1 & In 6 = 0 ->kW setpoint default In 5 = 0 & In 6 = 1 ->kW setpoint 2 In 5 = 1 & In 6 = 1 ->kW setpoint 3For For Mains (System 2) In 5 = 0 & In 6 = 0 ->kW setpoint on Pot
| Digital input | |
25 | Digital input 6
| J1-15 | Digital input | |||
Channel 1/2 selection | 26 | Digital input 7
| J1-16 | Not used, power by default on Analog Input 3 |
| |
Manu/auto selection | 27 | Digital input 8 | J1-17 | Not used, Manual synchro not available |
| |
| ||||||
Mains transducer 4-20mA COMMERCIAL POWER INDICATOR | 31 |
| Analog Input | J6-COMMON | Configured as “External transducer 4-20mA for Mains power measurement” Check documentation for wiring, 39Ohms resistor is mandatory.
| Check documentation for wiring & calibration |
|
|
| Shield | |||
29 |
| Analog Input 3 | J6-Input 3 | |||
|
|
|
| |||
Sync Check relay | 81 | J3 | Relay 2 | J3-1 | When used, the 81-82 relay of GCR can be replaced by MASTER Compact relay 2, relay is closed when sync is OK. | Relay output |
82 | Relay 2 | J3-2 | ||||
POWER MEASUREMENT CHANNEL 1 +/-20mA OR 4-20mA | 32 to 38 |
| Not used on MASTER | |||
POWER MEASUREMENT CHANNEL 1 +/-20mA OR 4-20mA | ||||||
Power indicator | ||||||
Power indicator | ||||||
| 39 | J1 | Negative connection: connect to Bat – terminal 1 – J1 | |||
| 40 |
| J2 CAN 1 | CAN H | Parallel lines and analog lines control not available on MASTER Compact, replace GENSET controllers by GENSYS Compact Prime controllers and connect CAN Bus for GEN Control (see Unigen replacement note) |
|
|
|
| Shield | Connect the cable shield herein | ||
| 42 |
| CAN L |
| ||
VGEN 100/230/400 VAC | 101 | J4 |
80 … 500VAC 35 … 75 Hz | L1 |
3 phases measurement must be connected | These lines must be protected externally with 100mA/600VAC fuses |
102 | L2 | |||||
|
| L3 | ||||
|
| N | ||||
VBUS MEASUREMENT 100/230/400 VAC | 103 | J4 |
35 … 75 Hz | L1 |
3 phases measurement must be connected
| These lines must be protected externally with 100mA/600VAC fuses |
104 | L2 | |||||
|
| L3 | ||||
|
| N | ||||
2. Configuration
A standard configuration file is available with this application note “Master Compact file - GCR Replacement”.
Mains circuit breaker is not considered and will be simulated as present by the MASTER controller, it is recommended to connect on digital input 7 the signal “MCB tripped” when the Mains circuit breaker is opened, in order to secure controller behavior in case power plant is isolated from Mains.
A review of the configuration depending on the use of the controller is required, nominal values and setpoint values must be filled with i4GEN Suite PC software.
Calibration of potentiometer input, transducer input must be checked.
3. Notes about wiring:
** All I/O are negative (-) to active on COMPACT
* EQUIPOTENTIALITIES: It is important to respect the following equipotential schematic with EARTH adequate wiring.
Potential differences between Neutral, Ground, Common CT, Battery negative and 0VDC COMPACT module could create an undesired current going through the COMPACT module, and the following problems can occur:
• Wrong voltage measurement & display values
• Wrong current measurement and display values
• Wrong analog inputs measurement and display values
• Damage of the controller in some situations
All earth points must be correctly connected and measurement of 0VDC has to be observed between them.
End of document.
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