GENERATING PLANT

MANAGEMENT
SYSTEM
FOR MARINE USE
Model GAC21

INSTRUCTION MANUAL

TERASAKI ELECTRIC CO., LTD.

MS 21用 (英)

2001.06
 GENERATING PLANT MANAGEMENT SYSTEM
GAC21

CONTENTS OF INSTRUCTION MANUAL

PART 1 General Specification and System Structure -------------- 1-1～1-26

PART 2 Generator Automatic Control Functions -------------------------
PART 3 Setting Value Display Functions ---------------------------- 2-1～2-34
3-1～3-9
PART 4 Inspection・Maintenance and
Self-Diagnostic Functions --------------------- 4-1～4-17

In this manual, safety precaution are ranked into two types;

“ DANGER” and“ CAUTION” these two ranks are defined
as follows.
DANGER
： A danger notice with this symbol indicates that neglecting the suggested
procedure or practice could be fatal or result in serious personal injury.

CAUTION
： A caution notice with this symbol indicates that neglecting the suggested
procedure or practice could result in moderate or slight personal injury
and/or property damage.

Note that failing to observe CAUTION notices could result in serious

Injury / damage in some situations.
Because safety notices contain important safety information, be sure to read
and observe them.

CAUTION Automatic Synchronous Closing Control Function

for Generator

The automatic synchronous closing control function for a generator, as mentioned in

the instruction manual for the GAC21 Generating Plant Management System, is
independent from the GAC21 Generator Automatic Controller.
For further information on this function, refer to the instruction manual for the Type
EAS-101 Digital Synchronizer.

TERASAKI ELECTRIC CO., LTD.

GENERATING PLANT MANAGEMENT SYSTEM
GAC21

INSTRUCTION MANUAL

PART 1

General Specification and System Structure

TERASAKI ELECTRIC CO., LTD.

 Table of Contents

1-1
1. Introduction -----------------------------------------------------------------------
2. Application and Performance ------------------------------------------------ 1-5
1-5
2.1 Applications --------------------------------------------------------------------
1-5
2.1.1 Type of Prime Mover and Generator Combinations -------------- 1-5
2.1.2 Voltage and Frequency Ratings for Generators ------------------- 1-5
1-6
2.1.3 Maximum Number of Generators that can be Controlled -------- 1-6
2.1.4 Generator Bus System --------------------------------------------------- 1-6
2.1.5 Air Circuit Breaker Closing Operation for Generators ------------ 1-6
1-6
2.1.6 Type of Prime Mover Generators -------------------------------------- 1-6
2.2 Performance ------------------------------------------------------------------- 1-6
2.2.1 Applicable Standards ----------------------------------------------------- 1-6
1-7
2.2.2 Environmental Conditions -----------------------------------------------
1-7
2.2.3 Control Power Supply ---------------------------------------------------- 1-7
2.2.4 Input of Measured Voltage/Frequency and Electric Power ------ 1-10
1-10
2.2.5 Structure and Installation Location of GAC21 Controller ------------------
1-10
2.2.6 External Dimensions and Mass ---------------------------------------- 1-11
3. System Structure ---------------------------------------------------------------- 1-25
1-26
3.1 Structure of GAC21 Controller --------------------------------------------
3.1.1 Type and Use ---------------------------------------------------------------
3.1.2 External Dimensions and Mass ----------------------------------------
3.1.3 Specification of Modules -------------------------------------------------
3.2 LED Display Setting Device -----------------------------------------------
3.3 Electric Power/Voltage/Frequency Transducer -----------------------

TERASAKI ELECTRIC CO., LTD.

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1. Introduction
The GAC21 Generating Plant Management System (hereafter referred to as“ GAC21 System” is
designed as a highly reliable total system that is very easy to use.
It features our system design based on affluent experiences as a dedicated manufacturer, and makes the
full use of our generator control technology and multiplex transmission technology that have successfully
been applied for a large number of our products for marine vessels.
The GAC21 System is a function-dispersed type system that operates mainly using its programmable
controller.
It consists of two control units, the GAC21 Automatic Generator Controller and the Type EAS-101
Digital Synchronizer, for a maximum of 5 generating plants.

GAC21 Generator Automatic Controller (GAC21)

The GAC21 Generator Automatic Controller (hereafter referred to as“ GAC21 Controller” ) auto-
matically controls a generator using its programmable controller.
It covers the management of the entire generating plant including the automatic load sharing function,
automatic start, automatic switching instruction, and power management of the generating plant.
The GAC21 Controller is used to automate the engine room of a marine vessel or to perform rational
power control for a super-streamlined marine vessel.
The settings of control parameters entered and stored in the GAC21 Controller can be modified by the
handy type setting device for LED display (hereafter referred to as “Setting device”), which comes with
the GAC21 Controller.
The Setting device also allows you to read out the measured values.

Digital Synchronizer (EAS-101)

The Digital Synchronizer (hereafter referred to as “EAS-101 Device”) is a small, lightweight unit using a
single-chip CPU.
It provides two functions, the synchronous closing control function and the synchronous detection control
function.
The GAC21 System uses the synchronous closing control function.

CAUTION Digital Synchronizer

The automatic synchronous closing control function for a generator, as mentioned in

the instruction manual for the GAC21 Generating Plant Management System, is
independent from the GAC21 Generator Automatic Controller.
For further information on this function, refer to the instruction manual for the Type
EAS-101 Digital Synchronizer.

Figs.1-1 and 1-2 shows the appearance of GAC21 Controller and its Setting device.

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Coupler lock

Setting device

24V DC source
SX bus Address Number Base board
(254) (1) (2) (3) (4) (5) (6) (7) (8) (9)

DIGITAL I/O Module (NP1W3206T)

DIGITAL Input Module (NP1X1606-W)
DIGITAL I/O Module (NP1W1606T)
TM interface Module (NP1L-TMB)
DIGITAL I/O Module (NP1W3206T)
ANALOG Input Module (NP1AX04-MR)
CPU Module (NP1PH-16)
POWER SUPPLY Module (NP1S-42) ----------〔(XX-X)：Type of Module〕

Fig,1-1 Appearance of GAC21 Controller (Three Generators)

１：LED Display (Red) 4 digit

２：TEN Key (0～9)

３：CANCEL Key (C)

４：ENTER Key (ENTER)

５：Add. No. ⇔ Value

Change over Slid switch

６：Now ⇔ New
Change over Slide switch
７：I/O Module Connector (40P)

８：Power source Connector (2P)

Fig.1-2 Appearance of Setting device

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The GAC21 system has many excellent features as listed below.

(1) Centralized control for Generating plant
Each generating plant uses the centralized control/function-decentralized system that controls the
generating plant with a single unit of the GAC21 Controller and simplifies the control circuit and
other related circuits.
If an error should occur in the GAC21 Controller or the TM-2 multiplex transmission system, the
operation control function by manual operations for each generating plant would remain intact.
The system is designed, in principle, so as to ensure the priority of manual operations and the
establishment of independent subsystems such as a safety subsystem and a warning subsystem.
Therefore, if the GAC21 Controller should fails, the safety of the power system and the marine
vessel would be secured.

No.1 GENERATOR No.2 GENERATOR No.3 GENERATOR

ENGINE CONTROL ENGINE CONTROL ENGINE CONTROL

ENGINE PROTECTION ENGINE PROTECTION ENGINE PROTECTION
MANUAL ACB CONTROL MANUAL ACB CONTROL MANUAL ACB CONTROL EACH
MANUAL GOV CONTROL MANUAL GOV CONTROL MANUAL GOV CONTROL GENERATOR
GEN PROTECTION GEN PROTECTION GEN PROTECTION INDEPENDENT

GAC-UMS CONTROL FUNCTIONS

GENERATOR MONITORING, BUS MONITORING, AUTOMATIC GENERATOR
START CONTROL, AUTOMATIC GENERATOR STOP CONTROL, AUTOMATIC GAC21 Controller
LOAD SHARING CONTROL, AUTOMATIC GENERATOR SYNCHRONIZING
CONTROL By EAS-101.

GAC-PMS CONTROL FUNCTIONS

PMS-G ： NUMBER OF DIESEL GENERATORS ON-LINE CONTROL
GAC21 Controller
PMS-TG： OPTIMUM LOAD SHARING CONTROL

PMS-M ： LARGE MOTOR START BLOCKING CONTROL

AUTOMATIC SYNCHRONIZING CONTROL EAS-101 Device

MANUAL SYNCHRONIZING CONTROL INDEPENDENT

GAC-UMS Control Functions

Generator monitoring, Bus monitoring, Standby generator control, Automatic load sharing control,
automatic synchronizing control (EAS-101),

GAC-PMS Control Functions

PMS-G ： Number of Diesel Generators on-Line Control
PMS-TG： Optimum Load Sharing Control
PMS-M ： Large Motor Start Blocking Control

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(2) Field adjustment function

The GAC21 System is equipped as standard with the Setting device, which incorporates the small
LED (light emitting diode) display function and key switch into a single unit.
This feature allows you to easily check various setting values and measured values related to control,
and also to change the setting values at ease.

(3) Self-diagnostic function

The GAC21 Controller constantly monitors its modules for any system error, communication error,
and transmission system error.
If any of those errors occurs, the corresponding warning indicator on the module turns ON.
All the errors will be output as GAC21 SYSTEM FAIL signals to the outside.

(4) Space saving in switchboard

The centralized control of the GAC21 System eliminates the need of installing a synchronous panel
because the centralized control of each generating plant is performed in the lower common zone
alone.
This results in downsizing the total length of the switchboard, thus allowing for saving the installation
space.

SX Bus and Address number of inner GAC21 controller Base board

(254) (1) (2) (3) (4) (5) (6) (7) (8) (9)

Power CPU TM Ana- Ana- Digital Digital Digital Digital Digital Digital
Supply Module Interface logue logue I/O I/O I/O I/O Input I/O
Module Module Input Input Module Module Module Module Module Module
Module Module (G1) (G2) (G3) (Common) (Common) (Setting
Device)
(NP1S (NP1PH (NP1L (NP1AX04 (NP1AX04 (NP1W (NP1W (NP1W (NP1W (NP1X (NP1W
-42) -16) -TMB) -MR) -MR) 3206T) 3206T) 3206T) 1606T) 1606-W) 3206T)

24V DC source
Setting device
TM Bus Switchboard relay module (ESM-1102)
Digital synchronizer (EAS-101)
Voltage, Electric power, Frequency Transducer Input
Various alarm and indication output to shipboard monitor

Fig.1-3 Configuration of the GAC21 Controller (Three generators)

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2. Application and Performance

2.1 Applications
2.1.1 Type of Prime Mover and Generator Combinations
The system can be used with the following types of generators and prime movers.
(1) Diesel engine driven synchronous alternators.
(2) Steam turbine driven synchronous alternators.
(Including those with main-engine exhaust-gas economizers.)
(3) Gas turbine driven synchronous alternators
(4) Shaft driven generators (generator systems)
・Variable frequency type

・Fixed frequency type

2.1.2 Voltage and Frequency Ratings for Generators

(1) Voltage rating
200 to 240V, 380V, 400 to 480V, 600V, 690V AC
3300V, 6600V, 11000V AC
(2) Frequency rating
50Hz, 60Hz
(3) Phases and wiring

Three-phase three-wire (3φ 3W) type or three-phase four-wire (3φ 4W) type

2.1.3 Maximum Number of Generators that can be Controlled

For generators that conform to items 2.1.1 and 2.1.2 above, the system can control up to a maximum
of 5 generating plants regardless of their prime mover/generator combinations.

CAUTION Control details and the maximum number of

controllable generators

・For controlling 4 generators maximum:

GAC-UMS function, GAC-PMS function, Communication function.
The Optimum Load Sharing Control (GAC-PMS-TG) is optionally available among
the GAC-PMS functions.

・For controlling 5 generators maximum:

GAC-UMS function, GAC-PMS function, Communication function.
The Number of Diesel generators on Line Control (GAC-PMS-G) and Large Motor
Start Blocking Control (GAC-PMS-M) are available among the GAC-PMS functions.
If the Optimum Load Sharing Control (GAC-PMS-TG) is required, contact us.

・For controlling more than 6 generators or using the dispersion control for generators,
contact us.

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2.1.4 Generator Bus System

(1) The standard bus between each generator uses a single generator bus system without bus-tie
breakers or disconnecting switches to separate the main bus into a number of bus sections.
(2) If the bus-tie breaker is installed on the main bus bar to perform the automatic control, the
maximum number of controllable generators may be limited depending on the system
configuration.
In this case, contact us.

2.1.5 Air Circuit Breaker Closing Operation for Generators

For generators of AC690V or less in output, TERASAKI AR series air circuit breakers (hereafter
referred to as the“ ACB” ) are normally used, the operation type of which may be motor stored energy
operated.
For generators of more than AC690V in output, vacuum circuit breakers or other applicable circuit
breakers are to be used.

2.1.6 Type of Prime Mover Generators

There are no restrictions on the drive voltage for a motor-driven governor system. For an electrical
governor system, the system must be constructed differently.

2.2 Performance
2.2.1 Applicable Standards
Conforms to the various shipping classification regulations.

2.2.2 Environmental Conditions

(1) Ambient temperature：0 to 55℃

(2) Humidity：Less than 95％

2.2.3 Control Power Supply

(1) Rated voltage:
24V DC (Three-phase, full-wave rectification equivalent)
(2) Acceptable power supply voltage variation:
＋30％(31.2V) to－25％(18V) of the rated voltage

(3) Power consumption at the rated voltage：GAC21 Controller, approx. 45W

2.2.4 Input of Measured Voltage/Frequency and Electric Power

Each 4 channels enabling the measurement for 2 analog input modules are used to measure the
voltage, power, and bus frequency equivalent to those for 3 generators.
Signal current of 4~20 mA DC output from the electric power (watt) transducer, voltage transducer
and frequency transducer provided outside the GAC21 Controller will be input.

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2.2.5 Structure and Installation Location of GAC21 Controller

Table 1-1 shows the structure and installation location of the GAC21 Controller.

Table 1-1 Structure and Installation Location

Name Type Structure Installation Location

GAC21 Controller GAC21 IP30 In the common section of

Main switchboard Model
MS21.
Setting device HT21-001 IP30 (Generator panel under
front side)

2.2.6 External Dimensions and Mass -

Table 1-2 shows the external dimensions and mass of the GAS21 Controller configured with
3 generators.
Table 1-2 External Dimension and Mass

External Dimensions (㎜) Mass

Name Type (ｇ)
W H D

GAC21 Controller GAC21 483 113 108 2785

Setting device HT21-001 100 160 38 275

3. System Structure
Fig.1-5 shows the configuration of the GAC21 System.
This system roughly consists of the following 3 components.

(1) GAC21 Controller

The GAC21 Controller performs the management of the entire generating plant.
Receiving the automatic control signals, it performs the prime mover control, the generator control,
and the ACB closing and tripping control.
It also performs the load sharing control and the frequency constant control, automates the
monitoring and control required for a marine vessel with its engine room automated, and provides
the rationalized power control.
The GAC21 Controller consists of multiple modules of the MICREX-SX series SPH programmable
controllers (hereafter referred to as “PC”) made by Fuji Electric Co., Ltd.

Fig.1-4 shows the module configuration for 3 generators.

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Base board
(254) (1) (2) (3) (4) (5) (6) (7) (8) (9)
DIGITAL I/O Module
(Setting device)
DIGITAL Input Module (Common)
DIGITAL I/O Module (Common)
DIGITAL I/O Module (G1, G2, G3)
ANALOG Input Module (Transducer)
TM interface Module (TM Bus)
CPU Module (CPU)
POWER SUPPLY Module (24V DC Source)

Fig,1-4 Module Structure of GAC21 Controller

(2) LED display Setting device

The LED display Setting device may be connected to the digital I/O module (Setting device) of the
PC, so that the setting value can be displayed and changed, and that voltage, power, and frequency
can be displayed.

(3) Digital Synchronizer Type EAS-101

The EAS-101 Device is used to perform the synchronous closing control over the bus of the ACB
for a generator. For the input for synchronous closing, the secondary voltage from the step-down
transformer for the bus and generator is used.
The voltage and frequency is measured, and the voltage difference, frequency difference, and phase
difference are detected.
The CPU calculates them to operate (Raise/Lower) the prime mover governor at a constant speed
and to perform the closing control for the ACB for the generator.

CAUTION Digital Synchronizer

The automatic synchronous closing control function for a generator, as mentioned in

the instruction manual for the GAC21 Generating Plant Management System, is
independent from the GAC21 Generator Automatic Controller.
For further information on this function, refer to the instruction manual for the Type
EAS-101 Digital Synchronizer.

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Fig.1-5 GAC21 System Configuration

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3.1 Structure of GAC21 Controller

3.1.1 Type and Use
Table 1-3 Type and Used

SX Bus
No. Module Name Type Used Qty.
Address No.

a － Power Supply NP1S-42 PC Source 24V DC １

b (254) CPU NP1PH-16 Program control １
c (1) TM Interface NP1L-TMB Alarm and display １
output to ship
monitor

d (2)(3) Analogue Input NP1AX04-MR Voltage, Electric ２

power, Frequency
transducer input

e (4)(5)(6) Digital I/O NP1W3206T G1,G2,G3 I/O ３

f (7) Digital I/O NP1W1606T Common I/O １

g (8) Digital Input NP1X1606-W Common input １

e (9) Digital I/O NP1W3206T Setting device １
h － Base board NP1BS-13 PC Installation １
(For Module 13slot)
Remark:：The GAS21 Controller configured with 3 generators.

3.1.2 External Dimensions and Mass

Table 1-4 External dimension and Mass

SX Bus External dimension(mm) Mass

No． Module Name
Address No. W H D (ｇ)

a － Power Supply 69.8 105 90 350

b (254) CPU 35 105 90 170

c (1) TM Interface 165

d (2)(3) Analogue Input 200

e (4)(5)(6) Digital I/O 140

f (7) Digital I/O 150

g (8) Digital Input 150

e (9) Digital I/O 140

H － Base board 483 113 31 840

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3.1.3 Specification of Modules

(a) Power Supply Module (Type：NP1S-42)

＋24V DC
－

LG

FG

NC

NC

Fig.1-6 Power Supply Module Front view and Terminal arrangement

Power supply specifications

ITEM Specification Remarks

Type NP1S-42

Rated input voltage 24V DC

(Input tolerance) (18 to 31.2V DC)
Rated output voltage 24V DC
(Output tolerance) (22.8 to 26.4V DC)
Alarm output 1(Monitoring of output voltage) Relay NC contact

Power consumption 45W or less Rated input voltage

maximum load

Status indication LED

Symbol Color Description

PWR Green Turns on when the output voltage is within the rated range
Turns off when out of the range.
ALM Red Turns on when the output voltage is within the rated voltage.

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(b) CPU Module (Type：NP1PH-16)

Fig.1-7 CPU Module Front view

Specifications
ITEM Specification

Type NP1PH-16

Control system Stored program. Cyclic scanning system

I/O connection method Direct input / Output (SX bus)

I/O control system Via SX bus, Synchronous refresh with Takt

CPU 16-bit OS processor. 16-bit execution processor

Memory types Program memory, data memory, temporary

Program memory capacity 16384 step

Diagnosis function Self diagnosis (memory checking, ROM sum checking,

CPU basic calculation checking), system configuration
monitoring, module fault monitoring

Backup of memory Battery in CPU module, Battery： Lithium primary battery

Calendar Available up to 12/31/2069 23:59:59,
Precision：± 27 s/month (at 25℃)
Internal current 24V DC 85mA or less
Consumption

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Status indication LED

Symbol Color Description

ONL Green CPU module it selfe:

ERR Red 《Lighting pattern 》
ONL ERR Status of CPU module it self
OFF OFF Power OFF, system resetting or initializing
Blink － SX bus establishment (in progress)
ON OFF CPU：Normal running
ON ON CPU is nonfatal fault running
OFF ON CPU fatal fault at a stop

RUN Green System control status by CPU module:

ALM Red 《Lighting pattern》
RUN ALM Status of system
OFF OFF Power OFF, or application program stop
ON OFF System normal running
ON ON System nonfatal fault running
OFF ON System fatal fault, at a stop
System is include CPU module

BAT Orange Turned on when data backup battery dropped or disconnected.

Key switch
The CPU operation is selected by the key switch.

Mode CPU operation, communication to the program loader

RUN When RUN is selected from STOP or TERM, the CPU module starts to run.
Monitoring and program reading are possible by the program loader.
(Data can be read and written), according to the usual state of RUN position.

TERM The CPU maintains the previous status.

When TERM is selected from STOP, the CPU module maintains the stopped
status.
When TERM is selected from RUN, the CPU module maintains the run status.
When TERM is selected on turning power ON, the CPU module has the run
status (default selection)
In this case the CPU module can maintain the previous status by the system
defining.

STOP When STOP is selected from RUN or TERM, the CPU module stops.
Monitoring and program reading are possible with the program loader.
(Data can be read and written)

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CPU No. Selection key switch

This switch is used to select the CPU number. Be sure to select“ 0” for a one-CPU system.

CAUTION KEY Switch and CPU No. Selection key switch

・Key switch
This adjustment is usually set to“ RUN” position before shipment.
Used for usually“ RUN” position.
・CPU No. Selection key switch
Used for usually setting“ 0” position.
Do not change during operation for generator running, otherwise, system stop
might be causes.

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(c) TM Interface Module (Type：NP1L-TMB)

Fig.1-8 TM Interface Module Front view

Status indication LED

Status ONL ERR SD RD
(Green) (Red) (Green) (Green)

Normal Normal ON OFF OFF OFF

Output data transmission ON OFF Blink OFF

Input data receiving ON OFF OFF Blink

Abnormal Fatal fault OFF ON OFF OFF

Nonfatal fault ON ON OFF OFF

Specifications
ITEM Specification

Type NP1L-TMB

Communication method Stored program Cyclic scan

Transmission line format Direct input/output system (SX bus)

Transmission speed 2kbps－5kbps

Input/Output signal points ・Input (transmission) module part：784 points (98 channel)
・Output (receive) module part：8～256 points
(1～32 channel variable)

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ITEM Specification

Transmission distance Max. 2 km

Transmission cable ７core cable

Output signal No volt transistor output

Transmission power supply 12V DC

12V DC power consumption 700 mW

External connection ６pin dynamic connector

TM line RAS TM master unit clock abnormal, Signal wire breaking down,
Check bit abnormal, Tow time checking abnormal detection

SX interface
ITEM Specification

No. of occupancy word Input 16 word・Output 8 word

Response time Input time delay ＋ Takt cycle
Status indication Refer to Status indication LED table

24V DC current consumption 150mA or less

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(d) Analogue Input Module (Type：NP1AX04-MR)

Signal name

1 NC
NC 2 3 NC
V1 4 5 COM
11 6 7 SLD
V2 COM
12 8 SLD
V3 10 9
11 COM
13 12 SLD
V4 14 13
COM
14 16 15
SLD
SLD 18 17
20 19

Terminal No.

Note：NC indicate a terminal not connected to an internal circuit.

Do not use NC terminals as repeating terminals.

Fig.1-9 Analogue Input Module Front view and Terminal arrangement

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Specifications
ITEM Specification

Type NP1AX04-MR

No. of input channels ４ channels

Input tolerance Current input：± 30mA
Input impedance Current impedance：250Ω or less
Conversion characteristic Current input：4-20mA
Resolution 10 bit
Overall accuracy ± 0.5% or less (25℃)・± 1.0% or less (0～55℃)
(For full scale)
Digital output format INT type (integer)
Sampling time 4ms/4 channels
External wire connection Detachable terminal block (M3) 20 poles
Status indication ONL：normal (Green LED)・ERR：abnormal (Red LED)
SETTING：light or blink on setting (Green LED)
Internal current 24V DC 120mA or less (when all channels are used)
consumption

Gain/Offset channel “
Rotary switch： 0” position setting
selection key switch
Used for this position
Gain/Offset setting key “
Slide switch： center” position setting
Switch
Used for this position

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(e) Digital I/O Module (Type：NP1W3206T)

Signal name Bit Connector Bit

No. Pin No. No.
0.0 1.0
0 B20 A20 0 L

・ 1
2
B19
B18
A19
A18
1
2
3 B17 A17 3
4 B16 A16 4
5 B15 A15 5
6 B14 A14 6
7 B13 A13 7
8 B12 A12 8
9 B11 A11 9
10 B10 A10 10
11 B9 A9 11
12 B8 A8 12
13 B7 A7 13
14 B6 A6 14
0.15 1.15
・ 15 B5 A5 15 L
・
NC B4 A4 NC
NC B3 A3 NC
NC B2 A2 PO
＋ ・
CO B1 A1 MO

Note：NC indicate a terminal not connected to an internal circuit.

Do not use NC terminals as repeating terminals.

Fig.1-10 Digital I/O Module Front view and Connector Pin arrangement

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Specification
ITEM Specification

Type NP1W3206T

No. of input points 16 points (16 points common × 1 circuit)

Input signal condition Rated voltage：24V DC・Max. 31.2V DC
Characteristics of input Input type：source type・Rated current：4mA
Circuit

No. of output condition 16 points (16 points common × 1 circuit)

Output power supply Rated voltage：12-24V DC・Tolerance：10.2-31.2V DC
Condition

Characteristics of output Output type：Sink type・Max. load current：0.12A/point,

Circuit
1.6A/common
Output protection method Built-in fuse：125V 2.5A (not changeable by user)
Surge absorption circuit：Zener diode
On/off time Max. 3600 time/hour (inductive load), Non limit (resistor load)
External wire connector 40-pin connector × 1 piece
Input/output signal For selected points by the switch. 0 to 15 points/total 16 points.
Indication LED indicator lights up when input is ON.
ONL：normal (green LED)
ERR：abnormal and the fuse blown out (red LED)
Occupied words 2 words
Internal current 24V DC・50mA or less (when all points are turned ON)
consumption

LED indication selection Slide switch：This adjustment is set to“ 1” position

Switch
before
shipment.

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(f) Digital I/O Module (Type：NP1W1606T)

Signal name

0
1 1 ・
・ 2 3
2

・
3
5
4 5
4 ・
7
6 7 ・
・ 9 6
CO ・
8 11 ＋
L 8 10 13 9
10 12 L
15 11
・ L
12 14 17 16 L
・
・ 14
PO
16
18
19 15 L
・
L MO
・
20 L
・
・ ＋
・
NC

Terminal No.

Note：NC indicate a terminal not connected to an internal circuit.

Do not use NC terminals as repeating terminals.

Fig.1-11 Digital I/O Module Front view and Connector Pin arrangement

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Specification
ITEM Specification

Type NP1W1606T

No. of input points 8 points (8 points common × 1 circuit)

Input signal condition Rated voltage：24V DC・Max. 31.2V DC
Characteristics of input Input type：source type・Rated current：7mA
Circuit

No. of output condition 8 points (8 points common × 1 circuit)

Output power supply Rated voltage：12-24V DC・Tolerance：10.2-31.2V DC
Condition

Characteristics of output Output type：Sink type・Max. load current：0.6A/point,

Circuit
4 A/common
Output protection method Built-in fuse：125V 7A (not changeable by user)
Surge absorption circuit：Varistor
On/off time Max. 1800 time/hour (inductive load), Non limit (resistor load)
External wire connector Detachable screw terminals (M3) 20 poles
Input/output signal 0 to 15 points/total 16 points.
Indication LED indicator lights up when input is ON.
ONL：normal (green LED)
ERR：abnormal and the fuse blown out (red LED)
Occupied words 2 words
Internal current 24V DC・35mA or less (when all points are turned ON)
consumption

TERASAKI ELECTRIC CO., LTD.

 1-23

(g) Digital input Module (Type：NP1X1606-W)

Signal name

・
1
2
1
0
2 ・
3
4
3
5
4 ・
5 ＋
6 7 ・
・ 7 6
8 CO
8 10 9
・ ・ 10 12 11
9
11
12 14 13
14 16 15
13
15
・
＋ C1 18 17
19
・
20

NC
NC ・

Terminal No.

Note： 1. Common terminals CO and C1 (Terminal No. 9 and 18) are electrically
separated and isolated from each other.
2. NC indicate a terminal not connected to an internal circuit.
Do not use NC terminals as repeating terminals.

Fig.1-12 Digital Input Module Front view and Connector Pin arrangement

TERASAKI ELECTRIC CO., LTD.

1-24

Specification
ITEM Specification

Type NP1X1606-W

No. of input points 16 points (8 points common × 2 circuit)

Input signal condition Rated voltage：24V DC・Max. 31.2V DC
Characteristics of input Input type：source , sink common・Rated current：7mA
Circuit
External wire connector Detachable screw terminals (M3) 20 poles
Input/output signal 0 to 15 points/total 16 points.
Indication LED indicator lights up when input is ON.
ONL：normal (green LED)
ERR：abnormal and the fuse blown out (red LED)
Occupied words 2 words
Internal current 24V DC・35mA or less (when all points are turned ON)
consumption

(h) Base board (Type：NP1BS-13)

SX bus plug Coupler lock

Fig.1-13 Base board Front view

Specification
ITEM Specification

Type NP1BS-13

SX bus transfer rate 25 Mbps

No. of stations Max. 254

No. of slots 13 slots

Out line size W：483 H：113 D：31

TERASAKI ELECTRIC CO., LTD.

 1-25

3.2 LED Display Setting Device

1) The Setting device allows for display various setting

values or measured values by entering or searching for
4-digit setting addresses.

2) The Setting device provides the connector for the

power source of 24 V DC and that for the digital I/O
module (Setting device).
The former connector is located near the PC.

3) The Setting device is located in the accommodation

pocket on the rear of the door for the common section
at the lower part of the generator panel.

Fig.1-14 Appearance of Setting device

ITEM Specification

Type HT-001

Indication LED (Red LED) 4 digit

Power consumption 24V DC (about 2W or less)

Connector ・For 24V DC power source：2p connector× 1
・Setting device－Digital I/O module connection
：40p connector×１
Connector code length 1000 mm

For details of displaying and changing the setting values, refer to Part 3 “ Setting Value Display Function” .

TERASAKI ELECTRIC CO., LTD.

1-26

3.3 Electric Power/Voltage/Frequency Transducer

As a control element for automating the GAC21 system generator, the electric power (watt), voltage,
and frequency of the generator are measured and converted into 4~20 mA DC by each converter and
then input to the analog input module for the GAC21 Controller.
Table 1-5 show the specification for each transducer and Fig.1-15 its appearance.

Table 1-5 Specification of transducer

ITEM
Type Measure point Input Output Remarks
Transducer

Electric power MT-2-1 Each generator 110V AC, 5A 4～20mA ＊1

(watt) Bus

Voltage VGS-1A-1-8 Each generator 150V AC 4～20mA

Bus

Frequency FGS-1LA-22-8 Main bus 110V AC, 55～65Hz 4～20mA ＊2

Notes
＊1：If the input is in the reverse flow, the output is maintained at 4 mA.
＊2：If the auxiliary power source is active and if the input is less than 55 Hz or zero, the output
is maintained at 4 mA.

For details of adjusting the transducers, refer to Part 4“ Inspection・Maintenance and Self-Diagnostic
Function” .

Electric power (watt) Voltage Frequency

Fig. 1-15 Appearance of Transducer

End

TERASAKI ELECTRIC CO., LTD.

GENERATING PLANT MANAGEMENT SYSTEM
GAC21

INSTRUCTION MANUAL

PART 2

Generator Automatic Control Functions

TERASAKI ELECTRIC CO., LTD.

 Table of Contents

1. Introduction -----------------------------------------------------------------------------------------
2-1
1.1 Functional Elements of GAC21 System Device -------------------------------------- 2-2
1.2 Control Mode Selection ---------------------------------------------------------------------- 2-3
2. Remote Manual Control Functions ---------------------------------------------------------- 2-5
2-5
2.1 Diesel Engine Start/Stop Control and Abnormal Trip ------------------------------- 2-6
2.2 Generator Air circuit breaker Close/Open Control ------------------------------------ 2-6
3. GAC-UMS Control Functions ----------------------------------------------------------------- 2-6
3.1 Generator Monitoring ------------------------------------------------------------------------- 2-6
2-7
3.1.1 Generator Voltage Monitoring ----------------------------------------------------------- 2-8
3.1.2 Detection of Trouble or Delay in Generator System Control ------------------- 2-9
3.1.3 Detection of Generators Available for Automatic Start-Stop Control --------- 2-9
2-9
3.2 Bus Monitoring --------------------------------------------------------------------------------- 2-10
3.2.1 Bus Voltage Monitoring ------------------------------------------------------------------- 2-10
3.2.2 Bus Frequency Monitoring --------------------------------------------------------------- 2-10
2-10
3.2.3 Two-stage Bus Monitoring ---------------------------------------------------------------- 2-13
3.3 Automatic Generator Start Control ---------------------------------------------------------- 2-15
3.3.1 Stand-by Generator Selection ----------------------------------------------------------- 2-15
2-18
3.3.2 Stand-by Generator Start Control Scheme ------------------------------------------
2-18
3.3.3 Causes of Automatic Stand-by Start and Control After Automatic Start ----- 2-15 2-19
3.4 Automatic Generator Stop ------------------------------------------------------------------ 2-19
2-20
3.4.1 Automatic Stop Sequence Selection --------------------------------------------------
2-20
3.5 Automatic Load Sharing Control ---------------------------------------------------------- 2-21
3.5.1 Types of Load Sharing Control ---------------------------------------------------------- 2-21
2-22
3.5.2 Automatic Frequency Control -----------------------------------------------------------
2-23
3.5.3 Generator Engine Governor Control --------------------------------------------------- 2-23
3.6 Automatic Synchronous closing Control Function ----------------------------------- 2-25
3.6.1 SYNCHRO DETECT Function ---------------------------------------------------------- 2-27
2-28
3.6.2 SPEED MATCHER Function ------------------------------------------------------------ 2-29
3.7 Generator Low-Load Detection Function ----------------------------------------------- 2-29
3.8 Warning Indicator Lamp Signal Output ------------------------------------------------- 2-30
4. GAC-PMS Control Functions ------------------------------------------------------------------ 2-31
4.1 Number of Diesel Generators on Line Control (GAC-PMS-G) --------------------
4.2 Optimum Load Sharing Control (GAC-PMS-TG/SG) --------------------------------
4.3 Large Motor Start Blocking Control (GAC-PMS-M) ----------------------------------
4.3.1 Detection of Start Enable Signal --------------------------------------------------------
4.3.2 Detection of Number of Generators to be Put on Line ---------------------------
5. Communication Function with Monitor System ------------------------------------------
6. Standard Operation Setting Values and Setting Ranges for Each Function -------
7. Monitoring and Control Functions When GAC21 System is in Failure ------------

TERASAKI ELECTRIC CO., LTD.

 2-1

1. Introduction
The automatic generator control function, one of the main functions of the GAC21 Generating Plant
Management System (hereafter referred to as “GAC21 System”), works with various input signals for
generators, which are sent by digital multiplex transmission or as individual signals.
It outputs the necessary control and status signals to the outside of the GAC21 System by the digital
multiplex transmission or as individual signals.
The automatic generator control function has been developed based on our rich experiences and abundant
records acquired over many years, and includes a variety of control function that meet the customers’
requirements.
The above control functions are roughly classified into the following 3 groups:

Remote Semi-automatic Control Functions and Monitoring Functions

Include general semiautomatic operation control functions for generating plants, and various kinds of
monitoring functions, error detector function, and warning indicator output function that are closely
related to the automatic control functions.

GAC-UMS Control Functions

Include the automatic control functions, such as automatic start control of stand-by generators, intended
for“ continuity of service” as required by the ship classification societies for ships with unattended
machinery spaces.

GAC-PMS Control Functions

Include the power management functions intended for “ fuel-consumption saving” and“ efficient
management of source and load equipment” .

Notes：
1) The setting values/setting ranges marked with an asterisk (＊) in the text may be changed or
displayed on the Setting device.
For the standard setting values for each function, see Table 2-2“ Setting values and setting
ranges for standard operation” .
2) For the setting value changing procedure, refer to Part 3 “ Setting Value Display Function”
of this instruction manual.
3) If you require any control function other than those of the“ standard specification” included in
this volume, contact TERASAKI.

TERASAKI ELECTRIC CO., LTD.

2-2

1.1 Functional Elements of GAC21 System Device

One GAC21 Generator Automatic Controller (hereafter referred to as“ GAC21 Controller” ) allows for
controlling 5 generators maximum.

Functional Element Remarks Functional Element Remarks

Control mode selection Automatic Start/Stop Order

(MANU-AUTO) Selection
ACB Close/Open Number of Generator Running ※3
Control

Governor motor control Optimum Load Sharing Control ※3,4

(Frequency/ Output control)

Frequency Constant Control in Large Motor Start Block Control ※3

Generator Single Operation
Engine Start/Stop Control ※1 Bus Voltage Monitor (High/Low)
Engine Abnormal Trip ※1 Bus Frequency Monitor (High/Low))

Generator Voltage Detection Alarm Indicator Lamp Output for

(Establishment) Generator
Generator Active Power Detection Indicator Lamp Output for Generator

ACB Abnormal Trip Detection Alarm Indicator Lamp Output for

Common Use
ACB Non Close Detection ※2 Indicator Lamp for Common Use

Proportional Load Sharing Control Total Power, Surplus Power Monitor

/Frequency Control in Generator and Detection
Parallel Operation

Preferential Trip (ACB Abnormal Setting Device Operation

Trip)

Automatic Synchronizing Control/ TM Communication Function

Synchronizing Fail

Automatic Load Shift and Self diagnostic Functions

ACB Trip Control

Automatic Standby Start and ACB

Close
Remarks:
※1：The GAC21 System not execute the engine control, engine control perform other engine
control modules.
※2：ACB non closure includes those due to Auto synchronizing fail, individual closing failure
and voltage non establishment.
※3：This function is optionally available.
※4：A maximum of 4 generators can be controlled..

TERASAKI ELECTRIC CO., LTD.

 2-3

1.2 Control Mode Selection

The generator control mode selector switch (COS-A) for selecting the generating plant control mode
are available in two-system arrangement.
Table 2-1 shows the control mode selector switch (COS-A) setting positions and fundamental generator
control schema.

Table 2-1 Mode selection switch setting position and control

Control & Engine Synchronous Frequency Automatic

Operation Start/Stop Closing Control Control
Control Control
Switch arrange
Setting position GAC-UMS/PMS

MANU Performed Performed Performed Not performed

A using ECS using BCS (*1) using GCS
system
AUTO Performed automatically as a part Performed Performed
of GAC-UMS/PMS control Automatically
(*2)

MANU Performed Performed Performed Not Performed

B using ECS using BCS (*1) using GCS
System
AUTO Performed automatically as a part Performed Performed
(*3) of GAC-UMS/PMS control Automatically
(*2)

Control & Automatic

Operation Load sharing control Parallel running of load Control
Switch arrange shift control
Setting position GAC-UMS/PMS

MANU Performed using GCS Performed using GCS, Not performed

A BCS
system
AUTO Performed automatically Performed automatically Performed
as a part of automatic
control

MANU Performed using GCS Performed using GCS Not Performed

B BCS
System
AUTO Performed automatically Performed automatically Performed
(*3) as a part of automatic
control

TERASAKI ELECTRIC CO., LTD.

2-4

“ A” system：“ MODE SELECTION” switch (COS-A)

［change over to AUTO－MANU］
One for each generator plant (TERASAKI standard)
“ B” system：“ STANDBY SELECTION” switch (COS-A)
［change over to MANU－G1, G2, G3 ……(AUTO) ］
One single switch is used for all generator plants.

ECS ：“ ENGINE CONTROL” switch ----［changeover to START－STOP or Push-button switch］

BCS ：“ ACB CONTROL” switch ----------［changeover to CLOSE－OPEN］
GCS ：“ GOVERNOR MOTOR” control switch ------［changeover to RAISE－LOWER］

Note 1：
(*1) Available to close the ACB synchronously by the“ AUTO SYNCHRO” push-button switch (ASS) for
semi- automatic control. (This function os optionally available)
(*2) Automatic frequency control is perform by the GAC21 Controller, during single operation and
parallel operation.
(*3) The“ AUTO” is mean setting position G1, G2, G3 …… .

Note 2： “ A” system and“ B

” At“system
AUTO” position in both“ A” and“ B” system arrangements, “ FULL AUTO
START” push-button
switch (AST) or“ FULL AUTO STOP” push-button switch (ASP) can also be used to perform automatic
operation processes from engine start to ACB synchronous closing or from load shifting to ACB
tripping/engine stop.
Note 3：“ A”
system
When“ A” system arrangement is used, control“ MODE SELECT” switch (COS-A) should be
set to
“ AUTO” after manual operation, even in the course of single-generator operation,
This will activate automatic frequency control.
Note 4：“ B”
system
When“ B” system arrangement is used, selection of any one generator causes all the remaining generators
to enter AUTO mode.
The selected generator is the 1st (first precedence) standby generator during auto start/stop sequence in
GAC-UMS and GAC-PMS. (See section 3.3.1“ Stand-by Generator Selection” ).

Note 5：
It is expected for the GAC21 system that the control“ MODE SELECT” switches (COS-A) is also used
when turbo and/or shaft generators are to be controlled.

Note 6：
For control operation procedure when GAC21 system fails, see section 7.“ Monitoring and Control
Functions in Case of GAC21 System” .

TERASAKI ELECTRIC CO., LTD.

 2-5

2. Remote Manual Control Functions

2.1 Diesel Engine Start/Stop Control and Abnormal Trip
The“ ENGINE CONTROL” switch (ECS) is used to start and stop the generator diesel engine.
The GAC21 Controller not execute the engine control, engine control perform other engine control
modules.

The under mentioned for reference to take one example of many.

(1) The Engine Control System

The engine control system is assumed to control engines from major manufactures in Japan and
overseas. Which are of compressed air starting type.
The following shows the specifications of the engine control system.

(2) General Specifications of the Engine Control System

a. Input signals:
・Start Interlock signals, including“ turning bar in place” signal,“ handle switch
operation position” signal, etc. (Total of three kinds of signals)
・Local/Remote selector switch.
・Engine Start command signal.
・Engine Stop command signal.
・Engine Speed switch (flame speed).
・Engine Abnormal signals, including“ abnormal drop in lubrication oil pressure”
signal, over speed signal, and“ abnormal rise in cooling water temperature” signal.
・Engine Trouble Reset signal.
b. Output Signals:
・Start-Valve Operation signal.
・Stop-Valve Operation signal.
・Emergency-Stop Valve Operation signal.
・Abnormal Stop Indicator Lamp signal. (Group or individual indication)
・Alarm Repose signal.
c. Control Timer:
・Start Fail Detection timer
・Alarm Rest timer
・Stop-Valve Excitation timer
・“ Drop in Lubrication Oil Pressure during Start” Tripping timer
d. Control Method of Start Valve :
Compressed air starting at a specified point of time
An excessive dropMethod
e. Control in lubricating
of Stopoil pressure
Valve or rise in cooling
and Emergency water
Stop Valve : temperature, over speed or the
like trip the Depending
engine to stop the engine.
on the specifications of engines used

TERASAKI ELECTRIC CO., LTD.

2-6

2.2 Generator Air circuit breaker Close/Open Control

The“ ACB CONTROL” switch (BCS) can be used to close or open of the ACB, the GAC21 Controller
have no relation to ACB manual control.
In the both“ A” system and“ B” system arrangement while generators have already been connected to
the bus.

・Manual control:
Synchronous closing operation proceeds in manual control mode, if a GAC21 system becomes
inoperative due to a trouble of GAC21 Controller, at that time, performed manual synchronous
closing operation by the SYNCHROSCOPE and“ SYNCHROSCOPE” switch (SYS).

・Semi-automatic control
If required, separate the“ AUTO SYNCHRO” push-button switch (ASS) will be provided for each
generator. The use of this switch allows for activating the synchronous closing function of the
EAS-101 Device, one of the components for the GAC21 System, to perform the automatic
synchronous closing of ACBs.

Interlock between the generator ACB and shore power connection circuit breaker is provided by
hard-wiring logic with the GAC21 Controller being bypassed.

3. GAC-UMS Control Functions

3.1 Generator Monitoring
The GAC21 Controller identifies the controlled status of each generator through the following
monitoring:

3.1.1 Generator Voltage Monitoring

The voltage of each generator is monitored to produce the following signals:

(1) Voltage Established Signal

This signal is produced with a time-delay when the started generator has built up a required
voltage.
・Operate point (VOLT ESTABLISH)：＊ 60 to 100% of rated voltage.
・Time delay (VOLT EST TIME) ：＊ 0 to 30 seconds.

・Reset hysteresis: 20% of rated voltage (Reset point 20% below operate point).

(2) Under voltage Signal --- (Optional)

This signal is produced with a time-delay when the generator voltage has been below a
predetermined value.
・Operate point (UNDER VOLT) ： 60 to 100% of rated voltage.
・Time delay (UNDER VOLT TIME) ： 0 to 30 seconds.
・Reset hysteresis: 2% of rated voltage (reset point 2% above operate point).

TERASAKI ELECTRIC CO., LTD.

 2-7

3.1.2 Detection of Trouble or Delay in Generator System Control

Here, a“ generator system” refers to a generator and its associated equipment under control of the
GAC21 system. In the event of a trouble or delay in control of a generator system, as listed below, the
GAC21 system will output the associated signal to an external device or system.
If it is a diesel generator system, then the GAC21 system will disable it from automatically starting
and remove it from the stand-by generator list.

(1) ACB ABNORMAL TRIP

This signal is outputted if the generator ACB is tripped by other than the following means:
By operation of the ACB CONTROL switch (BCS), or Automatic tripping on completion of
the load shift control.

(2) VOLTAGE NON-ESTABLISHED

This signal is outputted if the generator does not build up a required voltage within a
predetermined time as counted from the instant of its engine's low speed pickup to a specified
value (generally 300rpm).

・Voltage non-establish detect timing (VOLT NON EST TIME)：＊ 0 to 30 seconds.

(3) AUTOMATIC SYNCHRONIZING FAILURE

This signal is outputted if the automatic synchronizing (generator synchronizing and its ACB
closure) is not completed within a predetermined time as counted from the instant of an auto
synchro start command signal (external or internal).

・Auto synchro failure detect timing (AUTO SYNCHRO FAIL TIME)：＊ 0 to 240 seconds.

(4) ACB NON-CLOSURE

This signal is outputted when the generator ACB does not close within a predetermined time
as counted from the instant of the GAC21 system's giving a CLOSE command to the ACB.
・ACB non-closure detect timing (ACB NON CLOSE TIME) ： * 0 to 10 seconds.

Note：

The ACB NON-CLOSURE signal may be an OR-operated single group alarm output to
cover one of the following signal combinations；
・ VOLTAGE NON-ESTABLISHED, ACB NON-CLOSURE and AUTOMATIC
SYNCHRONIZING FAILURE.(standerd)
・ VOLTAGE NON-ESTABLISHED and ACB NON-CLOSURE (optional available).
・ All the output signals independently (optional available)

(5) Generator System Trouble Indication and Resetting

a) Indication of Generator System Troubles
Troubles mentioned in (1) to (4) above are individually detected for each generator system,
and cause the associated alarm outputs from GAC21 system to the outside.
Usually, these alarm outputs are used to turn on the visual alarm devices (Push-button
switches“ ACB TROUBLE RESET (ATR)” indicator lamp color Red) provided on each
associated generator panel of the main switchboard.

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2-8

b) Resetting of Generator System Trouble Alarm Output

When a generator system trouble alarm output has turned on the visual alarm device
mentioned in a) above, pressing this device resets the alarm output and turns off the alarm
light in the device.
For the voltage non-established alarm output, resetting is possible when the generator engine
speed is below the predetermined speed pickup point or after the generator voltage has
established (i.e., pressing the push-button switch does not reset the voltage non-established
alarm output if the engine is operating at synchronous speed and the generator is not
establishing voltage).

3.1.3 Detection of Generators Available for Automatic Start-Stop Control

The status of the engine, ACB and control switches is monitored for each generator to determine if the
generator can be automatically started or stopped in response to a bus trouble, under the“ Number of
Diesel Generators on Line control” (See section 4.1“ Number of Diesel Generator on Line Control
GAC-PMS-G ” control function), or by means of an external start signal (e.g. preference trip signal) or
an external stop signal.

(1) Detection of“ Ready for Automatic Start” Conditions

In general, a generator can be automatically started when all of the following conditions are
satisfied:

Ⅰ ) The generator engine“ CONTROL POSITION” select switch (COS-L) is set to

“ REMOTE” position.
Ⅱ ) The engine start interlock conditions are satisfied, or the engine is already rotating at
speeds above its predetermined speed pickup point.
Ⅲ ) All engine trouble alarm signals are reset and in normal state.
Ⅳ ) The engine is not under stop control.
Ⅴ ) All generator system trouble alarm signals (See section 3.1.2 (5)) are reset and in normal
state.
Ⅵ ) The ACB is not closed.
Ⅶ) The associated following control switches are set to the specified positions:
EXAMPLE
The“ MODE SELECTION” switch (COS-A)
: AUTO” is set to“ AUTO”
The“ “ MANU”
SYNCHRO －“position.
& POWER CONTROL” switch (COS-P)
: AUTO” is set to“ AUTO”
The“ “ MANU”
CONTROL －“position. select switch (COS-M) :
POSITION”
“ MSB” －“ECC” is set to“ ECC”
position.
The starting order of generators ready for automatic start is determined by the“ Stand-by
Generator Selection” function mentioned in 3.3.1 below.

TERASAKI ELECTRIC CO., LTD.

 2-9

Note：
The“ SYNCHRO & POWER CONTROL” switch (COS-P) and“ CONTROL
POSITION”
select switch (COS-M) is not necessarily required for the GAC21 system standard, and is
available as a request.
(2) Detection of“ Ready for Automatic Stop” Conditions
In general, a generator can be automatically stopped (remove from the line) when all of the
following conditions are satisfied:
Ⅰ ) The generator is on line with its ACB closed.
Ⅱ ) The associated control switches are set to the specified positions (See Ⅶ) of (1) above).
Ⅲ ) The generator is in the parallel operation.

The stopping order of generators ready for automatic stop is determined by the“ Automatic Stop
Sequence Selection” function mentioned in 3.4.1 below.
The generator specified as being in the single running order will not stop automatically. (System standard)

3.2 Bus Monitoring

The GAC21 Controller monitors the voltage and frequency of the bus to detect bus troubles as
mentioned below.

3.2.1 Bus Voltage Monitoring

This function monitors if the bus voltage is within predetermined limits (BUS VOLT LOW and BUS
VOLT HIGH), and outputs the bus low voltage or high voltage signal with a time delay to external
device or system when the bus voltage has been below the BUS VOLT LOW setting or above the
BUS VOLT HIGH setting. When necessary, these signals may be used to cause automatic starting of a
stand-by generator(s).

Voltage settings
・BUS VOLT HIGH ：＊ 100 to 125% of rated voltage
・BUS VOLT LOW ：＊ 75 to 100% of rated voltage
・Time delay (BUS VOLT HIGH TIME and BUS VOLT LOW TIME)：＊ 0 to 30 seconds

3.2.2 Bus Frequency Monitoring

This function monitors if the bus frequency is within predetermined limits (BUS FREQ LOW and BUS
FREQ HIGH), and outputs the bus low frequency or high frequency signal with a time delay to
external devices or system when the bus frequency has been below the BUS FREQ LOW setting or
above the BUS FREQ HIGH setting. When necessary, these signals may be used to cause automatic
starting of a stand-by generator(s).

Frequency settings
・BUS FREQ HIGH ：＊ 100.0 to 120.0% of rated frequency
・BUS FREQ LOW ：＊ 80.0 to 100.0% of rated frequency
・Time delay (BUS FREQ HIGH TIME and BUS FREQ LOW TIME)：＊ 0 to 30 seconds

TERASAKI ELECTRIC CO., LTD.

2-10

3.2.3 Two-stage Bus Monitoring

The above bus voltage and frequency monitoring may be performed in two stages, light trouble
(High/Low) and heavy trouble (High/Low), giving the corresponding alarm outputs to external devices
or system.
When necessary, these alarm signals may be used to cause automatic starting of a stand-by
generator(s).

3.3 Automatic Generator Start Control

The automatic generator start control is initiated by the detection of a bus trouble or as part of the
“ Number of Diesel Generators on Line Control” (See section 4.1“ GAC-PMS-G control functions”
),
or by the external auto start command signal.
This control covers from the automatic starting of the generator engine to the automatic closing of the
generator ACB, as appropriate for the particular power generating plant to which the GAC21 Controller
is applied.

3.3.1 Stand-by Generator Selection

Stand-by generators are selected by the GAC21 Controller functions.
For generators ready for automatic start, this function determines their starting orders as stand-bys
that respond to automatic start commands.
The stand-by select scheme differs depending on the“ MODE SELECT” switch (COS-A) arrangement.
The following describes an example where five diesel generators are standing by.

(1) One Mode Select Switch for Each Generator (Standard arrangement)

MANU AUTO MANU AUTO MANU AUTO MANU AUTO MANU AUTO

G1 G2 G3 G4 G5

Fig.2-1 Example of MODE SELECT switch

When mode select switches (one/generator) as illustrated above are provided on the main
switchboard or engine control console the stand-by generator select function checks each generator
for“ ready for automatic start” conditions and selects the generator ready for automatic start as 1st
stand-by, 2nd stand-by and so on, in the order they become ready for automatic start.
Since setting the mode select switch from“ MANU” to“ AUTO” position is one of the“
ready for
automatic start” conditions, the order of stand-by generators is usually determined from the
temporal order of setting their select switches from“ MANU” to“ AUTO” position.

TERASAKI ELECTRIC CO., LTD.

 2-11

SELECTION EXAMPLE
The select switches for G1 and G3 and G5 are set to“ AUTO” position as illustrated above.
G2 are on line. G1 became ready for automatic start first, G3 second, and G5 third.

Ⅰ ) Order of Stand-by Generators

Stand-by ： 1st → 2nd →

3rd
｜ ｜
｜
Ⅱ ) Moving Up from
Generator ： Lower
G1 Order
G3 to Higher
G5 Order
With the stand-by generator list as inⅠ ) above, if G1 is put out of the“ ready for automatic
start” conditions. Then G1 will be removed from the stand-by generator list and the order of
the other stand-by generators lower in order than G1 will be moved up as follows:

Stand-by ： 1st → 2nd

｜ ｜
Generator ： G3 G5

Ⅲ ) Addition of a New Stand-by Generator

With the stand-by generator list as inⅠ ) above, if G1 becomes ready for automatic start, then
G1 will be added to the bottom of the existing stand-by generator list as follows:

Stand-by ： 1st → 2nd →

3rd
｜ ｜
｜
(2) Single Mode Select Switch to Cover All Generators (arrangement available on request)
Generator ： G3 G5 G1

G1 G2 G3

MANU G4

G5
Fig.2-2 Example of STANDBY SELECT switch

When a“ STANDBY SELECT” switch as illustrated above is provided on the main switchboard or
generator control console.
The stand-by generator mode select function checks this switch position and each generator for
“ ready for automatic start” conditions and selects the generators ready for automatic start as 1st
stand-by, 2nd stand-by, 3rd stand-by and so on enable in ascending order of generator Nos.
(Illustrated above is clockwise direction on the select switch) starting from the position to which the
select switch is set.

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SELECTION EXAMPLE
The select switch is set to“ G2” position as illustrated above. Generators G1 are on line, and
generators G2, G3 and G5 are ready for automatic start.

Ⅰ ) Order of Stand-by Generators

Stand-by ： 1st → 2nd →

3rd
｜ ｜
｜
Generator ： G2 G3 G5

With the stand-by generator list as inⅠ ) above, if G3 is put out of the“ ready for automatic
start” conditions, then G3 will be removed from the stand-by generator 1st and the order of the
other stand-by generators lower in order than G3 will be moved up as follows:
Stand-by ： 1st → 2nd
｜ ｜
Generator ： G2 G5

Ⅲ ) With the stand-by generator list as in Ⅰ ) above, if G3 becomes ready for automatic start, then
G3 will newly be included in the stand-by generator list with its order as determined from the
select switch position.
The new stand-by generator list will be as follows:

Stand-by ： 1st → 2nd →

3rd
｜ ｜
｜
3.3.2 Stand-byGenerator
Generator：StartG2
ControlG3Scheme
G5
The scheme of stand-by generator start control in response to an automatic start command signal is in
following three kinds, to allow for selection of the most suitable scheme for individual applications.
This control is performed by the GAC21 Controller functions.

(1) Single Start Scheme without Followers

In this scheme, only the 1st stand-by generator is automatically started and controlled.
If this generator is removed from the stand-by generator list due to a start failure or later control
trouble, the stand-by start control is terminated without any further action.

(2) Follower Start Scheme

If the started 1st stand-by generator is removed from the stand-by generator list due to a start failure
or later control trouble, the order of the remaining stand-by generators will be moved stand-by will be
started as 1st stand-by and controlled.

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A failure of this stand-by too will be similarly followed and covered by the next lower order stand-by.
This sequence would be continued as long as there is a follower stand-by.
The stand-by start control will be terminated when there is no follower stand-by.

(3) Simultaneous start scheme

This control scheme allows the 1st and 2nd stand-by generators (and other stand-by generators if
necessary) to simultaneously start.
This scheme is divided into two control types:
One type standard arrangement:
In which the generator whose voltage is established earlier is put on line as the 1st stand-by.
Other type request arrangement:
In which the 1st stand-by and 2nd stand-by generators are sequentially put on line in this order.

3.3.3 Causes of Automatic Stand-by Start and Control After Automatic Start
The generator that is the 1st stand-by on the stand-by generator list is automatically started by the
automatic start command signal, which is generated on one of different causes.
In the case of follower start scheme, depending on the type of cause the 2nd stand-by on the list may
also be started simultaneously.
In the case of simultaneous start scheme, the order of stand-bys on the stand-by generator list may not
agree with the actual order of stand-bys after voltage establishment.
Operation control of the started stand-by generator after its voltage establishment differs depending on
the type of cause of automatic stand-by start, such as whether it is paralleled to the generator(s) on line
or it replaces the latter.
The following describes the automatic start. This control is performed by the GAC21 Controller
functions.

(1) Automatic Control on Bus Blackout

The bus blackout signal is produced on abnormal tripping of a generator ACB, which results in the
following conditions:
Dead bus trouble signal input from external device, and all generator ACBs are open.
Two types of automatic control are available for this cause:
Ⅰ ) 1st stand-by is started and put on dead bus.
Ⅱ ) 1st and 2nd stand-bys are started, the 1st stand-by is put on dead bus, then the 2nd stand-by is

synchronized to bus and put on line.

(2) Automatic Control on Bus Trouble

When the bus monitoring is made in two stages of minor and serious troubles (See section 3.2.3
“ Two–stage Bus Monitoring” ) different types of operation control are available for each level of
trouble for the user's choice.
When the bus monitoring is in single stage, the user may select one of the types of control for serious
trouble.

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a) Automatic Control on Light Bus Trouble

Ⅰ ) Alarm output only, no automatic stand-by start.
Ⅱ ) Started stand-by is always synchronized to bus and put on line.
Ⅲ ) Started stand-by is synchronized to bus and put on line if bus trouble exists at the time of

its voltage establishment, otherwise it is kept idling.

b) Automatic Control on Heavy Bus Trouble

Ⅰ ) Alarm output only, no automatic stand-by start.
Ⅱ ) Upon voltage establishment of started stand-by, generator on line is always removed and
replaced by the stand-by (blackout changeover).
Ⅲ ) Same asⅡ ) above if bus trouble exists at the time of stand-by's voltage establishment,
otherwise started stand-by is synchronized to bus and put on line.
Ⅳ ) Same asⅡ ) above if bus trouble exists at the time of stand-by's voltage establishment,
otherwise started stand-by is kept idling.
Note：
For types Ⅱ ), Ⅲ ) and Ⅳ ) of automatic control b), two stand-bys can be sequentially put on
line.
In this mode, a serious bus trouble will cause the 1st and 2nd stand-by generators to
simultaneously start.
After the 1st stand-by generator undergoes specified automatic operation control and the
ACB is closed, the 2nd stand-by generator is automatically synchronized to the bus and put
on line.

(3) Automatic Paralleling to Generator(s) on Line

In this control scheme, one or more stand-by generators are started on the automatic start command
signal, synchronized to the bus, and put on line for parallel operation with the generator(s) on line.
The control scheme is in two types, depending on the number of stand-by generators to be put on line.

a) Single Stand-by Synchronized and Put on Line

In this type of control, 1st stand-by is started on one of the following causes, synchronized to the
bus and put on line:
・Abnormal tripping of ACB of one of generators on line (parallel operation).
・Automatic start command under the“ Number of Diesel Generators on Line Control”
(GAC-PMS-G).
・Automatic start command under the“ Large Motor Start Blocking Control” single stand- by
start. (GAC-PMS-M).
Following causes are detected external to the GAC21 system:
・Preference trip system operation signal.
・Other signals.

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b) Two Stand-bys Synchronized and Put on Line

In this type of control, 1st and 2nd stand-bys are started on one of the following stand-by next:
・Automatic start command under the“ Large Motor Start Blocking Control” double stand-by
start. (GAC-PMS-M).
・Other causes detected external to the GAC21 system.

(4) Generator on Line Automatically Replaced by Stand-by (s) without Blackout Period
In this control scheme, one or more stand-by generators are started on the automatic start command
signal, synchronized to the bus and put on line. Then predetermined generator on line is automatically
removed after load shift control.
The control scheme is in two types, depending on the number of stand-by generators to be put on line.

a) Non-blackout Changeover to Single Stand-by

In this type of control, 1st stand-by is started on an external automatic start command signal.
The started stand-by replaces the predetermined generator on line.

b) Non-blackout Changeover to Two Stand-bys (Optional)

In this type of control, 1st and 2nd stand-bys are started on an external automatic start
command signal.
The 1st stand-by is synchronized and put on line. Then 2nd stand-by is synchronized and put on
line.
With the two stand-bys on line, the predetermined generator on line is removed after load shift
control.

3.4 Automatic Generator Stop

Automatic generator stop control is performed as part of the“ Number of Diesel Generators on Line
Control” (See section 4.1 GAC-PMS-G control function).
The automatic stop command signal by the GAC-PMS-G function causes a sequence of automatic
operations from the load-shifting, generator ACB tripping and to the stopping of the generator engine.
This control is performed by the GAC21 Controller functions.

3.4.1 Automatic Stop Sequence Selection

The stopping order of generators ready for automatic stop is determined by one of two methods,
depending on the“ MODE SELECT” switch (COS-A) arrangement (same switch as used for 3.3.1
“ Stand-by Generator Selection” ).
The following describes an example where five diesel generators are standing by.

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(1) One Mode Select Switch for Each Generator (Standard arrangement)

MANU AUTO MANU AUTO MANU AUTO MANU AUTO MANU AUTO

G1 G2 G3 G4 G5

Fig.2-3 Example of MODE SELECT switch

When mode select switches (one/generator) as illustrated above are provided on the main switchboard
or engine control console, the stopping sequence select function checks each generator on line for
“ ready for automatic stop” conditions and selects the generators ready for automatic stop as 1st
stopping, 2nd stopping, 3rd stopping and so on, in the reverse sequence of their becoming ready for
automatic stop.

SELECTION EXAMPLE
The mode select switches for G2, G3 and G5 are set to“ AUTO” position as illustrated above, G2, G3
and G5 were put on line in this order, and all of them are ready for automatic stop.
The generator specified as being in the last stopping order will not stop automatically.

Ⅰ ) Stopping Orders
The stopping generator list in this example will be as follows:

Stopping Order ： 1st → 2nd

｜
｜
Generator ： G5 G3
Ⅱ ) Addition of a New Generator on Line
With the stopping generator list as inⅠ ) above, if G1 is newly put on line and is ready for
automatic stop, then G1 will be added on top of the existing stopping generator list as follows：

Stopping Order ： 1st → 2nd →

3rd
｜ ｜
｜
Ⅲ ) Change of Stopping Orders
Generator ： G1 G5 G3
With the stopping generator list as in Ⅰ ) above, if G3 trips abnormally (assuming that the 1st
stand-by generator is G1), G3 is removed from the stand-by generator list and the order of
remaining generators is raised as follows:

Stopping Order ： 1st

｜
Generator ：
G5
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At this time, if the ACB of G1 in place of G3 is closed automatically and synchronously, the
order of stopping generators is as follows (See alsoⅡ ) above)：

Stopping Order ： 1st → 2nd

｜ ｜
Generator ： G1 G5

(2) Single Standby Select Switch to Cover All Generators (arrangement available on request)

G1 G2 G3

MANU G4

G5

Fig. 2-4 Example of STANDBY SELECT switch

When a“ STANDBY SELECT” switch as illustrated above is provided on the main switchboard or
generator control console.
The stop sequence select function checks this switch position and each generator on line for ready for
automatic stop” conditions and selects the generators ready for automatic stop as 1st stopping, 2nd
stopping, 3rd stopping and so on enable in descending order of generator Nos. (Illustrated above is
counter-clockwise direction on the select switch) starting from the position to which the switch is set.

SELECTION EXAMPLE
The stand-by select switch is set to“ G2” position as illustrated above. Generators G1, G2 and G5
are on line and all ready for automatic stop. In this case, the stopping generator list will be as
follows:
The generator specified as being the last stopping order will not stop automatically.

Stopping Order ： 1st → 2nd

｜
G1 G5
｜
Generator ：
Moving up and down of the stopping orders occurs in a similar manner to 3.4.1 (1).

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3.5 Automatic Load Sharing Control

The bus frequency and kW load on each generator on line are monitored, based on which the governor
control signals are outputted to the associated generator engine governors to maintain the bus
frequency at the rated value and to properly divide the total load among the generators on line according
to the predetermined load sharing mode.

Note：

The“ SYNCHRO & POWER CONTROL” switch (COS-P) does not come standard with the
system. When the“ SYNCHRO & POWER CONTROL” switch is added and is set to the“
AUTO”
position. the automatic load sharing function will be alive, irrespective of control mode selector
switch (COS-A) setting to“ AUTO” or“ MAMU” positions.

This control is performed by the GAC21 Controller functions.

Specifications
・Load sharing control accuracy ：＊ 5% of rated generator kW output (in reference to
mean loading percentage).
・Frequency control accuracy ：＊ 0.3 Hz
・Maximum LOAD LIMIT setting ：＊ 50 to 100% of rated generator kW output
・SHARING RATIO setting ：＊1.0 to 5.0
3.5.1 Types of Load
・Governor Sharing Control
Characteristic setting ：＊2.0 to 16.0 (sec/Hz)
(1) Proportional Load Sharing Control
The total kW load is divided among the generators on line so that their loading percentage values will
be proportional to their SHARING RATIO settings, where the loading percentage of a generator is
defined as follows:
kW Load on Generator
LOADING PERCENTAGE = × 100
Rated kW Load of Generator

(2) Optimum Load Sharing Control

In the optimum load sharing control, the SHARING RATIO of each generator should be set to an equal

value. See section 4.2“ Optimum Load Sharing Control (GAC-PMS-TG/SG)” for full information.

(3) Load Shift Control

If a load shift start signal is given by the automatic start-stop control function or from an external
source when more than one generator are on line, load on a predetermined generator is shifted to the
other generator(s) on line.
When load on this generator is reduced to nearly zero (5% or less of its rated kW output), its ACB is
automatically tripped.
That is, the target kW load share of a generator under load shift control is 0 kW.
If it is expected that load on the other generator(s) will exceed the Load Sharing Cancel setting (LOAD
LIMIT) as a result of load shift control, the load shift signal will not cause the load shift operation.

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3.5.2 Automatic Frequency Control

Regardless of the number of generators on line, this control function maintains the bus frequency at
the rated value, controlling the governor motor of each generator engine.
In case of single operation, the GAC21 Controller provides the control including governor motor
control, providing that the stand-by control“ MODE SELECT” switch (COS-A) has been set to
“ AUTO” position.

Note：

The“ SYNCHRO & POWER CONTROL” switch (COS-P) is provided, the automatic frequency
control does function if this switch is set to“ AUTO” or“ MANU” position take priority,
irrespective
of control mode selector switch (COS-A) setting to“ AUTO” or“ MANU” positions.
3.5.3 Generator Engine Governor Control
Actual kW load on each generator on line is monitored and compared with the target kW load share
mentioned in section 3.5.1 to compute：
・Power Deviation＝Target kW Share－Actual kW Load.
The bus frequency is also monitored to compute：
・Frequency Deviation＝Rated Frequency－Actual Bus Frequency.

According to whether these deviations are positive or negative in value, one of two governor control
signals is selected as follows：
・Positive Deviation … Governor Raise (UP) signal;

・Negative Deviation … Governor Lower (DOWN) signal.

These control signals are produced with respect to power deviation and frequency deviation.

According to the magnitude of the above deviations and based on the GOV CHARACT［sec/Hz］
setting：
The pulse duty ratio of these governor control signals is determined.

The governor control signal has been detected is output from the GAC21 controller to the generator
that is now operating at the frequency of once every 5 seconds and the maximum governor drive time
of 2.4 seconds (8 seconds/Hz).
The governor control signal is output based on the resultant value of power deviation and frequency
deviation.

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3.6 Automatic Synchronous closing Control Function

To perform the automatic synchronous closing control, use the EAS-101 Digital Synchronizer
(hereafter referred to as “EAS-101 Device”), which is one of the components for the GAC21 System.

CAUTION Digital Synchronizer

The automatic synchronous closing control function for a generator, as mentioned in

the instruction manual for the GAC21 Generating Plant Management System, is
independent from the GAC21 Generator Automatic Controller.
For further information on this function, refer to the instruction manual for the Type
EAS-101 Digital Synchronizer.

This function is used to place a generator on a live bus served by other generator or generators for
parallel operation with the latter.
This function compares the frequency of a started generator that has built up the voltage with the bus
frequency, and brings the generator frequency closer to the bus frequency through governor control.
When the differences in voltage and frequency between the generator and bus fall within their
predetermined limits.
If the frequency difference or voltage difference becomes smaller than the predetermined value, the
EAS-101 Device outputs the ACB closing signal to the outside via the GAC21 Controller, so that the
ACB is closed when the bus voltage phase matches with the generator voltage phase.

Specifications
・Acceptable frequency difference limit ：＊ 0.1 to
0.5 Hz
・Acceptable voltage difference limit 8 Hz ：＊ 2 to
10% of bus voltage
・Governor characteristic setting range ：＊ 2.0 to
・Maximum
16.0 (sec/Hz)permissible frequency difference for operation ：
・Circuit breaker closing time ：
＊ 0 to 500 ms
The following describes
・Automatic functionalfail
synchronizing elements
time of this function. ：＊ 0
to 240 sec
3.6.1 SYNCHRO DETECT function
This function compares the generator voltage signal with the bus voltage signal, both inputted from
the external potential transformers, to check if the following conditions are satisfied:

Voltage difference ...

Difference between the bus and generator voltages is within the acceptable voltage difference limit
(normally set to 3%).

Frequency difference ...

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Difference between the bus and generator frequencies is within the acceptable frequency
difference limit (normally set to 0.3Hz).

If these conditions are satisfied, then the EAS-101 Device function outputs an ACB close command
signal to the external generator ACB control circuit a certain length of time (ACB closing time,
normally set to 75 ms) prior to the instant when the generator voltage becomes exactly in phase with
the bus voltage.

3.6.2 SPEED MATCHER function

This function compares the generator voltage with the bus voltage, both inputted from the external
potential transformers, to detect the difference in frequency between them, according to which one of
the following governor control signals is produced：

Governor Raise (UP) ...

Produced when the generator frequency is lower than the bus frequency.

Governor Lower (DOWN) ...

Produced when the generator frequency is higher than the bus frequency.

These governor control signals are pulsed signals interval of maximum 5 seconds and governor driving
time 2.4 seconds (8sec/Hz) constant pulse repetition period, and the pulse duty ratio is varied
according to the magnitude of frequency difference and based on the GOV CHARACT (governor
characteristic) setting.
The governor control signals are outputted from EAS-101 Device through the GAC21 Controller to
the generator engine governor motor.

3.7 Generator Low-Load Detection Function

This function detects the low-load operation state of a generator and outputs the detected signal to an
external monitor as the warning signal.
If the measured power value of a generator during its operation decreases to and remains below the
setting value for low load, the signal is output.

・Low load setting range ：＊ 0 to 100％ (Rated output)

・Low load time setting range：＊ 0 to 240 seconds

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3.8 Warning Indicator Lamp Signal Output

The display program provides generator-related warning output and common one in the operation
pattern “AM2” of JIS F0412.

Alarm signal

＊１
Group alarm signal

Alarm indicator lamp

An alarm

Fig.2-5 AM2 Alarm signal pattern

Note:
1. When the power source of 24V DC is turned ON, the output signal and control are stopped for
2 seconds.
2. For the group warning signal ＊1, if a new error occurs during the output of the error signal,
the system is restored to the normal state (for 2 seconds) and then the error signal is output
again.

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4. GAC-PMS Control Functions

The following GAC-PMS functions are performed by the GAC21 Controller functions.

4.1 Number of Diesel Generators on Line Control (GAC-PMS-G)

This function controls the number of diesel generators on line in response to changes in the ship's
power demand.
This function is intended to ensure a higher degree of“ continuity of service” through minimizing
operations of the preference tripping system and generator overload protection and also to operate the
diesel generators within their high fuel-efficiency region.

Settings for GAC-PMS-G

・Start request point, K1 (START REQ DG-H) ：＊ 50 to 100%
・K1 timer, (START REQ TIME) ：＊ 0 to 30 seconds
・Stop request point, K2 (STOP REQ) ：＊ 50 to 100%.
・K2 timer, (STOP REQ TIME) ：＊ 0 to 2400
seconds
Note：
K1 and K2 are mathematical symbols used for explanation purposes only. In setting them, K1
should be greater in value than K2.

(1) Start Request (Automatic Start)

In Fig.2-6, assume the total kW load is increasing.
When the loading percentage of the diesel generator or generators on line reaches K1 (%) and this
condition exists for the time length set by the K1 timer, an automatic start command signal is
produced.
In response to this signal, the stand-by generator is automatically started, synchronized and put on line
for parallel operation with the generator(s) already on line.
This start request point K1 (%) is mathematically expressed as:

N
Σ
n＝1
PLn
K1 ＝ ─ ─ ─ ─ ─ 100〔％〕
N
───× Σ PRn
n＝1

Where … PLn ：load on generator all generator in kW

PRn ：rated output of all generator in kW
N ：number of generators on line

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100
P11 P12 P13
K1

P21 P22 P23

K2
P32 P33
P31

N＝1 2 N＝3 N＝4 TOTAL LOAD INCREASE

N＝1 N＝2 N＝3 N＝4 TOTAL LOAD DECREASE

N ： number of generators on line

P1N ： (＝K1) stand-by start request point (%)
P2N ： (＝K2) stop request point in expected loading percentage
after generator removal
P3N ： actual loading percentage before generator removal at P2N point

Fig.2-6 Diagram to show an example of number of diesel generators on line control

(2) Stop Request (Automatic Stop)

In Fig.2-7, if the total kW load decreases to such a degree that the removal of the 1st stopping
generator will not result in loading percentage more than K2 (%) for each diesel generator remaining
on line, and this condition exists for the time length set by the K2 timer, an automatic stop command
signal is produced. In response to this signal, load on the 1st stopping generator is shifted to the other
generator(s) on line, then the ACB of the first stopping generator is tripped and its engine is
automatically stopped (after a predetermined length of engine idling time (ENG IDLING TIME) when
necessary).
The stop request point K2 (%) is mathematically expressed as:

N
Σ
n＝1
PLn
K2 ＝ ─ ─ ─ ─ ─ 100〔％〕
N
───× Σ Pn－PR
n＝1

Where… PR：rated output of first stopping generator in kW.

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4.2 Optimum Load Sharing Control (GAC-PMS-TG/SG)

This control function is intended to operate the exhaust-gas turbo-generator (TG) or shaft-driven
generator (SG) at its maximum efficiency, thereby reducing the total operation hours and maintenance
costs of the diesel generator or generators (DG) that back up TG or SG.
When TG, or SG, and DG are on line, this function controls them so that TG, or SG, will be optimally
loaded to the conventional rated output value, which is set by means of an external digital switch, and
DG will never be loaded below a predetermined low load limit.
The optimum load sharing control as mentioned above is achieved through monitoring the load on each
generator on line, computing the load to be shared by each generator on line, and controlling the
governor motor of each generator engine according to the computed load share
(See section 3.5“ Automatic Load Sharing Control” ).
Fig.2-7, shows an example of optimum load sharing control that covers TG and DG.

PTG-R
TG TG
PTG-O
PTG-H

DG DG
PDG-L

PTG-L

LOAD ZONE
A B C D E F

TOTAL LOAD INCREASE TOTAL LOAD DECREASE

PTG-R ： rated output of TG in kW.

PTG-O ： conventional rated output of TG in kW for control purposes.
PTG-H ： stand-by start request point in kW, set in % of PTG-O.
PDG-L ： low load limit of DG in kW, set in % of DG's rated output.
PTG-L ： low load limit of TG in kW, set in % of PTG-O.

Fig.2-7 Example of optimum load sharing control

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Settings for GAC-PMS-TG/SG

・TG/DG Conventional rated output for control purposes：0 to 3000kW
(10kW minimum setting unit)
・Stand-by start request point ：＊ 80 to 100% (50 to 100% : available on request)
(Setting for used in“ Number of Diesel Generator on Line Control” same as 4.1 )
・DG low load limit ：＊ 0 to 50%
・TG/SG low load limit ：＊ 0 to 50%

The total kW load PL, is known as the sum of kW loads on generators on line.
The following describes the operation under GAC-PMS-TG for each PL zone specified in Fig.2-7.

(1) Load Zone A

TG is in single operation and load on it increases. When load on TG reaches PTG-H and this
condition exists for a predetermined length of time (the K1 timer setting mentioned in 4.1), an
automatic start command signal is given to a stand-by generator (DG).
In response to this signal, DG is automatically started, synchronized and put on line for parallel
operation with TG.

(2) Load Zone B

DG is loaded to its low load limit PDG-L constant, while the rest of load is shared-by TG.
For control in this load zone, the target load share for each generator is computed as follows:

DG ... DG rated output × DG low load limit setting (PDG-L)(kW).

TG ... PL－PDG-L (kW).

(3) Load Zone C

If load on TG reaches PTG-O (conventional rated output of TG in kW set by means of an external
digital switch) with a further increase of PL, DG low load limit control is canceled. Instead, TG is
loaded to PTG-O constant and DG shares the rest of load. For control in this load zone, the target
load share for each generator is computed as follows:

DG ... PL－PTG-O (kW), provided PL ＞ (PTG-O ＋ PDG-L).

TG ... PTG-O (kW).

That is, changes of PL above PL＝PTG-O＋PDG-L are covered by DG.

Where more than one DG are available as stand-bys, the GAC-PMS-G function controls the
number of diesel generators on line to cover changes in PL.

(4) Load Zone D

If a decrease of the total load PL results in a reduction of load on DG to its low load limit PDG-L,
TG optimum load sharing control is canceled.
Instead, DG is loaded to PDG-L constant and TG shares the rest of load.
Therefore, the target load share of each generator is as mentioned in (2) Load Zone B.

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(5) Load Zone E

If the load on TG is reduced to its low load limit PTG-L as a result of a further decrease of PL, DG
low load limit control is canceled.
Instead, TG is loaded to PTG-L constant and DG shares the rest of load.
This is to prevent the reverse power flow into TG.
For control in this load zone, the target load share for each generator is computed as follows:

DG ... PL－PTG-L (kW).

TG ... TG rated output× TG low load limit setting＝PTG-L (kW).

(6) Load Zone F

If the load on DG in percent of its rated output becomes equal to the TG low load limit setting (set
in % of PTG-L) with a still further decrease of PL, TG low load limit control is canceled.
Instead, TG and DG are controlled in a proportional load-sharing mode with PTG-R being the rated
output capacity of TG.
This is to prevent the reverse power flow into DG.

Note：
(1) The setpoint of PTG-H is expressed in percentage with respect to the TG conventional
output PTG-O (kW).
(2) In this example of optimum load sharing control, the last diesel generator remaining on line
is intentionally not removed.
It is also possible to design the control scheme to remove this diesel generator according to
the criteria mentioned in Paragraph (2) of Subsection 4.1 of this Part.

4.3 Large Motor Start Blocking Control (GAC-PMS-M)

The starting current of a large auxiliary's motor, such as the side thruster's or ballast pump's, can cause
serious service disturbances leading to a blackout of the electric power system.
This function is intended to prevent such troubles by securing, when necessary, the required power for
starting of a large motor.

Specifications
・Setting for required starting power ：＊ 0 to 2000kW.
・Number of motors under control ： 16 motors maximum.
・Setting for required starting confirmation time ：＊ 0 to 60 seconds
［standard setting time : 15 seconds］
(From closing operation of the stand-by generator ACB to output of
the motor start enable signal).

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2-28

4.3.1 Detection of Start Enable Signal

MCCB TH
MC
Main power source M

Control power source

TH × Start enable signal

From GAC21 system
STOP START
MC

MC

MC

To GAC21 system

Fig.2-8 Example of Large Motor Starter Circuit

For each large motor under this control, the required starting power PMn in kW is set. normally, each
PMn value is compared with the total surplus power PS (kW) as computed from the loading
conditions of the generators on line, to give the start enable signal to the starter circuit (See the
above diagram) of each large motor under this control.

(1) When PS ≧ PMn：

This means that there is a sufficient surplus power to allow for starting of that motor, and the
associated start enable signal is“ ON” .
Therefore, pressing the START push-button for that motor causes the motor to be started.

(2) When Ps ＜ PMn：

The available surplus power is not sufficient to allow for starting of that motor, and the associate
start enable signal is“ OFF” .
Pressing the START push-button does not cause the motor to be started (start blocking).
Instead, it causes one or more stand-by generators to be automatically started and put on line as
mentioned in 4.3.2, after which the START push-button should be pressed again to start the
motor.

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4.3.2 Detection of Number of Generators to be Put on Line

In the case of Ps＜PMn (4.3.1 (2)), pressing the START push-button applies a contact closure signal
to the GAC21 system.
In response to this, how many stand-by generators, one or two, have to be started are determined and
the corresponding number of automatic stand-by start command signals are produced.
As a result, the stand-by generator(s) is automatically started and put on line.
The number of stand-by generators to be started is determined as follows.
The expected total surplus power PSS (kW) when the 1st stand-by generator whose rated output is
PG1 (kW) is put on line is computed, i.e., PSS＝PS＋PG1.
The start-blocked motor's PMn value is then compared with PSS, and

(1) If PSS ≧ PMn：

An automatic start command signal is produced to start and put one stand-by generator on
line (single stand-by start).

(2) If PSS ＜ PMn：

Two automatic start command signals are outputted in parallel from the GAC21 system to
start and put two stand-by generators on line (double stand-by start).

5. Communication Function with Monitor System

The TM interface module (hereafter referred to as “TM module”) of the GAC21 Controller output
warning signals to the TERASAKI Monitor System via the TM multiplex transmission.
All the warning signals are output as NOR:CLOSE and the following ones are standard:

(1) Common output signals

・MSB PREF TRIP
・MSB BUS VOLT HIGH ・PREF TRIP/EMERG STOP SOURCE ABNORMAL
・MSB BUS VOLT LOW ・MSB 440V CIRCUIT LOW INSULATION
・MSB BUS FREQ HIGH
・MSB BUS FREQ LOW
・MSB DC24V SOURCE FAIL

(2) Output signals for each generating plant

・G/E OVER SPEED TRIP ・GEN OVER
CURRENT
・G / E LO INLET LOW P TRIP ・G E N ACB NON
CLOSE
・G/E C F W OUTLET HIGH TEMP TRIP ・GEN ACB ABNOR TRIP
・G/E START FAIL ・GEN
ACB SYSTEM FAIL
・G/E STOP SOLENOID ABNORMAL
・G/E LOAD LIGHT
・G/E REPOSE SIG
・G/E RUN HOUR (ACB ON)
TERASAKI ELECTRIC CO., LTD.
2-30

6. Standard Operation Setting Values and Setting Ranges for Each Function
The standard operation setting values used for the functions of the GAC21 Controller are shown in the
following table:
Table 2-2 Setting values and setting ranges for standard operation

SETTING ITEM SETTING RANGE STANDARD REMARKS

SHARING RATIO 1.0～5.0 1.0

GOV CHARACT 2.0～16.0sec/Hz 8.0
LOAD LIMIT 50～100 % 95
ENG IDLING TIME 0～2400 sec 600
VOLT ESTABLISH 60～100 % 95
VOLT ESTABLISH TIME 0～30 sec 7
VOLT NON EST TIME 0～30 sec 20
ACB NON CLOSE TIME 0～10 sec 3
AUTO SY FAIL TIME 0～240 sec 60
GEN LIGHT LOAD 0～100 % 20
GEN LIGHT LOAD TIME 0～240 sec 0
BUS VOLT LIGHT LOW 75～100 % 97
BUS VOLT LIGHT LOW TIME 0～30 sec 10
BUS VOLT LIGHT HIGH 100～125 % 103
BUS VOLT LIGHT HIGH TIME 0～30 sec 10
BUS FREQ LIGHT LOW 80.0～100.0 % 97.5
BUS FREQ LIGHT LOW TIME 0～30 sec 10
BUS FREQ LIGHT HIGH 100.0～120.0 % 102.5
BUS FREQ LIGHT HIGH TIME 0～30 sec 10
BUS VOLT LOW 75～100 % 90
BUS VOLT LOW TIME 0～30 sec 5
BUS VOLT HIGH 100～125 % 106
BUS VOLT HIGH TIME 0～30 sec 5
BUS FREQ LOW 80.0～100.0 % 95.0
BUS FREQ LOW TIME 0～30 sec 5
BUS FREQ HIGH 100.0～120.0 % 105.0
BUS FREQ HIGH TIME 0～30 sec 5
START REQUEST 50～100 % 90 PMS-G
START REQUEST TIME 0～30 sec 10 PMS-G
STOP REQUEST 0～100 % 70 PMS-G
STOP REQUEST TIME 0～2400 sec 600 PMS-G

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 2-31

7. Monitoring and Control Functions When GAC21 System is in Failure

Various monitoring and control functions covered by this section are executed when one set of the
GAC21 Controller provided for the entire system is in the normal state.
If the GAC21 Controller fails in the GAC21 System, basically only the manual control is available.
However, the fail-safe feature will stop the output of control signals from the unit in failure and will
maintain the generating plant in the operation state previous to the failure of the GAC21 Controller.
Tables 2-3, 2-4 and 2-5 shows the scope of stopping the monitoring and control functions and what
control is performed, if the GAC21 Controller fails.

Table 2-3 Monitoring and control functions in case of GAC21 Controller failure-1

When the device

and controller When GAC21 Controller is out of order Remarks
are in order

All the functions 1) The following functions are inoperative:

・Out of order
of GAC-UMS and ・GAC-UMS Generators running
・GAC-PMS In parallel, however
described in this Is maintained their
part are ensured
・Automatic synchronizing control status, and using
the“ GOVERNOR
・Automatic load sharing control
MOTOR” control
・Automatic load shifting
switch (GCS)
・Automatic frequency control enables manual
load sharing and
2) The relevant generating plant can always be
shifting operation.
controlled manually as follows:
Manual Control
・Sensor abnormal
Control and Operation Method
Not influential in
manual operations.
1. Engine start/stop Use the“ ENGINE
CONTROL” switch
(ECS) on the MSB
2. Governor control Use the“ GOVERNOR
(Frequency adjustment
MOTOR” control switchFor details, refer to
and output control). (GCS) on the MSB next table 2-4.

3. ACB closing/opening
Use the“ ACB ONTROL
”
4. Synchronous closing switch (BCS) on
After checking theMSB
the synchro-
scope pointer on the MSB
and ACB closed manually

5. Load sharing/shifting
Use the“ GOVERNOR
MOTOR” control switch
(GCS) on the MSB

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Table 2-4 Monitoring and control functions in case of GAC21 Controller failure-2
Module Module Sensor
Control Function and Operation Switches abnormal abnormal abnormal
(For control) (Except
control)

1. manual ・ACB CONTROL switch (BCS) Possible Possible Possible

control Possible Possible Possible
・ENGINE CONTROL switch (ECS)
Possible Possible Possible
・GOVERNOR MOTOR switch (GCS)
2. Semi- ・AUTO SYNCHRO PB switch (ASS) Impossible Possible *1, *2, *3
automatic Impossible Possible *1, *4
・AUTO LOAD SHIFT PB switch (LSS)
control Impossible Possible *2, *3, *8
・FULLAUTO START PB switch (AST) Impossible Possible *1, *4
・FULL AUTO STOP PB switch (ASP)
3. Automate ・GAC-UMS Impossible Possible *2, *3, *8
plant Impossible Possible *2, *3, *8
・GAC-PMS
control

4. Monitor・ ・AUTO FREQUENCY Impossible Possible *5

Alarm Impossible Possible *1, *4
・AUTO LOAD SHARING
Impossible Possible Possible
・PREFERENCE TRIP *6 *7 Possible
・ALARM, SETTING DEVICE operation
・Module fault (control-related) ：Means a fault of any PC module other than the TM module and the
Digital I/O combined module for the Setting device
・Module fault (not control-related)：Means a fault of the TM module or the Digital I/O combined module
for the Setting device
・Sensor fault:
*1：In case of the power (watt) transducer fault …
The malfunctioning generator stops the automatic control.
*2：In case of the voltage transducer fault …
The malfunctioning generator stops the automatic control.
*3：The normal generators can be controlled.
*4：The control between the normal generators can be performed …
Two or more normal generators.
*5：In case of the bus frequency transducer fault …
The automatic control of all the operating generators is stopped.
*6：Warning function… The GAC21 SYSTEM FAIL signal is output from the GAC21 Controller.
Among the module faults (control-related), the Power supply module fault or CPU
module fault will result in outputting the TM unit fault signal at the unit address occupied
by the TM module and disabling the operation of the Setting device.
*7：In case of the TM module fault …
The warning function is disabled.
However, the monitor detects the GAC21 SYSTEM FAIL and TM UNIT FAIL signals.

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In case of the I/O combined module for the Setting device fail …
The operation of the Setting device becomes impossible.
*8：In case of the power (watt) transducer fault …
The malfunctioning generator stops the automatic control when the generator voltage is
established (80% for 3 seconds).

Table 2-5 Control at failure of the GAC21 System

Failure Control action at failure

1. Major system failure The module fault (control-related) is defined here as a major failure.
・Failure in other than the power supply module and the CPU module:
The malfunctioning module stops the output signals and the
control signal output by the software.
The CPU module continues to operate.
・Failure in the power supply module or the CPU module:
The CPU module stops and all the output signals from the GAC21
Controller also stop.

Therefore, all the semi-automatic control and automatic control

functions are disabled.

2. . Minor system failure The module fault (not control-related) is defined here as a minor
failure.
・If a fault that is not directly related to the control of the generators
occurs in the TM module (including the TM transmission line) or the
I/O module for the Setting device, the CPU module continues to
operate.

Therefore, all the semi-automatic control and automatic control

functions remain active.

3. Minor system failure The sensor fault (in the power, voltage, and frequency transducers)
(Sensor fault) is defined here as included in the minor failures.
・Voltage transducer:
Any sensor fault is always detectable.
If the ACB is opened…
The control for concerned the generators is canceled.
If the ACB is closed… The current state is maintained.
A bus fault is detectable, but the automatic control is not
performed if a bus fault occurs.
----- continue

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Failure Control action at failure

3. Minor system failure ・Frequency transducer:

(Sensor fault) Any sensor fault is always detectable.
The control for running all the generators frequency is canceled.
A bus fault is detectable, but the automatic control is not
performed if a bus fault occurs.
・Power (watt) transducer:
Any sensor fault is detectable if the generator voltage is
established.
Therefore, if a generator stops, it is regarded as normal and may
be set as a stand-by generator.
However, when the voltage is established after the automatic
start, the sensor fault is detected and then the ACB NON CLOSE
signal is output.
Thus, the generator is no longer available as a stand-by
generator.
If a fault occurs when the ACB is closed …
The power control (load sharing) (load shift) for the generator in
question becomes uncontrollable.
The generator in question is controllable during its normal
generation period.

Therefore, all the semi-automatic control and automatic control

functions are limited.

End

TERASAKI ELECTRIC CO., LTD.

GENERATING PLANT MANAGEMENT SYSTEM
GAC21

INSTRUCTION MANUAL

PART 3

Setting Value Display Functions

TERASAKI ELECTRIC CO., LTD.

 Table of Contents

1. Introduction -------------------------------------------------------------------- 3-1

2. Operation Part of Setting Device ----------------------------------------- 3-1

3. Standard Setting Values and Addresses for Setting Value -------- 3-2

4. Function of Key switch and Slid switch ----------------------------------- 3-5

5. Procedure for Changing a Setting Value ------------------------------- 3-6

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 3-1

1. Introduction
As the display function for entering and modifying various parameter values and for displaying the
measured values, the handy type Setting device with an LED display (red) (hereafter referred to as
“Setting device”) is provided for the GAC21 System.
The communication between the GAC21 System and the Setting device is performed via the digital I/O
module for the Setting device, which is included in the GAC21 Controller.
However, this communication is only possible when the control-related modules and the digital I/O
module for the Setting device are normal.
In addition to the parameter values, the voltage and power for generators, and the measured value for the
frequency of the bus can be displayed.
The Setting device is normally removed and put in the accommodation pocket on the rear of the door for
the common section at the lower part of the generator panel.

2. Operation Part of Setting Device

Fig.3-1 illustrates the operation part of the Setting device.

For using and handling the keys and slide switches, refer to the subsequent items.
The Setting device has two connectors with 1meter connector cable, the one for the power source of 24V
DC for the Setting device and the other for the digital I/O module for the Setting device.
The power source for the Setting device is located near the GAC21 Controller.

１：LED Display (Red ) 4 character ５：Add. No. ⇔ Value Change over Slid switch

２：TEN Key (0～9) ６：Now ⇔ New Change over slide switch

３：CANCEL Key (C) ７：I/O Module connector（40P）

４：ENTER Key (ENTER) ８：Power source connector（2P）

Fig.3-1 Appearance of Setting device

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3-2

3. Standard setting values and addresses for setting values

The setting values and measured values can be viewed by entering a 4-digit number for each of them on
the Setting device.
Once a 4-digit number is entered, the corresponding setting value or measured value is searched for.
The format of numbers available for this search is predefined according to each group of setting values.
The meaning of each 4-digit number for a setting value is, in principle, is predetermined according to the
following standard.
The standard setting values and the numbers for setting values (hereafter referred to as “addresses”) are
shown in the list of the Table 3-1 below.

：SETTING ADDRESS－□ □
□ □
Serial number (01～99)
Group of setting item
(0: Constant setting, 1: Timer setting, 2: Measured value)
Generator number or other
(0：Common, 1：G1, 2：G2, 3：G3 …)

CAUTION Reading the 4-Digit Number Indicated with LEDs

The LED indication for SETTING VALUE shows no decimal point.

Therefore, take care not to misread the unit for the 4-digit number.
Tables 3-1, 3-2, and 3-3 show“ LED INDICATE” for the number in“ SETTING RANGE
” .
The number indicated with LEDs conforms to the following standard.
STANDARD SETTING/LCD INDICATION
SETTING VALUE LED INDICATION

１ ０００１

１．０ ００１０

１０ ００１０

１０．０ ０１００

１００ ０１００

１００．０ １０００

MEASURE VALUE/LCD INDICATION

ACTUAL VALUE LED INDICATION

５００ｋＷ ０５００

４５０Ｖ ０４５０

６０．０Ｈｚ ０６００

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 3-3

Table 3-1 List of Standard Setting Value for generator

STANDARD SETTING ADDRESS
SETTING ITEM SETTING
RANGE SETTING LED G1 G2 G3
INDICATE

SHARING RATIO 1.0～5.0 1.0 0010 1001 2001 3001

GOV CHARACT 2.0～16.0sec/Hz 8.0 0080 1002 2002 3002

LOAD LIMIT 50～100 % 95 0095 1003 2003 3003

ENG IDLING TIME 0～2400 sec 600 0600 1105 2105 3105

VOLT ESTABLISH 60～100 % 95 0095 1004 2004 3004

VOLT ESTABLISH TIME 0～30 sec 7 0007 1101 2101 3101

VOLT NON EST TIME 0～30 sec 20 0020 1102 2102 3102

ACB NON CLOSE TIME 0～10 sec 3 0003 1103 2103 3103

AUTO SY FAIL TIME 0～240 sec 60 0060 1104 2104 3104

GEN LIGHT LOAD 0～100 % 20 0020 1005 2005 3005

GEN LIGHT LOAD TIME 0～240 sec 0 0000 1106 2106 3106

STANDARD SETTING ADDRESS

SETTING ITEM SETTING
RANGE SETTING LED G4 G5
INDICATE

SHARING RATIO 1.0～5.0 1.0 0010 4001 5001

GOV CHARACT 2.0～16.0sec/Hz 8.0 0080 4002 5002

LOAD LIMIT 50～100 % 95 0095 4003 5003

ENG IDLING TIME 0～2400 sec 600 0600 4105 5105

VOLT ESTABLISH 60～100 % 95 0095 4004 5004

VOLT ESTABLISH TIME 0～30 sec 7 0007 4101 5101

VOLT NON EST TIME 0～30 sec 20 0020 4102 5102

ACB NON CLOSE TIME 0～10 sec 3 0003 4103 5103

AUTO SY FAIL TIME 0～240 sec 60 0060 4104 5104

GEN LIGHT LOAD 0～100 % 20 0020 4005 5005

GEN LIGHT LOAD TIME 0～240 sec 0 0000 4106 5106

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3-4

Table 3-2 List of Standard Setting Value for Bus Monitoring

STANDARD
SETTING ITEM SETTING RANGE SETTING
SETTING LED ADDRESS
INDICATE

BUS VOLT LIGHT LOW 75～100 % 97 0097 0001

BUS VOLT LIGHT LOW TIME 0～30 sec 10 0010 0101

BUS VOLT LIGHT HIGH 100～125 % 103 0103 0003

BUS VOLT LIGHT HIGH TIME 0～30 sec 10 0010 0103

BUS FREQ LIGHT LOW 80.0～100.0 % 97.5 0975 0005

BUS FREQ LIGHT LOW TIME 0～30 sec 10 0010 0105

BUS FREQ LIGHT HIGH 100.0～120.0 % 102.5 1025 0007

BUS FREQ LIGHT HIGH TIME 0～30 sec 10 0010 0107

BUS VOLT LOW 75～100 % 90 0090 0002

BUS VOLT LOW TIME 0～30 sec 5 0005 0102

BUS VOLT HIGH 100～125 % 106 0106 0004

BUS VOLT HIGH TIME 0～30 sec 5 0005 0104

BUS FREQ LOW 80.0～100.0 % 95.0 0950 0006

BUS FREQ LOW TIME 0～30 sec 5 0005 0106

BUS FREQ HIGH 100.0～120.0 % 105.0 1050 0008

BUS FREQ HIGH TIME 0～30 sec 5 0005 0108

START REQUEST 50～100 % 90 0090 0011

START REQUEST TIME 0～30 sec 10 0010 0109

STOP REQUEST 50～100 % 70 0070 0012

STOP REQUEST TIME 0～2400 sec 600 0600 0110

Table 3-3 List of Measuring Value

SETTING EXAMPLE LED SETTING ADDRESS
SETTING ITEM RANGE RATED INDICATE
G1 G2 G3

GEN POWER MEASURED --- 500 0500 1201 2201 3201

VALUE （kW）
GEN VOLT MEASURED --- 450 0450 1202 2202 3202
VALUE （V）
BUS FREQ MEASURED --- 60.0 0600 0201
VALUE （Hz）

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 3-5

SETTING EXAMPLE LED SETTING ADDRESS

SETTING ITEM RANGE RATED INDICATE
G4 G5
GEN POWER MEASURED --- 500 0500 4201 5201
VALUE （kW）
GEN VOLT MEASURED --- 450 0450 4202 5202
VALUE （V）
BUS FREQ MEASURED --- 60.0 0600 0201
VALUE （Hz）

CAUTION Search for Various Setting Values for Functions of GAC21 System

The standard setting values may be changed to the optical values depending on the
applicable ship. Some groups of setting values may be added.
To search for setting values, use address numbers for the following items included in “VOL. 3
GENERATOR AUTOMATIC CONTROL DEVICE --- GA” in the completed view of the main
switchboard.
・GENERATOR

・BUS MONITOR

・NUMBER OF DIESEL GENERATOR ON LINE CONTROL (GAC-PMS-G)

・OPTIMUM LOAD SHARING CONTROL (GAC-PMS-TG/SG)

・LARGE MOTOR START BLOCKING CONTROL (GAC-PMS-M)

4. Function of Key switch and Slid switch

This section describes the functions of the keys and slide switches shown in Fig.3-1, based on data
transmission and reception.

(1) ２ TEN numeric key (0～9)：

The numeric keys 0~9 are used to enter a 4-digit value or address.
After checking the position, Add. No. (data number indication position) of the slide switch ５ on
the Setting device, enter the data number (ADDRESS) for the setting value with numeric keys and
then transmit it to the Digital I/O module for the Setting device (hereafter referred to as“ module
for the setting device” ).

(2) １ LED indication：

The data number (ADDRESS) that has been entered with numeric keys and then transmitted will be
sent back to the Setting device and indicated on it.

(3) ４ ENTER Key：

Check the data number (ADDRESS) and press the ENTER key.
If the established data number is transmitted from the Setting device to the module for the setting
device, the module for the setting device searches for the appropriate setting value and then stores
that data.

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3-6

(4) ５ ６ Slid switches：

If the slide switch ６ on the Setting device is in the Now (current value display position) when it is
changed slide switch ５ from Add to the Value (setting value data display position), the module for
the setting device transmits the stored current value to Setting device, which is then displayed on
the Setting device.
If the slide switch ６ is in the New (changed value display position), enter the changed value on the
Setting device using numeric keys and then transmit it to the module for the setting device.

(5) The module for the setting device returns the transmitted changed value to the Setting device,
which is then displayed on the LED.
Establish the changed value by pressing the ENTER key on the Setting device.
After the changed value has been transmitted to the module for the setting device, the setting
range and the changed value are checked.
If the changed value falls in that range, that changed value is accepted.

(6) ３ ：
C Key（CANCEL）

If the entered value falls outside the setting range, an error is generated with“ 9999” displayed on the
LED of the Setting device.
To enter another value, press the CANCEL key. The displayed“ 9999” will be cleared.
Enter another changed setting value using numeric keys.
The CANCEL key is used to reset the specified data number (address) or the entered value to be
changed. When this data is reset, the LED on the Setting device simultaneously displays“ 0000” .

5. Procedure for changing a setting value

Before entering the ADDRESS for a setting value, check the following points:

Handling and Checking the Setting Device

CAUTION
Before Changing the Settings --- (1/2)
1. Check the setting positions of the slide switches:
Add. No. ÅÆValue ： Add. No. position

Now ÅÆNew: ： Now position

2. Connecting the connectors to the setter

Firmly connect the connector (2P) for the power source of 24V DC and the connector
(40P) for the I/O module for the setting , which come with the Setting device, to the power
receptacle of 24 VDC and the I/O module in the following order.
The power receptacle of 24 V DC is located near the GAC21 Controller.
1) First connect the connector for the I/O module.
2) Then connect the connector for the power source of 24V DC.
-To remove the connectors, reverse this order.
If you should connect the connectors in the reverse order, the setter and the module
would not be damaged.

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 3-7

Handling and Checking the Setting Device

CAUTION
Before Changing the Settings --- (2/2)
3. After connecting the connector for the power source of 24V DC, check that the LED

indicator shows“ 0000” .

4. Check that the shaded part on the top of the module, shown in Fig. 3-2, does not
indicate any illuminated LED error message like “ERR” or “ALM”.
For the “ERR” indication, refer to “Part 4“ Inspection･Maintenance and Self-Diagnostic
Functions.”

ERR/ALM LED indicate part

24V DC source Setting device
RECEPTACLE

Connector cables

(254) (1) (3) (2) (4) (5) (6) (7) (8) (9)

Source supply Digital I/O (Setting device)

CPU Digital input (common)
TM interface Digital I/O (G1, G2, G3, Common)
Analog input

Fig.3-2 Between GAC21 Module and Setting device Connection

An example of changing a setting value is given below:

This example assumes that the sharing ratio for No.1 generator is to be changed from the standard
setting value“ 1.0” to“ 2.0” .

Step ①：Check that two slide switches are in the Add No.
(Setting address) and Now (Current value) positions.
Also check that the LED on the Setting device 0000
Indicates“ 0000” . Add No Value Now

Step ②：Enter a address number (Address) using numeric keys

address: １ ０ ０ １ .
Every time each digit is entered, the LED on the Setting
device indicates the entered number.
I00I
Add No Value Now

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3-8

Step ③：Check with the LED display that the entered address is
correct, and then press the ENTER key.
If the entered address is wrong.
I00I
1001
Press the Ｃ key and clear the LED display on the Setting No Value
Add No Value Now New

device to“ 0000” and then enter a correct address.

Step ④：Change the slide switch from the Add No.(setting

address) position to the Value (setting value) position.
I00I
1001
Add No
No Value
Value Now New

Step ⑤：Since the slide switch is in the Now (Current value)

position, the LED on the Setting device indicates the
current setting value. 00I0
1001
In this example,“ 0010” is displayed. Add No
No Value
Value Now New

Note：No decimal point is displayed.

Step ⑥：Change the slide switch in the Now (Current value)

position to the New (Changed value) position.
This operation will clear the LED on the Setting device 0000
1001
Add No
No Value
Value Now
Now New
to“ 0000” .

Step ⑦：Enter the changed value using numeric keys, in this

example, ０ ０ ２ ０.
The entered value will be indicated on the LED on the
Setting device.
0020
1001
Add No
No Value
Value Now New

Step ⑧：Check with the LED that the changed value is correct,
and then press the ENTER key.
If the entered value is wrong, press the Ｃ key and
clear the LED display on the Setting device to“ 0000”
0020
1001
Add No
No Value
Value Now New

and then enter a correct value.

Step ⑨：Change the slide switch in the New (Change value)

position to the Now (current value) position.
This operation will display“ 0020” on the LED on the
0020
1001
Add No Value Now New
Setting device. Check that the data has been changed
to the entered value (0.2).

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 3-9

Step ⑩：Return the Value position of the slide switch to the

Add. No.(Setting address) position, which is the initial
position of that slide switch for the Setting device. 0000
Add No Value Now New
.
Now the setting value has been changed

The“ measured value” is displayed only and can be viewed by performing the steps ① through ⑤
.
Handling and Disposing the Setting Device
CAUTION
After Changing the Setting
1. Check the setting positions of the slide switches:
Add. No. ÅÆValue ： Add. No. position

Now ÅÆNew: ： Now position

2. Removing the setting device connectors

Remove the connector (2P) for the power source of 24V DC and the connector (40P) for
the I/O module, which come with the setting device, from the power receptacle of 24V
DC and the I/O module in the following order:
1) First remove the connector for the power source of 24V DC.
2) Then remove the connector for the I/O module.

-Even if this order is reversed, the setting device and the I/O module will not be damaged.

3. Notifying us of the changed setting value

If you change the setting value, notify us of the ship number, setting address, changed
item, and changed setting value, which are required to update our database.

End

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GENERATING PLANT MANAGEMENT SYSTEM
GAC21

INSTRUCTION MANUAL

PART 4

Inspection・Maintenance
and

Self-Diagnostic Functions

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 Table of Contents

1. Introduction ---------------------------------------------------------------------------- 4-1

2. Maintenance and Inspection ---------------------------------------------------- 4-2

2.1 General ----------------------------------------------------------------------------- 4-2

2.2 Electric Power･Voltage and Frequency Transducer Adjustment -------- -
4-3
2.3 Replacing a Module ----------------------------------------------------------------
4-5
2.4 Replace the ROM Card in the CPU Module ----------------------------------
4-7
2.5 Spare Modules --------------------------------------------------------------------
4-10

3. Self-Diagnostic Function ----------------------------------------------------------- 4-12

3.1 Check with the LED Indicators -------------------------------------------------- 4-12

3.2 Action Against the Detected Anomaly -------------------------------------- 4-12

3.3 Causes for Detected Failures ---------------------------------------------- 4-13

3.4 Troubleshooting ---------------------------------------------------------------- 4-14

3.5 Indication of SYSTEM FAIL for the GAC21 System 4-16

----------------------------

4. Service Network ---------------------------------------------------------------- 4-20

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 4-1

1. Introduction
The GAC21 Automatic Generator controller (hereafter referred to as“ GAC21 Controller” ) and the
Handy Type Setter with an LED Display (hereafter referred to as“ Setting device” ) are designed to
allow you to perform maintenance and checks at ease.

(1) The GAC21 Controller is located in the common section on the lower front of the generator
panel, allowing you to perform maintenance, checks, and replacement from the front of the
GAC21 Controller.

(2) If each module of a GAC21 Controller should detect any anomaly with its self-diagnostic
function, it would turn ON the “ERR” LED indicator located on its front to notify you that the
anomaly has occurred.

(3) The Setting device has no self-diagnostic function, but allows you to find anomalies, if any,
from the initial information displayed when the Setting device is connected.
For operations and display for changing any setting value, refer to“ Part 3 Setting Value

Display Functions.”

(4) If any anomaly should occur, take action in accordance with “Section 3.2 Action Against the
Detected Anomaly” of this section.

(5) Fig.4-1 shows the modular configuration of the GAC21 Controller.

Coupler Lock Base board

Setting device

24V DC source
SX bus Address Number
(254) (1) (2) (3) (4) (5) (6) (7) (8) (9)

DIGITAL I/O Module (NP1W3206T)

DIGITAL Input Module (NP1X1606-W)
DIGITAL I/O Module (NP1W1606T)
TM interface Module (NP1L-TMB)
DIGITAL I/O Module (NP1W3206T)
ANALOG Input Module (NP1AX04-MR)
CPU Module (NP1PH-16)
POWER SUPPLY Module (NP1S-42) (24V DC Source)

Fig,4-1 Module Configuration of GAC21 Controller (Three Generators)

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4-2

2. Maintenance and Inspection

2.1 General

CAUTION Checking a module of the GAC21 Controller

(1) Daily checks

a. Visually check the operating state of each module.
Check items:
1) Neither the“ ERR” nor“ ALM” LED indicator is illuminated on each
module.
2) The“ BAT” LED indicator for an abnormal battery level is not be illuminated on
the CPU module.
b. For the details of LED display on each module and the normal and abnormal
states, see“ 3.1 Check with LED indicators” .

c. For replacing a abnormally module, see“ 2.3 Replacing a Module” .

d. For the Automatic synchronizing control unit “Digital Synchronizer”, which is one of
the components of the GAC21 System, refer to the separate Instruction Manual for

“ Type EAS-101 Digital Synchronizer” .

(2) Others
1) Check that the installed state is as follows:
a. Each module is installed firmly.
b. The terminal screws for external wiring are not loosened.
c. The connectors for connection cables are inserted firmly.
2) Check to see whether or not the battery in the CPU module needs to be replaced.
For replacing the batter, see “2.5 (3) Replacing the battery for data backup use in
the CPU Module”.
(The expected service life of the battery is indicated on the battery ---- approx. 5
years after manufacture.)

Prohibition Against insulation resistance test

CAUTION and withstand voltage test

Do not perform the insulation resistance test and/or the withstand voltage test for the
GAC21 Controller since the module will be broken.
To perform either or both of these tests for the switchboard or Generator control
console with the GAC21 Controller, take the following actions:
(1) Remove the connection cable connected to the power inlet terminal of 24V DC
(power module) of the GAC21 Controller.
(2) Remove the input/output cable and connector connected to each module of the
GAC21 Controller.

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 4-3

CAUTION Maintenance for Components of the GAC21 System

Details of maintenance:
・ Disconnection and connection of the wiring connected to the GAC21 Controller
・ Removal/ insertion of connectors from/into each module
・ Replacement of wiring and equipment (including the power transducer, voltage
transducer, frequency transducer, and transformer and current transformer for
equipment) related to the GAC21 System.

To perform the above maintenance, be sure to observe the following instructions:

(1) If a generator is being controlled for the automatic operation, change the
operation mode to MANU.
Trying to replace any equipment in the AUTO mode will cause the system to
malfunction and will hinder the power plant from the normal operation.
(2) To replace a module of the GAC21 Controller, turn OFF the power source of 24V
DC.
(3) To replace any cable, connector, or transducer, turn OFF the power source of
24V DC.
(4) After replacing any cable, connector, transducer, or module, set the cable
connection terminals and the switches located on the module to the same
positions as on the removed members or module, and firmly insert the
connectors into the correct positions.
(5) Each module is very susceptible to static electricity.
If you handle it when you are static electricity charged, the module may be
damaged.
Before handling the module, discharge your static electricity by touching
appropriate nearby metal.

For the“ Type EAS-101 Digital Synchronizer” , refer to the corresponding instruction
manual.

2.2 Electric power･Voltage and Frequency Transducer Adjustments

The electric power (watt) transducer, voltage transducer, and frequency transducer (hereafter
collectively referred to as “the transducers”) supplied with the GAC21 System.
Convert the power, voltage, and frequency generated by each generator, which have been input via
the CT and PT, and then output them to the GAC21 Controller.
The transducers were adjusted when the GAC21 System was shipped from the factory.

The transducer types used are shown below.

･Electric power transducer：TYPE MT-2-1 (Each generator/1set)
･Voltage transducer ：TYPE VGS-1A-1-8 (Each generator/1 set)
･Frequency transducer ：TYPE FGS-1LA-22-8 (For Busbar/1 set)

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4-4

DANGER Readjustment of Output from the Transducers

If a generator is in the AUTO mode, change it to the MANU mode.

Trying to readjust the transducers may cause the generator to malfunction.

(1) The transducers convert the power (effective power), voltage, and frequency that are required
for executing the automatic control function for a generator, into the signal level of 4~20 mA DC
that can be sent via the analog multiplex transmission.
(2) Each transducer provides a trimmer (VR) for correcting the output.
Manually adjust the power, voltage, and frequency values to the rated ones while viewing the
readings on the instruments on the switchboard or the control panel for generators, and then
adjust the transducers by the following procedure.
For the positions of the trimmers (VR) for the transducers, see “Fig.4-2 Electric power
transducer, voltage transducer, and frequency transducer.”

Adjustment method：1
Measure the output current of the transducer with precision DC ammeter of low input impedance
(Max.500Ω ) and adjust the output adjuster so that output will equal to;

(20－4)× Rated value of input variable

Transducer output current ＝ ＋4〔mA〕
Max. measure value (FULL SPAN)

Adjustment method：2
Set the rated value by the transducer trimmer (VR) as read on the Setting device display function
(Part 3“ Setting Value Display Function, Table 3-3 List of Measuring Value” ).

Electric power Voltage Frequency

Fig.4-2 Electric power・Voltage and Frequency Transducer

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 4-5

2.3 Replacing a Module

The modules for the GAC21 Controller are installed on the baseboard of the GAC21 Controller.
To replace a module, perform the following steps:

DANGER Replacing a Module

(1) Stopping a GAC21 Controller

1) If the generator is in the AUTO mode, change the mode to MANU.
Trying to replace a module in the AUTO mode will cause the generator to
malfunction.
2) Shut down the power source of 24V DC for the GAC21 Controller.
The DC power is input to the power supply module for the GAC21 Controller.
To shut down the power source, remove the FUSE [Nameplate: GAC21 (DC
SOURCE)] that is located near the GAC21 Controller in the switchboard.
(2) Never connect or disconnect any hot line.
To remove a module, check that the “PWR” LED indicator (green) on the power
module has completely turned OFF, and then start removing the module.
(3) Remove the connectors or connection cables for the terminals, which are
connected to the module to be replaced.
In case of the terminal connections, after the completion of the replacement,
connect the terminals without making any mistake in the terminal numbers.
If the connected destination is unknown, refer to VOL. 2 [SCHEMATIC
DIAGRAM“ S” Section (GAC21 CIRCUIT)] in the view of the finished main
switchboard.

Procedure for replacing a module

(1) Mounting each module on the base board
Step ①：Raise the coupler lock which is attached to the slot where the module is inserted.
Hang the hock of the module’s backside on the lower part (the aluminum part) of
the base board.

Fig.4-3 Mounting modules to base board ①

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4-6

Step ②：Mounting upper part of the module’s , backside on the base board.

Fig.4-4 Mounting modules to base board ②

CAUTION Step ② for replacing a Module

Confirm that the hook of the module is stable on the lower part of the base board
and is not sliding left or right.
If the module is pushed in a sliding position, the connector may be damaged.

Step ③ ：Confirm the coupler lock to hang on the hole which is in the upper part of the
module’s backside.
If the module is loose, push the coupler lock to the direction of the arrow.

Fig.4-5 Mounting modules to base board ③

CAUTION Step ③ for replacing a Module

If the module should be mounted with not hanging the hook to the base board,
bend the coupler lock to remove the module with pushing the hook to the base
board. Removing by force might cause to be broken.

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 4-7

(2) Removing a module from the base board

CAUTION Removing a Module

To remove a module, pull down the coupler lock toward you and then perform the
reversed steps for installing a module.

2.4 . Replace the ROM card in the CPU module

Changing the only setting values by the Setting device.
However the automatic control flow changes for some reason, it is necessary replacing the ROM
card from CPU module.

To replace a ROM card, perform the following steps.

DANGER Replacing a ROM card (1/2)

Stopping a GAC21 Controller
1) If the generator is in the AUTO mode, change the mode to MANU.
Trying to replace a module in the AUTO mode will cause the generator to
malfunction.
2) Shut down the power source of 24V DC for the GAC21 Controller.
The DC power is input to the power supply module for the GAC21 Controller.
To shut down the power source, remove the FUSE [Nameplate: GAC21 (DC
SOURCE)] that is located near the GAC21 Controller in the switchboard.

CAUTION Removing a ROM card (2/2)

(1) Before using this ROM card, discharge the static electricity of the human
body. And furthermore, grip the knob and do not touch directly electric parts
on the printed circuit board except the write-protect switch.
(2) Never connect or disconnect any hot line.
To remove a module if necessary, check that the “PWR” LED indicator (green)
on the power module has completely turned OFF, and then start removing the
module.
(3) Before replacing the ROM card, be sure to check the current“ CHANGED

SETTING VALUE” .

(4) After replacing the ROM card, set the new ROM card to the“ CHANGED

SETTING VALUE” you checked before the replacement.

Knob
WRITE PROTECT

WRITE ENABLE

Connector Write protect switch

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4-8

Procedure for replacing a ROM card

(1) Placing the ROM card into the CPU module
Step ①：Shat down the GAC21 Controller power supply, and open the battery cover.

Fig.4-6 Placing ROM card ①

Step ② ：Turn down the battery folder. Insert the ROM card from the position of the
following figure of the CPU module to the backside.

Fig.4-7 Placing ROM card ②

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 4-9

Step ③ ：Push the knob the ROM card to the right firmly.

Fig.4-8 Placing ROM card ③

Step ④ ：1) Close the battery folder with pushing the battery leads not to be jammed.
2) Close the battery cover.

Fig.4-9 placing ROM card ④

(2) Removing the ROM card

Use the reversed procedure for placing the ROM card.

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4-10

2.5 Spare Modules

(1) As spare modules, each one of the following module type is supplied.
・ Power supply module -------------------- NP1S-42
・ (254) CPU module ------------------------NP1PH-16 （CPU No. setting key switch“ 0” position）
NP1L-TMB
・ (1) TM interface module -------------
NP1AX04-MR
・ (2)(3) Analogue input module ------- NP1W3206T
NP1W1606T
・ (4)(5)(6)(9) Digital I/O module ------ NP1X1606-W
・ (7) Digital I/O module -----------------
・ (8) Digital input module ---------------
(2) Maintenance of the power supply module for spare parts

Preventing the Electrolytic Capacitor

CAUTION
from its Capacity Loss
In order to prevent the aluminum electrolytic capacitor used in the power supply
module from its capacity loss, power on once apply 24V DC every 6 months.

(3) Replacing the battery for data backup use on CPU module.
CPU module incorporates the lithium primary battery for data backup use.
(no spare battery is supplied since the battery is consumed even if it is not used).

CAUTION Replacing the Battery for Data Backup (1/2)

(1) Replace the battery with a new one at the determined replacement time even if the
battery alarm is not indicated.
・Time of replacement：The replacement date of the battery is indicated on the

battery. This date comes 5 years (at 25℃) after the

manufacture.
・Battery type：NP8P-BT

・Nominal voltage：3.6 V

(2) If the“ BAT” LED indicator on the CPU module turns ON, immediately replace the
battery. After this warning has been issued, the CPU module will remain durable
against a power failure for approximately 1 week at 25 ℃ considering the

(3) possibility of over-the

Quickly replace looking the
battery warning.
within approximately 5 minutes.
If the battery is removed for longer time, the retained data will be lost.
The system fail alarm may be transmitted at the time of the 24V DC power supply
is turned on again, when the 24V DC power supply is turned off the long time
when the battery is wearing out. In this case, it returns be normal when the on-off
reset of the power supply is done again.

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 4-11

CAUTION Replacing the Battery for Data Backup (2/2)

(4) Procedure for replacing the battery

1) Shut down the power source of 24V DC for the GAC21 Controller.
If only the battery is to be replaced, this shutdown is not necessary.
2) Open the batter cover on the front lower part of the CPU module.
Refer to the figs.4-6 through 4-9 in“ 2.4 Replace the ROM Card in the CPU

Module” this part.

3) Remove the battery connector, replace it, and then secure the new battery.
4) Close the battery cover.
(5) Turn ON the GAC21 Controller source.

Tips:
The battery is used to back up the specific memory area of the CPU memory.
For example, if any set value is changed on the Setting device, the changed value is stored in
the memory area backed up with the battery.

Since this memory area is backed up with both the 24V DC power source and the battery, the
set values are not reset even if the 24V DC power source becomes unavailable.
However, if the 24V DC power source is lost for a long time when the battery runs out, the set
values will be reset to the initial value shown in the drawing for the finished system.

For this reason, the replacement of the battery is not necessary so far as the CPU module is
used without changing the initial values.
If any initial value is changed, replace the battery when necessary.
If you need to turn OFF the 24V DC power source when the battery is dead, check and record
the currently set values using the Setting device.
After the 24V DC power source has been restored, check again the set values using the
Setting device.
If the set values return to the initial values, change the initial values.

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4-12

3. Self-Diagnostic Function
3.1 Check with the LED indicators
The operating state of each module can be checked with the LED indicators located on the front of
the module.
Table 4-1 shows the states of the LED indicators for the normal operation and the Table 4-5
occurrence of any anomaly.
For the items and states displayed on the module, refer to“ 3.1 Structure of GAC21 Controller” ,
“ 3.1.3 Specification of Modules” and“ States indication LED” of Part 1.

Table 4-1 LED display for normal operation of each module

LED indicator
Modules PWR ALM ONL ERR RUN SD RD BATT Remarks
SX BUS Name
No.

－ Source ○ ●
supply
245 CPU ● ○ ● ○ ●
1 TM ○ ● ◎ ◎
2,3 Analogue ○ ●
4,5,6,7 Digital I/O ○ ●
8 Digital input ○ ●
9 Digital I/O ○ Setting
●
device

○ ： Turn ON ● ： Turn OFF ◎ ： Blink (Data input/output in progress)

3.2 Action Against the Detected Anomaly

CAUTION Action Against the Detected Anomaly

If an anomaly is found with the LED display on a module, take the following action.
1) Anomaly in the CPU module
Not just a CPU module anomaly, but also an anomaly in the system controlled by the
CPU can be displayed.
Even if the “RUN” LED shown in Table 4-1 is OFF statuses, an anomaly in any other
module can be detected. In this case, an anomaly occurs in another module.
If an anomaly is found in the internal CPU, identify the cause and make the
necessary replacement.
2) Anomaly in any module other than the CPU
If the “ERR” or “ALM” LED indicator on a module turns ON, identify the cause and
make the necessary replacement.

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 4-13

3.3 Causes for Detected Failures

Table 4-2 shows the possible causes for failures of the GAC21 Controller.

Table 4-2 Possible causes for failures of the GAC21 Controller

Failure module or device Possible causes for failures

CPU module CPU abnormal, Power source abnormal, Memory abnormal,

SX bus abnormal, Application abnormal, I/O module abnormal,
Power supply module
Common module abnormal, Hardware abnormal.
Analogue module Resetting the GAC21 Controller by turning OFF and then ON
the DC power source after a module has been replaced.
Digital I/O module

Digital input module

TM module Farm abnormal, ROM/RAM abnormal, SX bus abnormal, SX-

CPU abnormal, Setting abnormal, TM line abnormal (Clock
abnormal・Signal line break down・Check bit abnormal).
Resetting the GAC21 Controller by turning OFF and then ON
the DC power source after a module has been replaced.

Electric power・Volt ・ Cause of detection: If the output current decreases below 0mA
(electrical discontinuity) with the input signal of 4~20mA, the
Frqequency transducer
SENSOR FAIL signal is output (the upper limit is not detected).

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4-14

3.4 Troubleshooting
If the GAC21 system failure signal is output during the operation, recover the system in
accordance with the following chart.
If a failure occurs after any module has been replaced, take action according to the troubleshooting
chart on the next page.

Fig.4-10 GAC21 System Troubleshooting

(for any anomaly found during the operation)

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 4-15

An anomaly occurs after

a spare part has been
replaced *1) Action

Check for any Abnormal

removed module Put it back in place
or connector

Normal
*2)
Is the CPU No. NO Select the same CPU
Replace the CPU module same as that of the No. as that of the
previous module?
previous module
YES *3)
Is the Set the selection key
Selection key switch set to NO
Replace the Analogue switch to the sam e
input module the same position as on position as on the
the previous module?
previous module

YES
Replace the TM
interface module

Replace the digital

I/O module

Replace module type

Note:
*1) The RUN indic ator on the CPU module Identify the cause and take action in accordance
turn OFF or the ERR/ALM indic ator on with the 3.5 ”Indication of SYSTEM FAIL for the
the CPU module may be ON.
GAC21 System” in this PART.
*2) The CPU No. is norm ally set to “0”.

*3) For the position of the setting key switch,

refer to 3.1.3 (d) “Analogue input module”
in the PART 1. “General Specific ation and
If restoration is not possible, contact us
System Structure”.

Fig.4-11 GAC21 System Troubleshooting

(for any anomaly found after a space part has been replaced.)

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4-16

3.5 Indication of SYSTEM FAIL for the GAC21 System

If a system anomaly occurs, the self-diagnostic function of each module indicates that anomaly on its
LED display.
In addition, “GAC21 SYSTEM FAIL” or “TM UNIT ABNORMAL” signal is output to the external
monitor for the GAC21 System.
Tables 4-3, 4-4, and 4-5 show the output states of these FAIL signals.

Table 4-3 Output of GAC21 SYSTEM FAIL signal

Fail Module abnormally of GAC21 Controller
signal Output signal
output C T Digital I/O Digital I/O Sensor
Source P M Analogue & Input (For Fail
GAC21 supply U (For setting
If a module or a
control) device)
SYSTEM sensor has an
FAIL anomaly, the Output Out Out
put put
parallel output Output Output Not Output
is used. An anomaly in the TM Output
unit is detected by the
monitor.

Table 4-4 LED statuses in case of an anomaly in the TM module

Status ＯＮＬ ＥＲＲ ＳＤ ＲＤ

（Green） (Red) （Green） （Green）

Normal Normal operation ON OFF OFF OFF

operation
Output data Transmission ON OFF Blink OFF

Input data Receiving ON OFF OFF Blink

Anomaly Major failure OFF ON OFF OFF

operation
Minor failure ON ON OFF OFF

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 4-17

Table 4-5 Display in the FAIL mode (1/2)

LED indication on Alarm

Causes Abnormal module Output
No. Fail Mode for Remarks
GAC21
Failure ERR RUN ALM System
ONL
(PWR) Fail

１ CPU Module fail OFF ON OFF ON Output Note:2 Note:6

module
Module OFF OFF OFF OFF Output Note:1 Note:2
disconnect Note:7
Battery volt ON ON ON ON --- CPU module
low Note:12
Power supply Module fail ON --- --- ON Output Note:8 Note:2
module
Module ON --- --- OFF Output Note:8 Note:2
disconnect
Analogue Module fail OFF ON --- --- Output Note:9
module OFF OFF --- --- Output Note:1
Module Note:10
disconnect
Digital I/O & Module fail OFF ON --- --- Output Note:9
Input module Module OFF OFF --- --- Output Note:1
：For Gen/ disconnect Note:10
Common
ＴＭ Module fail OFF ON --- --- Output Note:2 Note:9
module OFF OFF --- --- Output Note:1 Note:2
Module Note:10
disconnect
Digital I/O Module fail OFF ON --- --- --- Note:9
module：For
Setting device Module OFF OFF --- --- --- Note:1
disconnect Note:10
２ 24V DC Pull out the --- --- --- --- Output Note:2
source Fuse for All modules
GAC21 LED OFF
Controller
12V DC TM module ON OFF --- --- --- TM module
source Power Note:2
source is
turn OFF
24V DC source Setting --- --- --- --- --- Note:5
for Setting device
device source
shutdown
３ Wrong Lack of a --- --- --- --- --- Detect unit
setting channel anomaly for
lack of a unit
Wire Pull out TM ON OFF --- --- --- TM module
disconnect module Note:2
connector
４ Sensor Wire Analogue --- --- --- --- Output Note:3
failure disconnect module
Input line
broken

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4-18

Table 4-5 Display in the FAIL mode (2/2)

LED indication on Alarm

Causes Abnormal module Output
No. Fail Mode for Remarks
GAC21
Failure ERR RUN ALM System
ONL
(PWR) Fail
５ Conne Wire Pull out --- --- --- --- --- Note:4
ctor disconnect connector
discon for control
nect module
-related
Wire Pull out --- --- --- --- --- Note:5
disconnect connector
for setting
device
Wire Expansion OFF ON OFF ON Output CPU module
disconnect bus plug Note:2
/pull down cable Note:11
disconnect
６ Setting CPU CPU No. OFF ON OFF ON Output CPU module
Wrong Channel select key Note:2 Note:7
setting switch
error located on
CPU
module is
set to other
than“ 0
”
［Note：1］
・If a module is disconnected, the LEDs on that module turn OFF.
［Note：2］
・The monitor detects any anomaly in all the units covered by the TM module.
［Note：3］
・If a sensor failure occurs (the analog input line is broken), the I/O status LED
(output side) on the Digital I/O module for the Setting device starts blink.
In this case, take the following action.
LED 0：G1 KW, LED 1：G1 V, LED 2：G2 KW, LED 3：G2 V,
LED 4：G3 KW, LED 5：G3 V, LED 6：BUS F, LED 7：NOT USE
［Note：4］
・For troubleshooting, check the items such as “The related indicators on the
switchboard are OFF” and “No warning signal is output though an anomaly exists.”
［Note：5］
・In the normal operation, the connectors on this module are not connected, but
connected only when the Setting device is used.
If the power source of 24V DC for the Setting device is shut down, the data
display function and setting change function on the Setting device are disabled
(no anomaly occurs in the GAC21 Controller).
［Note：6］
・The ONL LED and ERR LED are illuminated on all the modules other than the CPU
module. (The PWR LED is illuminated on the Power supply module; and only the
ONL LED is illuminated on the digital input module.)
If the watchdog timer failure occurs due to an application error, the ONL LED and
ALM LED are illuminated on the CPU module.
［Note：7］
・The LEDs on all the modules other than the CPU module turn OFF.
(The PWR LED indicator is illuminated on the power supply module; and the ONL
LED indicator on the TM module blink with the ERR LED illuminated.)
TERASAKI ELECTRIC CO., LTD.
 4-19

［Note：8］
・All the LED indicators on the other modules turn OFF.
［Note：9］
・On the CPU module, the ONL, ERR, RUN, and ALM LED indicators turn ON.
On the other modules, the ONL and ERR LED indicators turn ON.
(On the Power supply module, the PWR LED indicator is illuminated; and on the
Digital input module, only the ONL LED is illuminated.)
［Note：10］
・If any module other than the CPU and Power supply modules is disconnected, this
anomaly is classified according to the situation as follows:

… If the module is disconnected before the power is turned ON:

CPU module ----------------- The ONL and ALM LEDs turn ON.
Power supply module ----- The PWR LED turns ON.
TM module ---------------- The ONL LED turns ON and the ERR LED starts blink.
Other modules -------------- The ONL LED turns ON.

… If the module is disconnected after the power has been turned ON:
CPU module ----------------- The ONL, RUN, and ALM LEDs turn ON.
Power supply module ----- The PWR LED turns ON.
Other modules -------------- The ONL LED turns ON.

［Note：11］
・The ON/OFF statuses of the LEDs located on the modules other than the CPU
module are classified according to the situation of occurrence as follows:

… If the anomaly occurs before the power is turned ON:

Power supply module ---- The PWR LED turns ON.
TM module ------------------ The ONL LED starts blink and the ERR LED turns ON.
Other modules ------------- The ONL LED starts blink.

… If the anomaly occurs after the power has been turned ON:
Power supply module ---- The PWR LED turns ON.
Other modules ------------- The ONL and ERR LEDs turn ON.
(Except for the Digital input module, on which only the ONL LED turns ON.)

［Note：12］
・The BAT LED on the CPU is turns ON, and BAT LOW alarm is detect on monitor side
for abnormal watching.

TERASAKI ELECTRIC CO., LTD.

4-20

4. Service Network
For the supply of parts, maintenance, and other services, Contact the following network consisting
of the members of I.S.E.S.

HEAD OFFICE
TERATEC LTD. --- Terasaki Main Service & Spare Center
1-12-12 NISHITANABE. ABENOKU.OSAKA. JAPAN
TELEPHONE：＋81-6-6693-6971
FAX ：＋81-6-6693-1716
E-MAIL ： elparts＠teratec.co.jp/
Shipeng＠teratec.co.jp/
WEB SITE ： http://www.teratec.co.jp/

AMERICAN TERATEC INC. --- Covering USA

209 INDUSTRIAL PARKWAY NORTHVALE, NEW JERSEY 07647 USA
TELEPHONE：＋201-767-8080
FAX ：＋201-768-2570
E-MAIL ： ati＠teratecusa.com/

DAEWOO MARINE IND.CO.,LTD. --- Covering KOREA

756-8, YOCHONDONG, NAMKA ULSAN, KOREA
TELEPHONE：＋82-52-269-5996
FAX ：＋82-52-269-5998
E-MAIL ： dmico＠soback,komet.nm.kr/

DIRECT RESPONSE TERASAKI EUROPE LTD.

--- Covering Europe, Africa
TH
80 BEARDMORE WAY, CLYDEBANK GLASGOW G81 4 SCOTLAND. UK
TELEPHONE：＋44-141-941-1940
FAX ：＋44-141-952-9246
E-MAIL ： directresponse＠terasaki.co.uk/
WEB SITE ： http://www.terasaki.com.

GTI MARINE & OFFSHORE --- Covering NETHERLANDS

SLUISJESDIJK 37-3087 AD ROTTERDAM HARBOURNO, 2110
POST BOX; 59029-3008PA ROTTERDAM THE NETHERLANDS
TELEPHONE：＋31-10-42-95-200
FAX ：＋31-10-42-96-005
E-MAIL ： jreedijk＠gti-group.com
WEB SITE ： http://www.gti-group.com

TERASAKI ELECTRIC CO., LTD.

 4-21

NOVAMARINE INSTUMENTSPTY. LTD. --- Covering OCEANIA

30 DOWNIE ST, WICKHAM NSW 2293 AUSTRALIA
TELEPHONE：＋61-49-2694477
FAX ：＋61-49-2621210
E-MAIL ： jaris＠novamarine.com.au/

TERASAKI DO BRASIL LTDA --- Covering S.AMERICA

RUA COLDOVIL 259-PARADA DE LUCAS, RIO DE JANEIRO-RJ BRASIL
TELEPHONE：＋55-21481-1259
FAX ：＋55-21-481-0935
E-MAIL ： terasaki＠nttnet.com.br/

TERASAKI ELECTRIC (CHINA) LTD. --- Covering CHINA

72 PACIFIC INDUSTRIAL PARK, XINTANG ZENGCHENG, GUANGZHOU
511340, CHINA
TELEPHONE：＋86-20-8270-8556
FAX ：＋86-20-8270-8586
E-MAIL ： terasaki＠public.Guangzhou.gd.cn/

TERASAKI ELECTRIC CO,. (F.E.) PTE. LTD.

--- Covering SIGAPORE
28 BUKIT BATOK STREET22, SINGAPORE 659590
TELEPHONE：＋65-561-1165
FAX ：＋65-561-2166
E-MAIL ： tete＠terasaki.com.sg

TERASAKI (MIDDLE EAST) --- Covering MIDDLE EAST

C/O DAIKA SHIP & BOATS MAINTENANCE P.O.BOX 62073, DY160-1,
A1 JALFE, DUBAI, U.A.E.
TELEPHONE：＋971-4-3240052
FAX ：＋971-4-3240750

End

TERASAKI ELECTRIC CO., LTD.