Overview

The GENSYS 2.0 CORE is a rear-mounted, all-in-one genset control and paralleling module with an integrated PLC, designed to synchronize up to 32 generators. It works in conjunction with the remote display module RDM 2.0 via Ethernet and is configurable through CRE Config software or an embedded web interface. This system is extendable and optimized for space efficiency.

Main Features

• Control and Paralleling: Supports manual and automatic engine control, dead busbar management, isochronous or droop kW load sharing, constant voltage or droop kVAR load sharing, power factor control, and kW management modes (base load, peak shaving) when paralleling with mains.
• Programming: Embedded PLC functionality allows user programming of equations and sequences via text editor or Easy PLC graphical software.
• I/O Flexibility: Supports extensive input/output expansion via CAN bus modules, allowing up to 128 digital inputs, 64 digital outputs, 44 analog inputs, and 32 analog outputs.
• Communication Ports: Isolated RS485 (Modbus RTU), four CAN buses (including inter-module communication and J1939), Ethernet (Modbus TCP), and SD card reader.
• Compatibility: Compatible with all speed governors and AVRs, electronic engines (CAN J1939/MTU MDEC), PLC/HMI systems, power transducers, and CANopen I/O extensions.

Technical Specifications

Electrical Inputs and Outputs

• DC power supply: 8 to 40 VDC, 600mA at 12V, 300mA at 24V.
• AC voltage inputs: 100 to 480 VAC, 100mA max, no neutral connection required.
• AC current inputs: 0 to 5A, isolated per phase, overload up to 15A for 10 seconds.
• Frequency measurement: 45 to 70 Hz, minimum 15 VAC between phase and neutral.
• Voltage control output: +/-5 VDC adjustable or digital pulse outputs.
• Relay outputs: 5A for crank, fuel, and breakers (230 VAC max, NO + NC available).
• Transistor outputs: 350mA, overcurrent protected.
• Analog inputs: configurable calibration for oil pressure, water temperature, and spare inputs.

Environmental Conditions

• Operating temperature: -20 to +70°C.
• Storage temperature: -30 to +80°C.
• Humidity: 5 to 95%, tropical-proof circuits.
• Protection rating: IP20.

Physical Dimensions

• Size: 248 x 197 x 57 mm (9.76 x 7.76 x 2.24 in).
• Back size: 250 x 200 mm (9.84 x 7.88 in).
• Weight: 1 kg (2.2 lb).

Control and Protection Functions

• Electrical protections for generator: under/over frequency, under/over voltage, overcurrent, power limits, reactive power limits.
• Mains protections (optional): frequency, voltage, power, phase shift, and rate of change of frequency (df/dt).
• Phase sequence protection and phase shift compensation (e.g., Dyn11).
• Synchronization: manual and automatic frequency, phase, and voltage synchronization with on-screen differential meters and synchroscope.
• Alarm and event logging: last 50 alarms and shutdowns stored in non-volatile memory with data logging capability.

Paralleling and Mains Integration

The GENSYS 2.0 CORE supports paralleling of generators with mains power. For multiple generators paralleling with mains, the MASTER 2.0 module is used via CAN bus for advanced functions including:

• Three-phase mains failure detection.
• Multiple mains control and electrical protection.
• Display of electrical parameters for power plant and mains.
• Manual and automatic paralleling with mains (frequency, phase, voltage).
• Power factor control and kW power management modes such as no-break load transfer, base load paralleling, and peak shaving (export/import).

Connectivity and Compatibility

• Supports electronic engines via CAN J1939/MTU MDEC.
• Compatible with speed governors using ±10 VDC, pulse, kΩ, or PWM signals.
• AVR control via 0-10 V or pulse outputs.
• PLC/HMI communication via Modbus RTU (RS485) and Modbus TCP (Ethernet).
• Power transducers with 4-20 mA inputs.
• CANopen I/O extensions for GENSYS 2.0 and GENSYS 2.0 CORE.
• Mains communication via CAN inter-GENSYS.
• Analog load sharing via parallel lines.

Programming and Extension

The integrated PLC allows users to embed custom logic and sequences using simple text editors or graphical Easy PLC software. The system supports extensive I/O expansion through DIN rail-mounted modules connected via CAN bus, enabling a wide range of digital and analog inputs and outputs to be added as needed.

Certifications

Complies with European Union Directives EN 50081-2, EN 50082-2, and 73/23EEC.

Wiring and Installation

The document includes detailed wiring diagrams for single genset to mains applications, showing connections for power supply, speed governors, AVR, breakers, relays, analog and digital inputs/outputs, and communication ports. Isolated CAN buses and RS485 ports are used for inter-module communication and external device integration. The system supports chassis isolation options and external transducers for mains power measurement.

Summary of Critical Parameters and Best Practices

• Ensure proper isolation of communication ports to maintain signal integrity and reduce wiring complexity.
• Use the remote display module RDM 2.0 for enhanced monitoring and control capabilities.
• Leverage the PLC programming feature to customize control sequences and embed application-specific logic.
• Expand I/O as required using CAN bus extension modules to accommodate complex installations.
• Follow wiring diagrams carefully to ensure correct connections for safety and functionality.
• Utilize the MASTER 2.0 module for multi-generator paralleling with mains to enable advanced power management and protection features.
• Maintain environmental conditions within specified ranges for reliable operation.

Overall, the GENSYS 2.0 CORE offers a flexible, scalable, and robust solution for genset control and paralleling with integrated PLC capabilities, extensive communication options, and compatibility with a wide range of peripheral devices.