User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

1Summary
With high performance MPU, the GAC608 diesel generator set controller is provided
with many advantages, such as impacted structuresmall floor spaceeasy to connection
high reliability and so on. Additionally, based on overall control, realize all kinds of
automatic protection and site parameter adjustment, and so this device is widely used for
the automatic control system in all kinds of diesel generator set.
2Performance and characteristics
Automatic start/stop the generator set, alarm and stop the generator set for high
water temperaturelow oil pressureover speedlow speed, etc.
Built-in ATS control unit.
Built-in main power detection unit.
Detect and display the speed of diesel engine voltage of battery as well as
running time.
Built-in speed/frequency detect unitcan judge the states such as crank success ,
rated running , over speed and low speed.
Built-in preheating and pre-oil supply control.
Can output two different kinds of control signals for oil-break at the simultaneously,
so suitable for different models diesel engine.
With four gun control models which are high-speed start three-wire solenoid
valveservo motor and electric speed regulation , etc. So suitable for different gun
control mechanism.
Power supply range8~35Vsuitable for different voltage environment.
Built-in watch dog can never be dead halt , ensuring smooth program execution .
3Specification
Power supply: 8~35V DC
Input voltage (main power or generator set): 0~300V AC.
Working conditions: Temperature 0~50
Humidity (20~90)%
Storage condition: Temperature range -20~+60
Power consumption: <3W
4Parameter setting content
P00 Rated speed: 01500
11800 23000 33600
P01

Crank success conditions: 0Generator frequency

1Magnetic Pickup +

generator frequency
P02

Calculated value for the number of teeth of flywheel.

P03

Set value for the number of teeth of flywheel: 70255 (Default 125)

P04

Rated voltage: 80-255

P07

Gun control mode: 0Fixed gun

2Electromagnet control

1Servo motor control

3Electric speed regulation

P08

Time confirm for start signal: 1255S (Default 2S)

P09

Number of start: 19 (Default 3)

P10

Cranking time: 115 (Default 5S)

P11

Crank rest time: 560 (Default 10S)

P12

Idle running time: 0255 (Default 30S)

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User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

P13

Oil bypass delay time: 10255 (Default 15S)

P14

Time confirm for stop signal: 1-255 (Default 2S)

P15

High speed cooling time: 10255 (Default 120S )

P16

Idle speed cooling time: 0255 (Default 30S)

P17

Stop time : 1025 (Default 10S)

P18

Pre-heating time: 090

P19

Transfer rest time: 2255 (Default 2S)

P20

Generator set switch delay time: 5255 (Default 5S)

P21

Main power switch delay time: 1255 (Default 2S)

P22

Calibration point for battery voltage: (12V DC)

P23

Calibration point for battery voltage: (24V DC)

P24

Calibration point for main power voltage: (220V AC)

P25

Main power voltage display

P26

Calibration point for generator voltage: (220V AC)

(Default 0S)

P27 Generator voltage display

5Operating
a. Operation panel

MODEL: GAC608
Crank Failure

Cooling

Low Oil Pressure

High Water Temperature

Low Speed

Over speed

Emergency Stop /Stop Failure

Remote Signal

Fault Signal for Extension

Generator

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Voltage Abnormal

User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

Speed Display

Battery Voltage Display

Run time Display

Main power

Generator set

Manual

Setting/Reset

Manual turn off

Manual main power turn on

Load

Auto

Manual generator turn on

Manual Start

Manual Stop
b. There are manualautomatic and parameter setting models for choose. When under
manual or automatic mode, if press the
setting mode, while re-press
c. Manual operation

key by 3S, the machine enters into parameter

key by 3S, exit from parameter setting mode.

Startupwhen under manual state, continues to press

by 3Sthe generator set
shall be started, and judge that if the starting is successful ,rise up to high-speed for running
automatically. After oil bypass delay time, the generator set enters into normal running.
Within oil bypass delay time, the controller carries out detection for running conditions of
generator set without alarm and stop. In the normal running state , if there is any fault, the
generator set shall speed down and stop..
StopAfter the generator set enters into normal running, press
by 3s for normal
stop, then the generator set enters into standby state after high-speed and idle speed cooling. If
the generator set has not entered into normal running, it stops immediately.
ATS Manual operationContinues to press

key by 3sthe generator set turn on

while continues to press

key by 3sthe main power turn onContinues to press
by 3sif the ATS is three-section typethe ATS returns to middle positionif two-section
typereturns to main power turn on state.
d. Generator set automatic operation
Under automatic mode, if there is any abnormal condition for main power(Power-off
overvoltage or low voltage)all these shall be confirmed by starting signal delay, enter into
starting procedure then enter into normal running after starting idle speed delay
speed-up and oil bypass delay. When the starting signal disappears, the generator set
enters into stop procedure after stop signal delay confirmation, and enter into standby state
after high and idle speed cooling.
e. ATS Automatic operation
Under automatic mode, the generator set enters into running state and provide normal
voltage if the start signal is normal, and carry out automatic switching the generator set on
load after generator set switch delay, if there is failure, switch the main power on load
before generator set stop automatically. When the stop signal is completed with delay
confirmation, switch the main power on load automatically.
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User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

f. Fault removal
In the processing of running, if there is any failure, generator set will stop by speed
down immediately, and the corresponding indicator is on. Then press the set/reset key

the generator set will be reseted from the failure state.

g. Parameter display
Under auto and manual state, the four-digital nixietube can display speed of
generator setvoltage of battery and running time, and the data shall be updated every 1.5s,
you may press
or
key for parameter selection. If under setting state, the
four-digital nixietube is used for displaying parameter number and value.
h. Parameter setting
Continues to press
key by 3sthe controller enters into parameter setting mode,
and the nixietube displays the parameter number like PSuch as P01P02here, press
or
key for parameter selection, if the parameter number is selected, press
keythe nixietube shall display the corresponding parameter value, and the controller shall
make the corresponding digital flicker. If the hundreds'digit flickerspress
value shall be reduced by 100press

key, add 100; if the tensdigit flickers press

key, the value is added with 10, while press

the units'digit

flickers press

key, reduced 1.

Press

units'digit flickers, press

key , the

key, the value shall be reduced by 10; if

key, the value shall be added with 1while press

for choosing the digit of flickering display, when
keyreturn to display status of parameter number. Continues

to press
key by 3sexit from parameter setting state and save the parameter value.
I. Setting for the number of flywheel teeth
When crank success conditions (P01)

select 1 ( Magnetic Pickup

generator

frequency), must set the number of flywheel teeth. If the number of wheel teeth is known,
you may set the number of flywheel according to P03. If unaware of the number of flywheel
teeth, there is automatic test function for choose. You may test and set the number of
flywheel teeth by the steps as follows:
Continues to press
Press

key by 3s, enter into parameter setting status.

for slecting P02 then press

key for displaying the number of

flywheel teeth by auto calculation.

Press

key for starting the generator setthen release

after start.

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key immediately

User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

Use the AC voltage meter to detect the output voltage of magnetic speed sensor
generally, it should be in the range of 3V~30V, if not, adjust the clearance
between the magnetic speed sensor and flywheel.
If the generator set is working normally, the nixietube can display the number of
flywheel teeth by auto calculation.
When the number display is stable, press

keythen press

keythe number

shall flickers, this means the number of flywheel teeth is effective and saved into
P03.
Continues to press

key by 3s, the system shall quit from parameter setting

state and save the parameters.

6Typical Application
The typical diagram for GAC608 is shown as follows:
Load U V W N
U

U
V
W
N

V
W
N

10 13

14

16

15 12

11

GAC608
4 5

Speed Sensor

K5

Oil Pressure Sensor

K4

7
Oil Temperature Sensor

Raise Speed Relay

K3

Stop Relay

K2

Drop Speed Relay

K1

Alarm

6
Water Temperature Sensor

Crank Motor

Heater

K1

Fuel Valve

Emer. Stop

Battery+

K2

Stop solenoid

K5

Heat Relay

21 24 23 22 20 19 18 17
Crank Relay

Battery-

Meter Power
7Installation
The controller is designed to panel installation mode , and it is fixed by clamps when it is
installed. The overall dimension and panel tapping dimension are given as follows:

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Utility

Generator

ATS

User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

8Test run
Before operation, inspections that are recommended as follows should be carried out:
a. Check and assure that all connections are correct , and that diameter of wire is
suitable ;
b. The DC power supply of controller is equipped with fuse ,and the positive
supply (+Ve) and the negative supply (-Ve) connected with battery are connected
correctly ;
c. The emergency stop input is connected with the positive supply (+Ve) of the
battery though the NC terminal and fuse of emergency stop button.
d. The suitable operation should be taken to prevent the engine from crank
success (such as dismantling the connection of crank motor),check and assure that it
is correct , then connect with battery ,select manual mode ,the controller will execute
program .
e. Press down start button

the generator set will crank , after starts have been

carried out according to setting crank numbers ,the controller sends the signal that
indicates crank failure ; Press key

to make the controller resetting ;

f. Restore the measure that prevents the generator set from crank success( such
as restoring the connection of crank motor ); Press start button

again the

generator set will crank , if crank is normal , the generator set will operate from idle
state (if idle has been set ) to normal state . In the meantime observe the running
condition of engine as well as voltage and frequency of AC generator. If there is
abnormal , stop the generator set ,then check connections of each part according to
this hand book ;
g. Choose auto state thought the front panelthen turn on the main power ,the
controller switches over ATS (if it exist) to mains on load after pass through the main
power normal delay , after cooling time , and then shut down to go into standby state
until the main power is abnormal again;
h. After the main power is abnormal again, the generator set will crank into normal
running state, and then switch the ATS to generator set on load. If not, you may check
the connections of ATS according to this hand book
f. For more information, please contact our technicists in time.

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User's manual for GAC608 controller

Fujian Fu'an Deppblue Electronic Co.,Ltd.

9Troubleshooting
Fault Symptom

Possible measures
1.Check the battery
2.Check the connection of controller
3.Check the DC fuse

The controller is not work

Generator set

1.Check if the water temperature is over high

2.Check the voltage of generator
3.Check DC fuse
1.Check if the emergency button is normal
2. Check if the positive pole of battery has been connected
to emergency stop button correctly
3.Check if there is opening or short in connection

stop

Controller emergency stop

Lower oil pressure alarm after Check the oil pressure sensor input and its connection
crank success
High water temperature
alarm after crank success

Check the water temperature sensor input

connection

Failure to crank

1. Check the actuator and its connection

2. Check fuel
3. Check the battery voltage
4. Check magnetic and its connection

and its

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