GC600

Controller for genset working in parallel

in island mode and/or with the mains

GC600
Datasheet_EN_REV_1.8
 DESCRIPTION

The highly capable GC600 processor-based genset controller, is extremely well featured for parallel applications, it
includes a large PLC to ensure customers’ onsite application requirements can be fully met.

A large full colour display makes these controllers suitable for a wide range of applications while presenting operating
status in a clear easy to view format.

Available in two versions, It can be interfaced with both CANBUS J1939 electronic engines and traditional engines, with
digital/analogue sensors.

Based on the type of plant, the most convenient version is available:

GC600 is well recommended in case of multiple gensets working in parallel In island mode.
Multiple parallel to the mains is also included.

GC600Mains is the perfect solution for the management of a single genset working in parallel to the mains by the internal
power regulator.

This version is especially recommended in case of CHP plants, where some additional performances are required for the
management of the auxiliary services of the plant.

Soft loading and unloading is automatically performed. In this case, the controller is able to directly control the Mains
Circuit Breaker also in manual mode, through the specific button on the controller.

Both GC600 versions have a PLC with PID blocks. Customized logics are therefore available, avoiding the use of external
traditional PLC.

Based on the load demand, the controller is able to automatically start/stop the genset.
A smart load management is available, in case of a power station composed by gensets of different nominal powers, it
is possible to automatically select the most convenient gensets able to supply the load, avoiding any waste of fuel and
power.
Automatic running hours equalization is also available.

GC600 and GC600Mains have a TFT 4.3’’ high-quality coloured display, for an easy and quick visualization of the genset
measures and statuses.

Comprehensive communications are also available as standard, like USB, RS232, RS485 (insulated) and Ethernet for the
remote monitoring. The adjustable parameters of the controller allow its use for standard and customized tasks.

All the parameters can be set directly by the controller’s keyboard or, alternatively using the free software tool
(BoardPRG3), available from SICES’ website. It is also available a free PLC editor software, for PLC logic setting.

GC600 and GC600Mains provides storage for occurred events and periodical data.
Stored info can be accessed and viewed from the front panel display.

GC600 and GC600Mains include a hardware watchdog able to advise the user in case of the internal microcontroller
failure.

GC600
Datasheet_EN
 INPUTS - OUTPUTS AND AUXILIARY FUNCTIONS

18 Digital inputs 18 Digital outputs 6 Analogue inputs 2 Analogue outputs

AND/OR 537 Event 16 Calendars USB port

Logic control history log

RS232 RS485 PLC Logic control Ethernet connection

• N. 18 Opto-insulated digital Inputs.

• N. 18 Digital outputs.
• N. 6 Analogue inputs, if not used con be used to:
- Digital inputs (not insulated),
PWM output - Resistive analogue inputs,
- analogue inputs 0...10V,
- Current analogue inputs.
• N. 2 Insulated analogue outputs for frequency and voltage regulation.
• PWM (500Hz) direct interface with CATERPILLAR and gensets with similar
regulation system.
• N. 18 Configurable digital outputs.

Communication:
TIER4 final
STAGE V • N. 2 MODBUS RTU Serial Ports: RS232 and insulated RS485.
• N. 1 Ethernet Port 10/100Mbps.
• N. 1 USB FUNCTION for the configuration.
• Internal clock with history log.
• Direct interface to SIMONE for remote plant supervision.

GC600
Datasheet_EN
 OPERATION MODE

OFF/RESET
Engine start inhibition.
The load is forced to be supplied from the mains.
When the engine is running and the operating mode is changed to ‘OFF’ position, the engine shutdown sequence is
activated.
Reset of all alarms.
Enable parameters change (programming).

PROGRAM
Access to all programmable parameters.
Programming access can be controlled by means a three-level password.
Some parameters can be changed even if the engine is running.

MANUAL
Engine manual START and STOP controls are enabled.
The genset protection functions are activated.
The starting command is automatically disabled when the engine is running.
MCB and GCB pushbuttons are enabled when the genset is in operating range.
Their function depend on the operating mode selected.
Manual synchronization can easily accomplished by built in function.

AUTOMATIC
The operating sequence depends on the selected application:
Single Prime Mover, Stand-by, Stand-by and Short Time Parallel, Single Parallel to Mains, Multiple Prime Mover, Multiple
Parallel to Mains.

TEST
Automatic start for testing operations with safety protections enabled.
Test can be made unloaded, loaded or in parallel to mains.
Upon mains failure, the load is immediately supplied by the genset.

MAIN FEATURES >> Available in two versions: GC600 and GC600Mains.

>> Graphic color display TFT 4.3’’ - 480x272 pixel - Visual area 95 x 54 mm.
>> PLC with PID functions included.
>> Interfaced with both electronic and traditional engines.
>> Measurements: Mains/bus and genset voltages, frequency; genset currents
(.../5A or../1A).
>> Active, reactive and apparent power measures.
>> Engine speed and battery charge voltage.

GC600
Datasheet_EN
 MEASURES

Mains/Bus voltages: L1-N, L2-N, L3-N, L1-L2, L2-L3, L3-L1.

True RMS measure.
Lx-N max. voltage < 300Vac cat. IV.
100/400V Nominal voltage input reading available with auto adjustment.

Generator voltages: L1-N, L2-N, L3-N, L1-L2, L2-L3, L3-L1.

True RMS measure.
Lx-N max. voltage < 300Vac cat. IV.
100/400V Nominal Voltage input reading available with auto adjustment.

Generator currents: L1, L2, L3, N (*).

True RMS measure.
Nominal max. current: 5Aac and 1Aac.
Integrated CTs.
(*) Neutral generator current as alternative to differential protection or to be used
for measure mains power from CT (Standard) or Tore (option).

Generator and mains frequency meter: Resolution = 0.1 Hz. Accuracy = ±50ppm, ±35ppm/°C (typical).

Battery voltmeter: Resolution = 0.1V.

Oil pressure gauge: VDO 0-10 Bar, VDO 0-5 Bar, Veglia 0-8 Bar (configurable curve based on sensors
available).

Coolant or oil thermometer: VDO, Veglia, BERU (configurable curve based on sensors available).

Fuel level: VDO, Veglia, BERU (configurable curve based on sensors available).

Engine revolution counter: By pick-up. Programmable teeth number. Same input can be used by W signal.

D+ for the measure of the alternator battery charger voltage.

Active and reactive power, power factor, are available as total measure and also for each
single phase. Power and currents maximum reached values are stored with date and time.
Additional analogical measures related to the engine are available in case of engines with
CANBUS J1939 interface.

GC600
Datasheet_EN
 PROTECTIONS

Mains protections • Rate of Change of Frequency (81R ROCOF).

• Vector shift.
• Undervoltage (27).
• Overvoltage (59).
• Underfrequency (81U).
• Overfrequency (81O).
• 27T - Low voltage protection time-dependent.
• 27Q - Low voltage protection with directional reactive power.
• (FNN-VDE Q-U-protection).

Generator protections • Underfrequency (81U).

• Overfrequency (81O).
• Undervoltage (27).
• voltage unbalance wrong phases sequence (47).
• Overvoltage (59).
• Power reverse direction (32).
• Loss of excitation (Reverse reactive 40).
• Time dependent overcurrent (51) IDMT.
• Instantaneous overcurrent (50).
• Synchro-check (25).
• Negative sequence current (46).
• Maximum neutral current (50N).
• Earth fault protection (64).

Engine protections • Overspeed (12).

• Incomplete sequence (48).
• Belt-break.
• Coolant temperature warning and alarm.
• Oil pressure warning and alarm.
• Oil temperature warning and alarm.
• Water level warning and alarm.
• Max. power.
• Fuel level.
• Battery failure (min./max. voltage).

Automatic adjustment of the power output based on the mains frequency value.
This feature allows to actively support the mains in case of over/under production.

GC600
Datasheet_EN
 EMBEDDED >> Engine diagnostic code.

FUNCTIONS >> Periodical test.

>> Real Time Clock with internal rechargeable Lithium battery.
>> Fuel pump management.
>> Events log.
>> Pre-glow and coolant heater management.
>> Remote start and stop.
>> Override function.
>> Hours counter for maintenance schedule.
>> Daily counter with embedded calendar for the maintenance.
>> Embedded horn alarm.
>> Engine speed measurement by pick-up, frequency or W.
>> Programmable by PC or using the keyboard of the controller.
>> Remote firmware update.
>> SMS communication.
>> SNMP, NTP (for the automatic clock update), DNS and DHCP support.
>> N. 1 Threshold as load shedding. Additional logics available with the PLC
functions.
>> Internal active and reactive powers regulation.
>> Internal load-sharing.
>> Internal synchronizer.
>> Powerful load management suitable for plants composed by gensets of different
powers.
>> Insulated CAN interface for PMCBUS application (LOAD–SHARING and parallel
management).
>> Up to 16 gensets connected together.
>> Up to 16 MC100 supported.
>> Up to 4 alternative configurations.
>> Easy plant configuration.
>> N. 3 Levels of power reserve for unexpected changes of load request.
>> Ramp modulations for load and unload.

GC600
Datasheet_EN
 COMMUNICATIONS

GC600/GC600Mains • N. 1 USB FUNCTION for the configuration.

• N. 1 RS232 Serial port Modbus RTU (external modems can be connected here).
• N. 1 RS485 Insulated serial port Modbus RTU.
• N. 1 RJ45 Port as Ethernet interface TCP/IP.
• N. 1 Insulated CANBUS J1939 and MTU MDEC interface.
• N. 1 Insulated CANBUS (PMCBUS) for the load sharing.

As option • REWIND - GPRS/GSM/GPS Device.

• PSTN/GSM Modem.

TECHNICAL DATA >> Supply voltage: 7…32 Vdc.

>> Power consumption: typical less than 2W.
>> (Auto mode, Standby, AMF active, LCD Lamp Saving active).
>> Operating frequency 50Hz or 60Hz.
>> LCD with backlight.
>> Operating temperature: -25 °C to +65 °C.
>> Storage temperature: -30 °C to +80 °C.
>> Protection degree: IP65 (gasket included).
>> Weight: 600gr.
>> Overall dimension: 244 (W) x 178 (H) x 83 (D) mm.
>> Panel cut-out: 218 (W) x 159 (H) mm.
>> Specific function for French market EJP / EJP-T.
>> EMC: conform to EN61326-1.
>> Safety: built in conformity to EN61010-1.

GC600
Datasheet_EN
 CURRENT INPUTS GENERATOR MAINS/BUS
SUPPLY C.T. 1 ÷ C.T. 3 VOLTAGE VOLTAGE

JC 2 1 JD JE 4 3 JF 2 1 4 3 JG 2 1
JB SIGNAL 4 3 2 1 6 5 4 3 2 1
JA RS232 GROUND
POWER ON

AUX OUT 4
AUX OUT 3
AUX OUT 2
AUX OUT 1

(6) C.T. 3

(3)L1

(2)L2

(3)L1

(2)L2
+BATT.

(4) C.T. 2

(1)L3

(1)L3
(3) C.T. 2

(2) C.T. 1
(5) C.T. 3

(4)N

(4)N
(1) C.T. 1
GND

TR2
+ -

6 5 4 3 2 1 6 5 4 3 2 1 5 4 3 2 1

OFF
5 4 3 2 1 3 2 1

WATCH_DOG
HARDWARE
INPUT 18
INPUT 17
INPUT 16
INPUT 15
INPUT 14
COMMON

OUTPUT 9
OUTPUT 8
OUTPUT 7
OUTPUT 6
OUTPUT 5
INPUT 13
INPUT 12

INPUT 10
COMMON

INPUT 11

OUTPUT 13
OUTPUT 12

OUTPUT 10
OUTPUT 14

OUTPUT 11
S4
INPUT 9

VOUT2-

VOUT2+
0V
JS

VOLTAGE 10V
MAX OUTPUT
ON
S2 S3 OUTPUT
COMMON COMMON
NEGATIVE PLUS
COMMON COMMON
NEGATIVE OPEN COLLECTOR NEGATIVE OPEN COLLECTOR LEVEL ±1..10V
JO NEGATIVE PLUS
JP JR
JQ
DIGITAL INPUTS DIGITAL DIGITAL DIGITAL AN. OUTPUT 2
14 ÷ 18 INPUTS 9÷13 OUTPUTS 10 ÷ 14 OUTPUTS 5 ÷ 9 (AVR VOLTAGE)
10/100Mb/s

GC600

176
AN. OUTPUT 1
(SPEED GOVERNOR)

ANALOG
JT
JY

CANBUS 1 INPUTS 1÷2 JU OUTPUT LEVEL

(PMCBUS) ±1..10V

AN. INPUT 1 (0..10V)

AN. INPUT 2 (0..10V)

VOLTAGE 10V
(RESERVED) P1

RS485 SERIAL

MAX OUTPUT
JX
+5V (RESERVED)

VOUT 1-
0V (RESERVED)

VOUT 1+
REF. IN 1 (GND)

REF. IN 2 (GND)
S6
120R
JW

0V
OFF ON
S5
1 2 3
120R
CAN_L
CAN_H

OFF ON
N.C.

A
A
B
B
RS485

JNB 1 2 3 1 2 3 4 1 2 3 4 5 6
- +
TR1
USB 2.0
120R
S1 OFF ON
(3) FUEL SOLEN.

(6) COM MCB

(3) COM GCB
(2) +BATTERY
(1) AN. REFERENCE

(6) GND RESERVED

CAN_L
CAN_H

(5) OIL TEMPERAT.

(4) NO MCB
(3) OIL PRESSURE

(5) NC MCB
(1) NO GCB

(2) NC GCB
(4) W. TEMPERAT.

(4) D+ (an.
(1) START
(2) FUEL LEVEL
N.C.

(1) C.T. 4

(2) C.T. 4
(7) IN PICK-UP

input 7)
(1) INPUT 1

(2) INPUT 2
(3) INPUT 3
(4) INPUT 4
(5) INPUT 5
(6) INPUT 6
(7) INPUT 7
(8) INPUT 8

(8) FILT RTN

1 2 3
(9) IN W
USB POWER

SW1

USB 2.0 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2
JNA JM JL JK 1 2 3 4 JJ JI 1 2 3 4 5 6 JH

CANBUS 0 ECU DIGITAL INPUT 1÷8 ANALOG INPUTS 3 ÷ 6 ENGINE COMMANDS CURRENT CIRCUITS 72
INTERFACE and ANALOG INPUTS 7 INPUT C.T. 4 BREAKERS
218 83
242

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