Gcu-Dg3 User Manual PDF

GCU-DG3
User's Guide
EGCON Co.,Ltd
A manual of Generator Control Unit
GCU (GENERATOR CONTROL UNIT)

MODEL : DG3
A table of contents
1. Outline 4
2. Product Features 4
3. Specifications and Functions 4
4. Condition of Specifications 4
5. Functions of Control Switch 5
6. LCD Display 6
7. Structures 8
8. Preparations before use 8
9. Connection Socket and Rating 10
10. Abbreviation 11
11. Manual Operation 12
12. Automatic Operation 12
13. Remote-control Operation 13
14. Protection Control Drive test of Engine Generator 13
15. Modification of Option Setting 14
16. A list of Option Setting 17
17. Specification table of GCU-DG3 Compatibility Gauge Sensor 23
18. The Number of Major Engine Ring Gear 23
19. Mechanical Failures and Solutions 24
EGCON Co., Ltd

http://www.egcon.co.kr [email protected]
TEL: 032-677-9806
FAX: 032-677-9807
GCU -DG3 User's Guide
EGCON Co,. Ltd
Cautions For Safety

1. Before use, please be well-informed of manual and drawing to use this product safely.
2. Please keep all cautions for safety to prevent potential accidents and dangers.
3. Cautions for safety are divided into 'warning' and 'caution' and each meaning is as follow.
warning
potential injury or death may
potential
arise
damage may arise in case
in
case
that
violates
instructions
Caution
injury
or
product
that violates instructions
4. Meanings of picture signals indicated in the manual are as follow.

Please be careful of potential product
Please
be
damages.
electrocution.
careful
of
potential
5. Please keep the manual close to product.
Warnings
1. Please do not begin wiring work when power supply is input or
driving a car to prevent electrocution and fire.
2. Please do not disassemble power supply even it is not input to prevent electrocution by
charged current in product.
3. Please do not touch with wet hands to prevent electrocution.
4. Please do not touch when sheath of electric wire is damaged to prevent electrocution.
5. Please do earthing of electric wire to prevent electrocution.
Cautions
1. Please permit a regular power supply to product to prevent product

damages and fire.
2. Please be careful of input of foreign substances in product to prevent short circuit and fire.
3. Please connect subordination fitted to capacity of input and output sockets to prevent
product damages and fire..
4. Please do not connect wires arbitrarily to prevent product damages and fire.
5. Only technicians or educated operators are allowed to use this product to prevent human
injuries or components damages connected to this product from irrational use.
6. For this product is made of electric components, please do testing that needs high voltage
such as inner voltage test or insulation resistance test only after separation of product to
prevent components damages.
7. Please use fuse and electric wire of regular capacity to prevent fire.
8. Please hold this product tightly because it is treated for high-vibrated engine generator.
9. Please install after checking untangled parts when moving.
EGCON Co,. Ltd
1. Outline
GCU-DG3 is a Diesel Engine Generator Controller that contains digital instrumentation function and digital
protective relay. Especially, this is easy and convenient to use that it is optimized for national
environments.
2. Product Features
2.1. Watt-hour meter [kWh]
2.2. Function of Digital protective relay (OVR, OCR, UVR, OFR, UFR).
2.3. Input of RPM, OPG, WTG, DCV, ETM gauges and OTG
2.4. Interface functions of commercial electricity and non-electricity by automatic operating signals
2.5. Functions of remote control and observation through RS485 MODBUS-RTU-typed communication
2.6. Double protection of starter motor by detection of engine rotating speed and oil pressure switch
2.7. Input of condition printing function
2.8. Input of 18 Fault History functions
2.9. Input of overspeed and overvoltage testing switch
2.10. Preheating function of engine preheating plug for small engine
2.11. Input of alert sounds
2.12. pause Solenoid burn preventive designal
2.13. Function of administrator password
2.14. Function of change from interface capacity for starter and pauseper(15A), ACB input, and block to
high capacity
2.15. Input of generator pauseper function when there perceives not MPU signal in normal operation
3. Capacity and function

3.1. Control power supply: 8~35Vdc, Consumption voltage: below 5W on standby, 360W on maximum
3.2. Speed perception: MPU detection 0~7,000Hz, 3~20Vac
3.3. Detection of commercial power: Max. 500Vac, 3 Phase 4 Wire 380/220Vac or single Phase 220Vac
3.4. Automatic operation signal: commercial power or dry contact
3.5. Fault detection:10, Alert:4
3.6. Operating electricity instrumentation and scope accuracy: 3 Phase 4 Wire
NO.
Instrumentation item
Range
Accuracy
L-L
(Line to line Voltage)
30 ~ 500Vac
1%
L-N
(Phase to phase Voltage)
10 ~ 300Vac
1%
(Line current)
0 ~ 6.5A
1%
Hz
(Frequency)
45 ~ 65Hz
1%
PF
(Power factor)
-0.3 ~ +0.3
1%
kW
(Active power)
0 ~ 99999kW
1%
kVAR (Reactive power)
0 ~ 99999kVAR
1%
kVA
(Rated apparent power)
0 ~ 99999kVA
1%
kWh
(Quantity of active power)
0 ~ 99999kWh
1%
10
kVARh (Quantity of Reactive power)
0 ~ 99999kVARh
1%
4 Page
EGCON Co,. Ltd
4. Circumstance
4.1. Operating Temperature: -10 ~ 40C
4.5. Maximum Operating Altitude: 3,000m
4.2. Storage Temperature: -24 ~ 45C

4.3. Relative Humidity: 0% ~ 90% Noncondensing
4.4. Vibration : amplitude-0.35mm,
4.6. Maximum Storage Altitude: 4,500m

4.7. Installment inner area where no existence of
influences of dust and salt
frequency-0~30Hz
5. Functions of Control Switch
5 Page
EGCON Co,. Ltd
(1) Operation Control Switch
(2) Controling switch for setting change
Switch for turning to the left in
Increasing change of setting, Changing
operation mode
in operation mode
<OFF> - <MNU> - <ATO> - <R-M>

Switch for turning to the right in
Decreasing change of setting,
operation mode
Changing in operation mode
<OFF> - <MNU> - <ATO> - <R-M>

Generator start switch in MNU(manual
Only in <OFF> Mode, transferring to
mode)
setting page
Generator pause switch in MNU(manual

mode)
Save after setting change
Buzzer pause switch when detecting

fault, Lamp Test Function when OFF
mode
Fault Reset Button
(3) ACB Control Switch
(4) Lamp
Fault: lighting when commercial

Blocking ACB in MNU(manual mode),
electricity is abnormal, Normal:
ACB block indicating lamp
lighting when commercial electricity

is normal
Operation: lighting when generation
Blocking ACB in MNU(manual mode),
is in operation, Fault: lighting when
ACB block indicating lamp, input is
there detecting all sorts of faults.
impossible when operation voltage is
Remote: lighting when selecting
low.
remote operation mode(GCU control

is not in operation when selecting)
6 Page
EGCON Co,. Ltd
6. LCD Display
(0)
G C U - D G
G E N .
C O N T R
V E R
0 .
E G C O N
C O .
3
O L
UN I T
9 1
,
L T D .
1. Version
2. Indicating short alert sound and screen for 5
seconds and transferring to start-up screen when
inputting power supply.
1. Start-up
(1)
< O F
R - S
R
H z
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
T
:
:
:
O
R - M
0 0 0 0
0 . 0 b a r
2 0 . 0 ' C
2. Indication of R-S voltage, R-current, and

frequency of generator
3. Indication of RPM, OPG, WTG measurements
4. Pressing <UP> transfers to screen (7) and
pressing <DOWN> transfers to next screen.
(2)
<
R
S
T
O
-
F
S
T
R
F
:
:
:
>
MN U
A
0 0 0 V
R : 0
0 0 0 V
S : 0
0 0 0 V
T : 0
T
0
0
0
O
R - M
0 . 0 A
0 . 0 A
0 . 0 A
O
-
F
N
N
N
F
:
:
:
>
MN U
A
0 0 0 V
R : 0
0 0 0 V
S : 0
0 0 0 V
T : 0
T
0
0
0
O
R - M
0 . 0 A
0 . 0 A
0 . 0 A
1. Indication of line voltage and phase current of
(3)
<
R
S
T
>
W:
F :
H :
MN U
A T O
R - M
0 0 0 . 0
k W
1 . 0 0
0 0 0 . 0
k WH
1. Indication of active electricity, its quantity, and
(4)
< O F F
k
p
k W
>
R :
A :
F :
MN U
A T O
R - M
0 0 0 . 0
k V A R
0 0 0 . 0
k V A
1 . 0 0
1. Indication of reactive electricity, apparent
(5)
< O F F
k V A
k V
p
(6)
<
R
E
D
>
MN U
A
0 0 0 0
O P G
0 2 3 H 0
O T G
2 5 . 8 V
WT G
1. Indication of line voltage and phase current

2. Pressing <DOWN> transfers to next screen
generator
power factor of generator
power, and power factor of generator
1. Indication of engine's rotating speed, operation

O
P
T
C
F
M
M
V
F
:
:
:
T O
R : 0 . 0 b
:
0 0
:
0 0
M
a r
' C
' C
time, battery voltage, oil pressure, coolant

temperature, and oil temperature
2. Right H of ETM<operation time> indicates 6
minutes per unit
7 Page
(7)
(8)
EGCON Co,. Ltd
< O F F >
N o r ma l
P o w e r
MN U
A T
R - N : P o w
S - N : P o w
T - N : P o w
<
1
2
3
MN U
A T O
R - M
4 : 4 8 X
7 : 5 1 X
5 : 5 9 X
8 : 5 1 G X
6 : 2 7 G X
O
:
:
:
F
6
2
1
F
3
6
2
>
Q X
WX
X
O
R - M
e r
O N
e r
O N
e r
O N
1. Indication of normal state of phase voltage of

commercial electricity
1. Indication of (OPTION) output

2. Pressing <UP> transfers to previous screen.
3. Pressing <DOWN> transfers to screen (1).
Indication of OPG and WTG differs according to option setting.

< O F
R - S
R
H z
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
T
:
:
:
O
R - M
0 0 0 0
0 . 0 b a r
2 0 . 0 ' C
< O F
R - S
R
H z
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
T O
R - M
: 0 0 0 0
:
O N
:
O F F
In case that OPS MODE and WTS MODE are

set to be SENSOR.
In case that OPS MODE and WTS MODE are

set to be SWITCH.
7. Structures
7.1. Dimension : W240 * H172 * D62 (mm).
7.2. Panel Cutting : W211 * H158.
7.3. Treatment Hall : W226 * H58
7.4. Weight : 1kg
7.5. Appearance drawing
8 Page
EGCON Co,. Ltd
8. Preparations before use

8.1. Connect input and output socket of GCU-DG3 with circuit diagram 1 and 2 to circuit.
2.5sq -
[ a circuit diagram 1 ]
l Please connect voltage and current of generator power supply identically
to prevent voltage indication error.
Cautions
l Please do not connect CNT socket when inputting commercial electricity

directly for detection of power outage signal.
[ a circuit diagram 2 ]
9 Page
EGCON Co,. Ltd
8.2. Please set option setting of GCU-DG3 fitting to generator.

If setting option differently from generator, there will arise a problem and
especially human accident may arise when detection of overspeed becomes
Warning
unoperated on account of wrong setting of [5.PICK-UP SETTING]. Please be

sure to inquire of engine generator manufacturing company the number of ring
gear.
Alarm machine make sound when input and output sockets of GCU are different from drawing and there
will be indication of 'fault' on LCD when there are wrong parts.
Option setting menu

[2. GEN-SET SETTING] --> [ 1. ENGINE TYPE ] : Engine fuel control type - ETS/ETR
[ 2. OPS MODE ]
: VAL, CONT, NONUSE
[ 3. WTS MODE ]
: VAL, CONT, NONUSE
[ 4. CT RATIO ]
: CT setting
[ 8. COM POWER ]
: How to detect power outage signal

- USED : Direct input of commercial electricity
- Input of outer signal(CNT socket)
[4. SPEED SENSOR SET] --> [1.SENSOR ] : Setting of generator speed sensor
- VOLT : Sensor of generator speed in generator voltage
- MPU : Sensor of generator speed in Magnet Pick Up
sensor
[5. PICK-UP SETTING] --> [ 1. GEAR NUMBER ] : Setting of the number of engine ring gear
10 Page
EGCON Co,. Ltd
9. Connection Socket and Capacity

Name of socket
Explanation
Formality
BP+, BP-
Input of control power supply
DC 8~35V , 15A
88x
Starter output
BP+ Voltage output, 15A on maximum
5x
pauseper output
23x
Preheating output
COM. Power R S T N
Input of commercial electricity
3P4W, 380/220Vac
GEN. Power R S T N
Input of generator power supply
3P4W, 380/220Vac
R-L, R-K
S-L, S-K
T-L, T-K
Input of L, K of R in generator
CT
Input of L, K of S in generator
CT
Input of L, K of T in generator
CT
5Aac
5Aac
5Aac
52TX-c, 52TX-a
ACB TRIP interface
Dry contect , AC250V, 15A (2sec)
52CX-c, 52CX-a
ACB CLOSE interface
Dry contect , AC250V, 15A (2sec)
86X-c, 86X-a
Fault indication interface
Dry contect , AC250V, 10A
6X-c, 6X-a
WTS
Engine operating indication

interface
Input of over-temperature
interface
Dry contect , AC250V, 10A

NORMAL OPEN , DC- Connection
OPS
Input of oil pressure switch
NORMAL CLOSE, DC- Connection
EPB
Input of emergency pause switch
OCGR
Input of overvoltage relay
AFR
Input of potential fault
52-ON, 52-OFF
Input of ACB blocking signal
DC- (Connection)
CNT
Automatic operation interface
MPU+, MPU-
Input of magnet pick-up(MPU)
Shield cable must be earthing.
OPU
Input of oil pressure sensor
Use of VDO oil pressure sensor
Input of coolant temperature
VDO and DongNam company, please
sensor
refer to standard
VDO and DongNam company, please
WTU
OTU
486+, 485-
Input of oil temperature sensor

Communication connecting
socket
Operation when connecting AUTO

Mode to DC
refer to standard
Shield cable must be earthing.
- CT L socket ( R-L, S-L, T-L) is connected. For separate use, please use after opening case.
11 Page
EGCON Co,. Ltd
10. Signals and Marks

l GCU : GENERATOR CONTROL UNIT
l ETS : How to supply power supply to solenoid when
pauseping
l ETR : How to supply power supply to solenoid when
operating
l 86X
: Fault indicating relay
l 6X
: Operation indicating relay
l 23X
: Preheating relay
: Operation motor
l PS
: Pinion Solenoid
l 88
: Operation assistance magnet
l RPM : Rotating speed system

l 5S
: pause Solenoid
l 88X
: Operation output relay
l EPB : Emergency pause button

l OPU : Oil pressure sensor
l OTU : Oil temperature sensor
l 52G : ACB
l SM
l MPU : MAGNETIC PICKUP
l WTU : Water Temperature Sensor

l OPS : Oil pressure switch
l WTS : Water temperature switch
l IDLE SPEED : The lowest speed of engine without

assistance of engine operation motor
11. Manual Operation

11.1. Use of operation mode setting button, setting operation mode to <MNU>(manual mode)
11.2. Pressing operation button to operate engine
(1) Please check engine stopping method in case that only motor operates and engines does not operate.
(2) When engine is in operation, please press RPM and there will be an indication of oil pressure
measurement in OPG(For use of OPS, indication will be OPG: OFF)
(3) When actual engine speed and RPM are different, please insert measurement correctly in <5. PICK-UP
SETTING> of option setting after pausing engine.(The number of ring gear is different according to
engine manufacturing company.)
(4) Starter motor circuit is blocked in over IDLE SPEED.
(5) When starting engine, starter output is blocked as oil pressure switch operates without input of IDLE
SPEED after OST time.
(6) RUN lamp is lighted and 6X operates after operation of engine and input of IDLE SPEED signal.
(7) When oil pressure switch of OFT time is not open in IDLE SPEED, engine will pause after detection of
low voltage.
(8) When signal for engine rotating speed and oil pressure switch are not open, starter output is blocked
after 7 seconds of starter output.
(9) When oil pressure switch operates without IDLE SPEED signal, output of starter motor is
11.3. Engine pause
(1) Engine is paused when pressing pause button or setting MODE to OFF by pressing operation mode.
(2) In normal operation of engine, engine is paused when pressing EPB or engine protective circuit or
generator protective circuit(OVR) operates.
12 Page
EGCON Co,. Ltd
12. Automatic operation

12.1. Setting operation mode to <ATO>
12.2. When commercial electricity is in outage, engine operates after SDT time.
12.3. When commercial electricity is in outage and it is returned, engine does not start and SDT time
initializes.
12.4. When electricity is in outage, there comes output of battery "+" in 23X and it is blocked in over IDLE
SPEED.
12.5. When starter output operates and it can not reach to IDLE SPEED, engine fault will be detected and
it will pause after GCU pauses 3 times for 7 seconds.
12.6. When starter output operates and oil pressure switch is open, starter output will be blocked after OST
time.
12.7. When engine is in normal operation, RUN LAMP will be in outage.
12.8. When there is normal detection of generator power supply, ACB will be input after waiting time.
12.9. When commercial electricity is returned in normal operation of engine, engine will pause after blocking
ACB, preparing for re-outage in CDT time and cooling engine.
12.10. When commercial electricity is in outage in CDT operation, there will be input of ACB and initialization
of CTD immediately.
13. Remote Operation

13.1. Please connect 485 link line.
13.2. Please select <R-M> in operation mode.
13.3. All operations are possible in computer except in GCU.
14. Protection Control Drive test of Engine Generator

14.1. Movement when fault and alarm operate(When protection equipment is operating, RESET after pressing
buzzer pause.)
Detected items
overspeed, low-voltage, over-temperature,
operation failure
Overvoltage, voltage unbalance, low and high
frequency
EPB
low-voltage, over-current, current unbalance,
OCGR, AFR
Over-temperature alarm, low-voltage alarm,
low and over-voltage battery
Engine pause
86X, BUZZER
BASE : GEN STOP

(Selectable)
GEN RUN (Selectable)
14.2. EPB ( EMERGENCY PUSH BUTTOM ) Emergency pause test

(1) Confirmation of engine operation, RUN LAMP lighting of GCU, and normal RPM.
(2) Press EPB
(3) GEN FLT LAMP lights, alarm sounds, and engine pauses.
(4) Press buzzer pause, unfasten EPB, and press RESET.
13 Page
EGCON Co,. Ltd
* * * E R R O R _ _ M E S S A G E * * * - Screen when input of EPB
- Indication that pressing HORN RESET button

H O E N
E P B
E R R O R
R S E S T
P R E S S
* * * E R R O R _ _ ME S S A G E * * *
- Transferring to start-up screen after pressing FAULT

RESET button.
E P B
E R R O R
F A U L T
R S E S T
P R E S S
14.3. Over speed test( OVER SPEED )

Detective measurement of overspeed has to be changed and tested that overspeed test is dangerous
when increasing the number of engine rotating.
Default of OVER SPEED SETTING in [ 7. OVERSPEED ] of SETTING MANU [ 6. GEN-PROTECTIVE
SET ] is 2150RPM and if changing the Default to 1800RPM, then GCU will be recognized as overspeed.
Therefore it is necessary to return 1800RPM to the Default after test.
Test operates through pressing overspeed test switch.(Pressing more than a second)
(1) Operate engine.
(2) Confirm RUN Lamp lighting and RPM of ECU.
(3) Recognizing overspeed, lighting GEN FLT Lamp after setting time, sounding alarm, and pausing
engine.
(4) LCD Screen indicates OVER SPEED ERROR_MESSAGE.
(5) When pressing buzzer and resetting, it will return to normal state.
14.4. Low Oil Pressure Test
(1) When oil pressure switch operates after engine starting, output of starter motor becomes blocked and
when oil pressure switch is closed, pause output of ETS TYPE becomes blocked.
(2) Setting to oil pressure switch.
1) Start engine.
2) Confirm RUN LAMP lighting and RPM of ECU.
3) Interface OPS socket.
4) Lighting GEN FLT Lamp after setting time, sounding alarm, and pausing engine.
5) LCD Screen indicates OPS ERROR_MESSAGE.
6) Reset after pressing buzzer pause button.
7) Setting to oil pressure sensor.
8) Start engine.
9) Confirm RUN LAMP lighting and RPM of GCU.
10) Interface or open OPU socket.
12) LCD Screen indicates OPS ERROR_MESSAGE.
14.5. HIGH WATER TEMPERATURE Test. ( WTS )
(1) Setting to over-temperature switch
1) Start engine.
3) Interface WTS socket.
5) LCD Screen indicates WTS ERROR_MESSAGE.
14 Page
EGCON Co,. Ltd

(2) Setting to temperatrue sensor.
1) Start engine.
3) Interface or open WTU socket.
5) LCD Screen indicates WTS ERROR_MESSAGE.
14.6. START Fail Teat . ( OVER CRANKING )
1) This changes mode automatically and let engine not operate.
2) This unlights commercial electricity or interface CNT socket.
3) Starter output after SDT time.
4) Lighting of OCL Lamp and buzzer alarm after 3 times of 7-second start and 7-second pause.
5) LCD Screen indicates OVER CRANK ERROR_MESSAGE.
7) Deleting all things that let engine not operate and returning to normal state.
14.7. Other tests for fault are similar as above.
15. Modification of Option Setting

15.1. Setting to option setting mode
(1)
(2)
(3)
(4)
(5)
< O F
R - S
R
H z
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
S
> . T I M
2 . G E N
3 . G E N
E T T I N
E
S E T
- S E T
- P R O T
G
T
S
E
>
5
6
7
.
.
.
.
S
P
P
P
P
I
A
-
E
C
S
R
E
K
S
E
D
S E N S O
- U P
S E T
WO R D
S E
L A Y
E R R
>
9
1
1
.
.
0
1
S
P
.
.
E
R
A
R
N
O
C
S
S
T
B
4
O
E
&
8
R
S E
C T
S
A T S
5
S E
> 2 . R e l a y
1 3 . F a u l t
T O
R - M
: 0 0 0 0
:
O N
:
O F F
S
I N G
E T T I N G
C T I V E
S E T
R
S E T
T I N G
T T I N G
O R
T Y P E
L E C T
E T T I N G
MO D E
S E T
T
O u t p u t
S e t
H i s t o r y
1. Press <PAGE> in <OFF> mode.

2. Transferring to <SETTING>.
3. <PAGE> is possible only in <OFF> mode.
1. Cursor(>) indicates <TIME SETTING>.

2. Pressing <ENTER> to enter time setting.
3. Pressing <DOWN> to transfer to <2.GEN-SET
SETTING>.
1. A cursor indicates item 4.

2. Pressing <UP> transfers to above item.
3. Pressing <DOWN> transfers to below item.
1. A cursor indicates item 8.

2. Pressing <UP> transfers to above item.
3. Pressing <DOWN> transfers to below item.
1. This is the last page.
2. Items of options settings are all 12 and it is
impossible to do option setting when generator
is in operation.
15 Page
EGCON Co,. Ltd
15.2. After setting value of option, setting value of <GEN-SET SETTING> appears and method to set is all
same.
(1)
< O F
R - S
R
H z
(2)
S E T
> . T I ME
2 . G E N - S
3 . G E N - P
(3)
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
S
1 . T I M
> . G E N
3 . G E N
T
S
E
R
T
:
:
:
O
R - M
0 0 0 0
N O N U S E
N O N U S E
I N G S
E T T I N G
T
S E T T I N G
O T E C T I V E
S E T
E T T I N
E
S E T
- S E T
- P R O T
G
T
S
E
S
I N G
E T T I N G
C T I V E
S E T
(4)
2 . G
> . E N
2 . O P
3 . WT
E N
S E
G I N E
S
MO D
S
MO D
T
S E T T
T Y P E :
E :
N O N
E :
N O N
I
E
U
U
N
T
S
S
G
R
E
E
(5)
2 . G
1 . E N
> . O P
3 . WT
E N
S E
G I N E
S
MO D
S
MO D
T
S E T T
T Y P E :
E :
N O N
E :
N O N
I
E
U
U
N
T
S
S
G
R
E
E
(6)
2
1 .
2 .
3 .
.
E
O
W
G
N
P
T
E N
S E
G I N E
S
MO D
S
MO D
T
S E T T
T Y P E :
E :
N O N
E :
N O N
I
E
U
U
N
T
S
S
G
R
E
E
2
1 .
2 .
3 .
.
E
O
W
G
N
P
T
E N
S E
G I N E
S
MO D
S
MO D
T
S E T T
T Y P E :
E :
C O N
E :
N O N
I N G
E T R
T
U S E
(8)
2 . G
1 . E N
> . O P
3 . WT
E N
S E
G I N E
S
MO D
S
MO D
T
S E T T
T Y P E :
E :
C O N
E :
N O N
I N G
E T R
T
U S E
(9)
S E T
1 . T I ME
> . G E N - S
3 . G E N - P
(7)
T
S
E
R
Pressing < PAGE > in < OFF > transfers to

<SETTINGS> mode.
1. Cursor(>) indicates <TIME SETTING>.

2. Pressing <DOWN> to transfer to <2.GEN-SET
SETTING>.
1. Pressing <ENTER> transfers to detailed item of

<GEN-SET SETTING>.
2. The number of detailed items of <GEN-SET
SETTING> is 8.
1. Pressing <DOWN> transfers to <2.OPS MODE>.
1. Pressing <ENTER> lets a cursor locate in front

of setting value.
1. Black and square-shaped cursor locates in front

of setting value.
2. Pressing <UP> or <DOWN> changes setting
value..
1. This is a screen that value is changed to
<CONT>.
2. Pressing <ENTER> saves the value.
3. A cursor locates at the front of item.
1. Pressing <UP> or <DOWN> here may transfer to

another item.
I N G S
E T T I N G
T
S E T T I N G
O T E C T I V E
S E T
1. Pressing <PAGE> to transfer to above item.

2. This is the transferred screen to the above item.
3. Pressing <PAGE> exits option setting.
16 Page
(10)
< O F
R - S
R
H z
F
:
:
:
>
MN U
A
0 0 0 V
R P M
0 0 0 A
O P G
0 0 . 0
WT G
EGCON Co,. Ltd
T O
R - M
: 0 0 0 0
:
O N
: N O N U S E
1. This is the returned screen of measurement

screen after exiting option setting.
15.3. Password input when setting <PowerON_PW> to <USE>.
(1)
(2)
G C U - D G
C O N T R
V E R
0 .
E G C O N
C O .
G E N .
3
O L
UN I T
9 2
,
L T D .
- - P A S S WO R D - _ _ _ _
E n t e r
k e y
P r e s s.
1. Inputting DC power supply makes a brief buzzer

sound, indicates on left screen for 5 seconds,
and transfers to next screen.
1. For <PowerON_PW> is set to <USE>, there will

be a screen for password.
. .
2. Pressing <ENTER> lets a cursor locate at the

first box for insertion.
(3)
- - P A S S WO R D - _ _ _
E N T E R
k e y
P r e s s .
1. This is the screen that a cursor locates at the

first box.
. .
2. Pressing <UP> or <DOWN> to insert numbers.

3. Pressing <ENTER> transfers to next box.
(4)
(5)
(6)
- - P A S S WO R D - 1 1 1 4
E n t e r
k e y
P r e s s.
1. After filling all numbers, press <ENTER> to

. .
transfer to the start-up screen.
- - P A S S WO R D - 1 1 1 4
F A I L
P r e s s
E N T ER . .
.
1. If password is wrong, there will be a message
- - P A S S WO R D - _ _ _
E N T E R
k e y
P r e s s .
1. Press <ENTER> to insert numbers again.

. .
of <FAIL Press ENTER> as left, but screen does

not transfers to the start-up.
2. Inserted password become deleted and the

cursor will locate at the first box.
15.4. How to insert password when setting <Setting_PW> to <USE> is same as above. However, if pressing
<PAGE> when inserting wrong password transfers to start-up screen.
17 Page
EGCON Co,. Ltd
16. SETPOINT
16.1. TIME SETTING
NO.
Menu
Explanation
Range
Default
SDT
Waiting time for starting
0~60sec
3 sec
CDT
0~60min
5 sec
OST
Waiting time for pausing

Blocking time of starting output after pressing oil
0~60sec
5 sec
OFT
pressure switch
Waiting time for detection of oil pressure
0~60sec
5 sec
UDT
Waiting time for detection of low-voltage
0~60sec
5 sec
STOP
Output time for ETS-typed pause
0~60sec
5 sec
MAX CRK_T
Starting output time
0~60sec
7 sec
ACB OPEN_T
Waiting time for ACB blocking in automatic mode
0~60sec
5 sec
ACB CLOSE_T
Waiting time for ACB input in automatic mode
0~60sec
5 sec
10
B_LED ON
Unlight time after lighting LCD backlight
0~60min
2 min
11
BZ STOP_T
Blocking time of alarm sound
0~60min
2 min
16.2. GEN-SET SETTING

NO.
Menu
Explanations and setting scopes
Default
ETR : A type that engine operates when power supplies to

1
ENGINE TYPE
oil solenoid.
ETS : A type that engine pauses when power supplies to
ETR
oil solenoid.
2
OPS MODE
SWITCH
: Switch use with fault detecting type
(Detection of oil
SENSER
: Sensor use with
pressure)
NONUSE : Not using fault detecting type
WTS MODE
3
(Detection of
water
temperature)
fault detecting type
SWITCH
: Switch use with fault detecting type
SENSER
: Sensor use with
fault detecting type
NONUSE : Not using fault detecting type
NONUSE
NONUSE
CT RATIO
CT ratio setting (5/5A~5000/5A)
50/5A
START RPM
RPM setting for starting output (400~800RPM)
600RPM
START OIL_P
Setting of oil pressure of starting output (3~6bar)
3.0bar
COM UVR
Voltage setting of commercial power
170V
COM POWER
outage checking
USED : Checking commercial power outage with outage

signal
USED
NONUSE : Using outage signal as input of CNT socket
18 Page
EGCON Co,. Ltd
16.3. GEN-PROTECTIVE SET

NO.
Menu
GEN UVR
OPE. UVR
GEN OVR
OPE. OVR
GEN OCR
OPE. OCR
OVER SPEED
OPE SPEED
Wrn OIL_P
10
Explanations
Detective setting of low-voltage
Setting Scope
Default Value
70~ 220 Vac
180.0 Vac
0 ~ 59 sec
5 sec
100~ 300 Vac
235.0 Vac
0 ~ 59 sec
1 sec
2.0 ~ 8.0
5 A
0 ~ 59 sec
5 sec
1000~2500 RPM
2150
0 ~ 59 sec
0 sec
Setting of low-oil alarm
1.0 ~ 9.9 bar
3.0 bar
Err OIL_P
Setting of low-oil fault
1.0 ~ 9.9 bar
1.5 bar
11
OPE OIL_P
Waiting time for low-oil fault
0 ~ 59 sec
1 sec
12
Wrn WATER
Setting of over-temperature alarm
40 ~ 110
90
13
Err WATER
40 ~ 110
100
14
OPE WATER
0 ~ 59 sec
5 sec
15
HIGH BATT
Setting of battery overvoltage
20 ~ 40 Vdc
30 Vdc
16
LOW BATT
Setting of battery low-voltage
08 ~ 25 Vdc
08 Vdc
17
OPE BATT
0 ~ 59 sec
5 sec
18
CURR UNBAL
10 ~ 99 %
30 %
19
OPE C_UNBAL
0 ~ 59 sec
5 sec
20
VOLT UNBAL
10 ~ 99 %
30 %
21
OPE V_UNBAL
0 ~ 59 sec
5 sec
22
Gen Freq MAX
Setting of over-frequency detection
50 ~70 Hz
70 Hz
23
Gen Freq MIN
Setting of low-frequency detection
45 ~ 60 Hz
45 Hz
24
OPE Freq
0 ~ 59 sec
5 sec
Waiting time for low-voltage

detection
Setting of over-voltage detection
Waiting time for over-voltage
detection
Setting of over-current detection
Waiting time for over-current
detection
Setting of overspeed
Waiting time for overspeed
detection
Setting of over-temperature
detection
Waiting time for over-temperature
detection
Waiting time for battery overvoltage

and low-voltage detections
Setting of detective scope of
current unbalance
Waiting time for detection of
current unbalance
Setting of detective scope of
voltage unbalance
Waiting time for detection of
voltage unbalance
Waiting time for over-frequency

and low-frequency detection
19 Page
EGCON Co,. Ltd
16.4. SPEED SENSOR SET

NO.
Menu
Explanation
Default
VOLT : Speed sensor in generator

1
SENSOR
voltage
VOLT
MPU : Speed sensor in Magnet

PickUp
DISPLAY
Indicative unit for rotating speed
(RPM) Presently not used
16.5. PICK-UP SETTING

NO.
Menu
Explanation
Setting Scope
Default
The number of MAGNET PICK-UP

1
GEAR NUMBER
SENSOR per rotating of generator(The
0~ 255 EA
121 EA
number of ring gear)
16.6. PASSWORD SETTING

NO.
Menu
Setting_PW
PowerON_PW
Explanations and Setting Scope

USE
: Using password in option setting
NONUSED : Not Using password in option setting
Default
NONUSED
USE : Using password at the first start-up

(All operations are useless if not knowing password)
NONUSED
NONUSED : All operations are possible without password

3
4
Password
_ _ _ _ : Changing password with pressing [DOWN]
VALUE
Yes : Initializing all values of option setting
DEFAULT
NO : Not initializing all values of option setting
1111
NO
16.7. P-RELAY ERROR TYPE

NO.
Menu
Contents
Selection of
TYPE
using relay
functions
Explanations and Setting Scope

INT. VAL - Using relay functions such as INT. VAL - UVR, OVR,
OCR
NONUSE - Not Using relay functions(only for detection of fault)
Default : (INT. VAL)
20 Page
EGCON Co,. Ltd
16.8. SENSOR SELECT

NO.
Menu
Explanation
Setting Scope
Default
OP MODEL
Selection of oil pressure sensor
VDO
VDO
WT MODEL
Selection of water temperature sensor
VDO, DONGNAM
DONGNAM
OT MODEL
Selection of oil temperature sensor
VDO, DONGNAM
DONGNAM
OP CALIB
-4.0 ~ 4.0bar
0.0bar
-40 ~ 40
0.0
l Revision of oil pressure sensor value

l Value revision when using VDO sensor: unit
is 0.3bar
l Revision of water temperature sensor value
l Value revision when using VDO sensor: unit
5
WT CALIB
is 3C
l Value revision when using DONGNAM
sensor: unit is 5C
16.9. PROTECT SETTING

NO.
Menu
Detection
Setting Value
Overspeed, over oil, over

temperature, start failure,
GEN RUN, GEN STOP
Default
BASE
UVR
Detection of low-voltage
GEN RUN, GEN STOP
GEN RUN
OCR
Detection of over-current
GEN RUN, GEN STOP
GEN RUN
OCGR
Detection of over-current
GEN RUN, GEN STOP
GEN RUN
AFR
GEN RUN, GEN STOP
GEN RUN
CURR UN
USED , NONUSE
USED
overvoltage
Detection of preliminary
fault input
Detection of current
unbalance
(3 )
GEN STOP
16.10. ACB & ATS MODE SET

NO.
1
Menu
Setting Scope
ACB & ATS MODE SET
ACB , ATS , NONUSE , MCCB TRIP
Default
ACB
16.11. RS485 SET

NO.
Menu
Setting Scope
Default
ADDRESS
Setting of communication address (1 ~ 16)
BAUD RATE
9600bps
9600bps
RS485 CK
No : RS485 TEST nonuse

YES : RS485 TEST on - LCD indicate
21 Page
NO
EGCON Co,. Ltd
16.12. Relay Output Set

NO.
Menu
Setting Scope
Default
1.
RO1
Output setting of indication relay for actual state
63QX
2.
RO2
26WX
3.
RO3
12X
4.
RO4
48X
5.
RO5
59X
6.
RO6
27GX
7.
RO7
51X
8.
RO8
51GX
Setting lists and explanations

NO.
Indication
Explanation
63QX
Operation in fault of low oil
26WX
Operation in fault of over temperature
12X
Operation in fault of overspeed
48X
Operation in fault of automatic mode start
59X
Operation in fault of overvoltage
27GX
Operation in fault of low voltage
51X
Operation in fault of over current
51GX
Operation in fault of over current
88X
Operation in starting output
5X
Operation in pausing output
5EX
Operation in fault of emergency pause
51CX
Operation in blocking input
51TX
Operation in blocking input
23X
Operation in preheating output
AFX
Operation in preliminary fault input
27C
Operation in normal commercial electricity
84G
Operation in normal generating power supply
86X
Operation in fault output of generator
14X
Operation in above IDLE SPEED of generator
13X
Operation in above SYNCHRO SPEED of generator
L-M
Operation when movement is manual mode.
L-A
Operation when movement is automatic mode.
R-M
Operation when remote control is manual mode.
R-A
Operation when remote control is automatic mode.
OFF
Operation when movement mode is OFF.
22 Page
Other
EGCON Co,. Ltd
16.13. Fault History
1
1
2
3
3
:
:
:
1
7
8
9
.
5
5
1
F
9
1
2
a u l t
X
E r
X
E r
X
E r
H i
4
5
6
s t o r y
:
:
:
3 . F a u l t
:
:
:
H
1
1
1
i
0
1
2
s t o r y
:
:
:
1 3 . F a u l t
1 3 :
1 4 :
1 5 :
H
1
1
1
i
6
7
8
s t o r y
:
:
:
- Fault History
NO.
Indication
Explanation
12X Er
Fault of generator's overspeed
63Q_Er
Fault of generator's low oil
63Q_Wa
Alarm of generator's low oil
Other
Open of generator's oil sensor

4
63Q_Op
(In case that it can not detect oil sensor in the process of
generator operation. )
26W_Er
Fault of generator's over temperature
26W_Wa
Alarm of generator's over temperature
26W_Op
Open of generator's temperature sensor

(In case that it can not detect oil sensor in the process of
generator operation. )
8
48X Er
Operation failure in automatic mode
59X Er
Fault of generator's overvoltage
10
27X Er
Fault of generator's low voltage
11
51X Er
Fault of generator's over current
12
59X_Un
Fault of generator's voltage unbalance
13
51X_Un
Fault of generator's current unbalance
14
OCGR Er
Fault of over current
15
AFR Er
Detection of preliminary fault
16
EPB Er
Detection of emergency pause input
17
Low Bat
Fault of battery's low voltage
18
High Bat
Fault of battery's overvoltage
19
UFR Er
Fault of generator's low frequency
20
OFR Er
Fault of generator's over frequency
23 Page
EGCON Co,. Ltd
17. Specification table of GCU-DG3 Compatibility Gauge Sensor

VDO OPU
psi
Resisting
bar
0
15
30
45
60
75
90
105
120
135
150
165
175
190
205
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Dong Nam - WTU

temperature
Resistance
value()
10.00
27.00
44.00
61.00
78.00
95.00
112.00
129.00
146.00
163.00
180.00
197.00
208.33
225.33
242.33
()
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
VDO - WTU
temperature( Resistance
()
170.00
135.00
110.00
92.00
78.00
66.00
56.00
47.00
41.00
35.00
32.00
28.03
24.05
20.08
16.10
12.10
8.10
4.10
0.10
)
38
40
46
51
54
60
65
71
76
79
85
90
96
98
104
110
115
118
121
()
240.00
226.75
200.25
173.75
160.50
134.00
114.00
94.00
78.00
70.00
60.50
51.00
45.00
42.00
36.00
30.00
24.00
21.00
18.00
18. The Number of Major Engine Ring Gear

Manufacturing
of engine
JOHN DEERE
PERKINS
DOOSAN
INFRACORE
(Daewoo
Heavy
Industries)
Engine Model
3179D
4039D
6059T
6059TA
2006TWG2
2006TG2A
2006TTAG
C2240
DC24
DB33
DB58
DB33
P034TI
DB58
D1146(T)
P86TI
2156
2366
DE12T
P126TI
D2848L,(E)
D2842L,(E)
D2840L,(E)
P158LE
P180LE
P222LE
Ring Gear
Manufacturing
Engine
Ring Gear
teeth
142
142
129
129
158
158
175
108
108
122
122
129
129
129
146
146
146
146
152
152
160
160
160
160
160
160
of engine
Model
D399
DG399
G298
D379
G379
G342
DB58
0846
D349
D348
D346
D34
3306
DE12T(I)
G333
D2840L,(E)
3406
3409
3412
NT855G6
L10
6BT56G
4BT39G
KT19G
KT50
D6AZ
D6BR
teeth
183
183
183
183
183
151
123
156
151
151
151
152
156
152
156
160
113
113
136
118
118
159
159
142
159
143
129
CATERPILLAR
CUMMINS
HYUNDAI
24 Page
EGCON Co,. Ltd
19. Failure Causes and Measures

Statue
Power supply is not
working(Nothing can be
seen on LCD).
Cause
DC blocker opens.
DC fuse disconnects.
Wrong connection of wiring
Battery discharges.
Battery discharges.
Start-up is not
working(Starting motor is
not rotating).
Start-up is not
working(Starting motor is
rotating).
Start-up is not
working(Start-up works,
but it is turned off soon)
OPG alarm sounds when

turning on power supply.
The rotating number of

generator is not correct.
Generator is operating,
but GEN. RUN LAMP is
not working.
Power value is not

correct.
Indication of power factor
is not normal.
Even though commercial
power supply is in outage,
automatic operation of
generator is not working.
No input of ACB
Fault of starting assistance

magnet
Fault of starting motor
Wiring is not connected or
wrongly connected.
Fault of preheating plug
Wrong setting of engine type
in option setting
Wrong PICK-UP Setting in
option setting
Wiring of OPG is not
connected or wrongly
connected.
Wiring of OPG is not
connected.
Wrong setting of OPS MODE
in option setting
Not using proper sensor
Wrong PICK-UP Setting in
option setting
Wiring of PICK-UP is not
connected.
Wiring of GEN.VOLT is not
connected.
Wrong CT RATIO Setting in
option setting
Generator voltage input and
CT input are different.
Second wiring of CT is
wrongly connected.
Soultions
Close DC blocker.
Change to new fuse of same capacity.
Correct wiring through referring circuit
diagram.
Use after charging battery more than 5
hours.
Use after charging battery more than 5
hours.
Use after changing start
Use after changing start motor.
diagram.
Use after changing preheating plug.
Select ETR and ETS correctly after
inquiring of engine manufacturing
company.
Inserting the number ring gear correctly
after inquiring of engine manufacturing
company.
diagram.
diagram.
Set OPS MODE correctly.
For OPU, use product of VDO company.
Inserting the number ring gear correctly
after inquiring of engine manufacturing
company.
diagram.
diagram.
Insert the number of used CT correctly.
diagram.
Correct wiring with drawing after
confirming polarity of CT.
Wrong COM POWER Setting

in option setting

diagram.
The value of generator

voltage is lower than the
value of UVR setting.
Make generator voltage normal through

adjusting AVR.
25 Page

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What is the purpose of the manual?

What is the purpose of the manual?

What components does the GCU-DG3 control?

What components does the GCU-DG3 control?

GCU-DG3

A manual of Generator Control Unit

GCU (GENERATOR CONTROL UNIT)

EGCON Co., Ltd

GCU -DG3 User's Guide

EGCON Co,. Ltd

Cautions For Safety

potential injury or death may

damage may arise in case

that violates instructions

4. Meanings of picture signals indicated in the manual are as follow.

5. Please keep the manual close to product.

1. Please permit a regular power supply to product to prevent product

GCU -DG3 User's Guide

EGCON Co,. Ltd

3. Capacity and function

(Line to line Voltage)

(Phase to phase Voltage)

kVAR (Reactive power)

(Rated apparent power)

(Quantity of active power)

kVARh (Quantity of Reactive power)

GCU -DG3 User's Guide

EGCON Co,. Ltd

4.5. Maximum Operating Altitude: 3,000m

4.2. Storage Temperature: -24 ~ 45C

4.6. Maximum Storage Altitude: 4,500m

5. Functions of Control Switch

GCU -DG3 User's Guide

EGCON Co,. Ltd

(1) Operation Control Switch

(2) Controling switch for setting change

Switch for turning to the left in

Increasing change of setting, Changing

<OFF> - <MNU> - <ATO> - <R-M>

Decreasing change of setting,

Changing in operation mode

<OFF> - <MNU> - <ATO> - <R-M>

Only in <OFF> Mode, transferring to

Generator pause switch in MNU(manual

Save after setting change

Buzzer pause switch when detecting

(3) ACB Control Switch

Fault: lighting when commercial

electricity is abnormal, Normal:

ACB block indicating lamp

lighting when commercial electricity

Blocking ACB in MNU(manual mode),

is in operation, Fault: lighting when

ACB block indicating lamp, input is

there detecting all sorts of faults.

impossible when operation voltage is

Remote: lighting when selecting

remote operation mode(GCU control

GCU -DG3 User's Guide