Synchronization and load sharing module

Technical documentation

CRE technology believes that all information provided herein is correct and reliable and reserves the right to update at
any time. CRE Technology does not assume any responsibility for its use unless otherwise expressly undertaken.
CRE technology
Allée Charles-Victor Naudin - Zone des Templiers - Sophia Antipolis
06410 BIOT - FRANCE
Téléphone : + 33 (0)4.92.38.86.82 - Fax : + 33 (0)4.92.38.86.83
www.cretechnology.com [email protected]
SARL au Capital de 300.000 Euros
RCS Antibes : 7488 625 000 15 - N°TVA FR54 488 625 583
 Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property
propert damage.
Contact your CRE dealer for course training.

History:
VERSION DATE MODIFICATION
A initial document Initial
nitial document
B March 2007 New PCB and Embedded software
C November 2007 Administrative
dministrative update
D December 2008 Neutral
eutral in wiring diagram (three phase with neutral)
G December 2009 MODBUS modification
m
H February 2010 Connection to EFC speed regulator
Firmware v1.28 :
• 500Hz PWM speed output.
I May 2010 • MODBUS Read/Write functions.
• External
E speed potentiometer features.
• External
E synchronization input features.
Commissioning tips for small generating sets (below
( 200kW).
J February 2011
Description
escription of the automatic load/unload feature (using CAN bus load sharing).

Documentation List:
A51Z090004 : Technical documentation for UNIGEN
U PLUS and Industrial UNIGEN
NIGEN.
A51Z190104 : Application note : GCR/UNIGEN
GCR/ PLUS,, wiring mains synchronisation.
synchronisation
A51Z090100 : Application note : Generating set auto synchroniser and load sharer.
sharer
A51Z190101 : Application note : Load shedding.
shedding
A51Z190102 : Application note : Paralleling lines wiring for Carantec/UNIGEN
Carantec/UNIGEN PLUS.
A51Z190103 : Application note : Replacement of a Pow-R-Con ‘DYN2-94026’94026’ by a UNIGEN
U PLUS.
A51Z180006 : Application note : Procedure to download the complete firmware of a UNIGEN
U PLUS.
A51Z290001 : Application note : Moving generators.
A51Z090202 : Application pictures.
pictures
A51Z090030 : Complete variable list with label, units and limits.
limits

A51Z1 UNIGEN PLUS

A51Z0 MPS 5.0

A51Z2 UNIGEN Industrial

Industria

2/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 Contents

History: ................................................................................................................................................................................................2

Documentation List: ............................................................................................................................................................................2

1. Overview ......................................................................................................................................................................................4
1.1. UNIGEN front cover ............................................................................................................................................................4
1.2. Global functions ...................................................................................................................................................................5
2. Features .......................................................................................................................................................................................6
2.1. Synch check relay .................................................................................................................................................................6
2.2. Reverse kW relay .................................................................................................................................................................7
2.3. kW Indicator .........................................................................................................................................................................7
2.4. Remote speed control input ..................................................................................................................................................7
2.5. PWM 500Hz (A51M141 modules only) ..............................................................................................................................8
2.6. Isochronous load sharing (UNIGEN PLUS) using parallel lines .........................................................................................8
2.7. CAN load sharing .................................................................................................................................................................9
2.7.1. Plug’n’play CAN protocol ............................................................................................................................................9
2.7.2. Automatic load/unload request .....................................................................................................................................9
2.8. Load sharing .......................................................................................................................................................................10
2.8.1. Ramps .........................................................................................................................................................................10
2.8.2. Automatic TRIP OUT .................................................................................................................................................10
2.8.3. Manual load/unload request.......................................................................................................................................11
2.9. DROOP load sharing ..........................................................................................................................................................11
2.10. COMMAND MODE (UNIGEN PLUS) ........................................................................................................................11
2.11. MAINS PARALLELED (UNIGEN PLUS) ...................................................................................................................11
2.12. Modbus (UNIGEN PLUS) .............................................................................................................................................13
3. Settings .......................................................................................................................................................................................15

4. Display .......................................................................................................................................................................................16

5. Terminals ...................................................................................................................................................................................17
5.1. Terminals description .........................................................................................................................................................17
5.2. Wiring diagram...................................................................................................................................................................19
5.3. Connection specifications ...................................................................................................................................................19
6. Risk ............................................................................................................................................................................................20
6.1. Caution ...............................................................................................................................................................................20
6.1.1. Grounding: .................................................................................................................................................................20
6.1.2 Wiring rules:...............................................................................................................................................................20
6.1.3 Vibrations: ..................................................................................................................................................................20
6.2. Power plant start-up/Commissioning .................................................................................................................................21
Environment ......................................................................................................................................................................................24

Dimensions ........................................................................................................................................................................................24

3/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

1. Overview
1.1. UNIGEN front cover
Each terminals of the industrial UNIGEN are also available on UNIGEN PLUS.

Only for UNIGEN PLUS: this symbol is used in technical documentation to indicate UNIGEN PLUS special features.

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1.2. Global functions
The main functions performed by the UNIGEN are followings :
• Automatic and Manual synchronization (cf. SW5 et SW6 configuration).
• Active load sharing in isochronous, droop mode or Command mode (UNIGEN PLUS only).
• Reactive load sharing in isochronous voltage, droop mode or power factor fixed (UNIGEN PLUS only).
• Compatibility with all speed governors (cf. SW2 configuration) and AVR on the market.
• Remote speed control by potentiometer (cf. SW7 configuration).
• Internal synch check relays, useful for auto and manual synchronization.
• Phase sequence protection.
• Load sharing with CAN plug and play (cf.SW1 configuration) or with paralleling lines (UNIGEN PLUS
only, cf. SW3 configuration).
• Automatic load/unload.
• Reverse kW relays.
• 2 analogue outputs (0…5V et 0…20mA/4…20mA) for kW meter (cf. SW4 configuration).
• MODBUS RTU on serial port RS485 (UNIGEN PLUS only, cf. SW8 configuration).
• Command mode (Unigen Plus only).
• Mains Paralleled (UNIGEN PLUS only).

5/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

2. Features
2.1. Synch check relay
SYNC_OK output (terminals 34/35) permit the coupling of generators when all following conditions are correct:
correct
• Voltage of generator and bus bar within a 15 - 130% window from nominal voltage (500V).
(500V)
• Voltage difference between generator and bus bar, < 10%.
• Frequency of generator and bus bar within a 30 - 130% window from nominal frequency.
frequency
• Phase Angle difference between generator and bus bar. <+/- 10°.
• Frequency difference between generator and bus bar, < 0.01Hz.
0
• Phase sequence correct.

SW5 switch allow or not the coupling when SYNC_IN logical input (terminal 3) is active.
SW6 switch allow or not the coupling on dead busbar.
SYNC_OK relay behave like on the following board:
board

Logical inputs Configuration Electrical conditions

onditions Relay

∆φ,, ∆Hz, ∆V SYNCH_OK

BREAKER_IN SYNC_IN SW5 Deadbus
SW6 and phase (Terminals
(Terminal 5) (Terminal 3) Synchronization (No voltage on
Dead BusBar sequence 34/35)
(manual/auto) bus)

OFF X X NOK open

Active X X NO OK close
(connected
to 0VDC)
ON X YES NOK close
ON X NO NOK open
Inactive X OFF X X open
(not connected)
OFF ON X NOK open
Inactive X ON NO OK close
(not connected)
ON ON YES NOK close
ON ON NO NOK open
X: No matter.

NOTE :
Since firmware v1.28, SYNC_IN input is activated only if voltages (Genset and BusBar/Mains)
BusBar/Mains are greater than 80% of
nominal frequency. This setting can be changed using parameter E01226.

At start, on deadbus, there is a delay before closing the ‘SYNC

‘ OK’ relay (E01033, default value is 3.0s).

CAUTION :
One generator has to be started alone to close on the dead
bus before starting the other generators.
generators

The ‘SYNC OK’’ green LED confirms the activation of the relay:
relay
• LED ON = contact closed..
• LED OFF = contact open.

6/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 2.2. Reverse kW relay
UNIGEN includes a reverse kW relays, terminal 9 & 10. This relay output closes when the kW of the generator is
below -5% of the nominal kW during more than 20 seconds.
The ‘REV. kW’ red LED confirms the activation of the relay:
• LED ON = contact closed.
• LED OFF = contact open.

2.3. kW Indicator
UNIGEN has two analogue outputs for kW indicator on terminals 11, 12 and 13. These outputs allow the display of
active power (kW).
Outputs are between 0-5VDC, 0-20mA or 4-20mA depending on SW4 configuration. A multi-turn potentiometer allows
the calibration of the output to adapt it to your indicator.

2.4. Remote speed control input

UNIGEN includes a remote speed control input on terminals 14, 15 and 16. This input is provided for connecting
an external potentiometer (5kΩ). The mid point of those potentiometers (5 turns for a 10 turns potentiometer) will
generate a 0V signal to the cursor input and will not generate any speed deviation.

The potentiometer is taken into account depending on switch SW7:

• OFF position, potentiometer is always read by UNIGEN.
• ON position, potentiometer value is set to zero when generator breaker is closed (BREAKER_IN logical
input active), normaly read when generator breaker is open.

Maximal deviation speed + / - 3.00Hz (recommended range for output speed setting):
• +5V applied on cursor input will increase the speed of + 3.00Hz.
• -5V applied on cursor input will decrease the speed of -3.00Hz.

This input can also be used as 0-5VDC for a master PLC control. In this case the nominal speed have to be adjusted
with 2.5VDC applied on cursor input.

EFC Cummins connection:

Due to a big sensitivity of Cummins EFC input speed, following wiring must be done.

speed input 15k speed out

17 ( Speed Out)
8
Speed 1.5k
governor
EFC Cummins 18 (Speed Ref)
9 speed ref

2 (0v)
2 ( battery - )

Unigen

7/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 2.5. PWM 500Hz (A51M141 modules only)
UNIGEN PLUS offering PWM output features are identified with a modification label (A51M141). This option must be
specified when ordering parts from your dealer.
Connection to the speed regulator must be done as shown below:

The output is protected against short-circuit to 0V. The PWM adjustment is done with the OFFSET and GAIN
potentiometers of the speed output. Picture below shows the behaviour of the potentiometers on the output signal.

2.6. Isochronous load sharing (UNIGEN PLUS) using parallel lines

When ‘DROOP’ (terminal 4) input is opened and switch SW3 (plines/canbus) is on plines position (OFF), UNIGEN
PLUS is set to isochronous load sharing mode, it compares its power with the level of the paralleling lines and
generates an output signal to the speed governor to adjust its power.
Voltage on parallel lines
(terminals 44 and 45)

3V

0V KW%
0% 100%

8/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 2.7. CAN load sharing
When ‘DROOP’ (terminal 4) input is opened and switch SW3 (plines/canbus) is on canbus (ON for UNIGEN PLUS),
UNIGEN is in isochronous load sharing mode. The load setpoint will be calculated via the CAN connection.
connection
Up to 8 UNIGEN modules can be connected via CAN bus.
The CAN bus needs terminal resistorss at each end of the bus. Switch SW1 (CAN bus OFF/120Ω)
OFF/120 to ON on the first
and last UNIGEN
NIGEN modules. SW1 should be switched OFF on the other UNIGEN.

2.7.1. Plug’n’play CAN protocol

As soon as several UNIGEN are connected together through CAN bus,, they choose automatically a generator number
different from each other. They are able to share the load without any settings. If one UNIGEN disappear from the
CAN, it is no longer taken under account by the others, and they
they continue to share the load isochronously.
isochronously
The rules of the Plug’n’play CAN protocol are described below:
• UNIGEN must receive information on the availability of the GE. (Input SET_UNAVAILABLE). If this information
is set to 0 then the UNIGEN will not participate to the negotiations.
• A generator is considered as slave when the SLAVE INPUT input is connected to 0V.
• At least one UNIGEN must be configured as master (SLAVE INPUT not selected).
selected)
• At power up, all UNIGEN connected to the CAN bus will be automatically attributed a set number (1, 2, 3...)
according to the power supply sequence of the UNIGEN.
UNIGEN
• At power up, all UNIGEN are fully operational during 2mn (No stop negotiation), then the automatic
load/unload mode starts.

2.7.2. Automatic
omatic load/unload request

If the power plant load goes below 20% of the nominal power during more than 2 minutes, stop negotiations begin
to elect one of the slave generators to stop.
stop
If the power plant load goes above 70% of the nominal power of the power plant during 10 seconds, start
negotiations begin to elect one of the slave generators to start.
start
If the load is between 20% and 70% of the nominal power than the actual number of generators on the bus bars
will not change until 20% or 70% threshold is reached.
reached
N.B: Both 20% and 70% thresholdss are parameters that can be modified using a PC.

The ‘START ON LOAD REQUEST’ relay output can be used to start and stop the slave generators depending on the
load request.
The ‘START ON LOAD REQUEST’ green LED confirms the activation of the relay:
• LED ON = contact closed..
• LED OFF = contact open.

‘SET UNAVAILABLE’ input:

• If UNIGEN is stopped and its SET UNAVAILABLE input is activated it will inhibit the start (‘START
(‘ ON
LOAD REQUEST’ relay kept open and ‘TRIP
‘ OUT’’ relay closed) in case of the load request.
request

CAUTION:
If UNIGEN
NIGEN is running and on the bus bar, as soon as ‘SET
UNAVAILABLE’ is closed the ‘TRIP OUT’ relay is activated
(closed) to open the breaker of the generator.
generator

Load shedding inhibition:

• Don’t connect the ‘START
START ON LOAD REQUEST’
REQUEST’ relay: the load shedding will not have any influences.
influences
• In droop mode the load shedding is inhibited.
inhibited

9/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

‘START ON LOAD REQUEST’ relay behaviour is described in the schematic below:
Power plant
load
Load threshold

Unload threshold

Slave generator
load

Low limit
Unload Load
delay Ramp delay
BREAKER IN Ramp

TRIP OUT

START ON LOAD REQUEST

Start on load request

delay
Unload Load
request request

Note: at start up, ‘START ON LOAD REQUEST’ relay is closed. All generators are started because it is impossible to
know the level of load before start.

2.8. Load sharing

2.8.1. Ramps
Ramp sequences:
• The first generator on the bus bars takes immediately the load with no ramp.
• The other generator load ramp stops when generators reach the load setpoint (average power plant load).
• The unload ramp stops when the power reach 5% of its nominal power.
Load and Unload ramp rates are using the same potentiometer. The single turn potentiometer named ‘RAMP
TIME’ adjusts the ramp time from 0 seconds to 180 seconds. This setting is the time to transfer 100% of the
nominal power.

kW Power plant power

100%
60%

Ramp Time
⇒ Load Time
0%
60sec. 36sec.

2.8.2. Automatic TRIP OUT

‘TRIP OUT’ relay (terminals 7 and 8) is used to open the breaker once the unload ramp is finished. The relay is closed
when the kW of the generator which is unloading reaches 5% of the nominal kW.
The ‘TRIP OUT’ green LED confirms the activation of the relay:
• LED ON = contact close.
• LED OFF = contact open.

10/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 2.8.3. Manual load/unload request

The Load /Unload ramps are managed by the ‘UNLOAD’ input (terminal 6):
• ‘UNLOAD’ (terminal 6) input disconnected = when the breaker closes, the load ramp starts immediately.
• ‘UNLOAD’ (terminal 6) input connected to 0v = the generator starts an unload ramp.

2.9. DROOP load sharing

When DROOP (terminal 4) input is connected to 0 VDC, UNIGEN is in Super droop mode. In this mode the load
sharing is managed between 50.50Hz (0% load) and 50.00Hz (100% load).
For this specific droop, it is not needed to set precisely the engine speed, and any connections are required between
each UNIGEN, even the 0V.
kW and kVAR load sharing are managed with droop.

Freq

50.50Hz

50.00Hz KW%
0% 100%

2.10. COMMAND MODE (UNIGEN PLUS)

When the following conditions are met:
1. ’DROOP’ input is opened (terminal 4 not connected).
2. ‘COMMAND MODE’ input is closed (terminal 39 connected to the 0VDC).
3. Generator breaker is closed (terminal 5 connected to the 0VDC).
Then the UNIGEN Plus is in ‘Command mode’. The setpoint load is fixed via the remote potentiometer of kW set
point (terminals 40/41/42) and the power factor is fixed to 0.95 using parameter E11020.

The low limit of the potentiometer is 5% and the high limit is 110% of nominal kW. Behaviour of kW setpoint
(potentiometer) is described on schematic below:

Voltage on
Potentiometer KW setpoint

CW: 5V

CCW: 0V
or setpoint not
connected KW%
5% 110%

COMMAND mode is described in the second schematic shown on chapter ‘MAINS PARALLELED’.

2.11. MAINS PARALLELED (UNIGEN PLUS)

When the following conditions are met:
1. ‘DROOP’ input is opened (terminal 4 not connected).
2. ‘COMMAND MODE’ input is opened (terminal 39 not connected).
3. ‘MAINS PARALLELED’ input is closed (terminal 38 connected to the 0VDC).
4. Generator breaker is closed (terminal 5 connected to the 0VDC).

11/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

Then UNIGEN PLUS is in ‘Mains paralleled’ mode. The setpoint load is fixed by the paralleling lines (terminals 44/45)
(coming from the GCR for example) and the power factor is fixed at 0.95 by the parameter E11020.
A 0V in paralleled lines (terminals 44/45) is that the generator takes 0% of load, a 3V in paralleled lines is that
the generator takes 100% of load.

Behaviour of kW setpoint (paralleling lines) is described on schematic below:

Voltage on paralleled lines
(terminals 44 and 45)

3V

0V KW%
0% 100%

COMMAND mode and MAINS PARALLELED active power behaviour are described in the schematic below:

Mains load
Load
impact

Generator load

Load setpoint::
Command mode load=kW sepoint input,
Mains paralleld load=paralleling lines input.

Low limit

Unload Low
request limit

Paralleling of stop generator

the generator

Active power set point behaviour in different mode is described in the following table:

Terminal 38 Terminal 39 SW3

Terminal 6 Terminal 5 Terminal 'mains 'command plines /
Mode kW management
'unload' 'breaker in' 4 'droop' paralleled' mode' canbus

X open X X X X waiting not

open close close X X X droop frequency
paralleling lines
load sharing
open close open open open OFF (T44-45)

Can bus
open close open open open ON load sharing
( T46-47)
kW set point
COMMAND mode
open close open X close X (T 41)

paralleling lines
Mains paralleled
open close open close open X (T 44-45)

open close open X X X Unload Ramp time pot. (RV3)

Close = connected to 0VDC.
Open = not connected.
= Pink cells concern UNIGEN PLUS only.

12/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 2.12. Modbus (UNIGEN PLUS)
Switch SW8 (Modbus OFF/120Ω) to ON (120Ω resistor) when the UNIGEN PLUS is used on end of line. All the logical
and analogue input/output values and all the other parameters which appear in the UNIGEN PLUS menus can be read
by the serial port RS485 terminals 49A and 50B (2 wires). UNIGEN PLUS behaves as a MODBUS slave device.

Support of MODBUS RTU by the UNIGEN PLUS is performed using the following parameters:
• Communication speed: 4800, 9600 and 19200 (default: 19200).
• Number of bits by character: 8.
• Number of parity bits: 0.
• Number of stop bits: 1.
• RTU address: 1 to 569B.
• Supported function: 04 (analogue reading) and 03 (registers reading) and 06 (registers writing).
• The RTU address of the variables is the same than their number plus 1, converted in hexadecimal.
For example variable E00110 (Mains break input), its RTU address is 006Fh (111). See the
A51Z090030.xls file to know the variable number.

MODBUS registers writing meets the following rules:

• Ex0xxx measures are “Read only”.
• Ex1xxx parameters are factory set to “Read only”. It is possible to switch them to “Read/write” using the
embedded Web site. To do so it is necessary to connect to UNIGEN with a laptop in level 2 (distributor
password). Go to Configuration/Modification by variable nb page, enter the parameter that you want to
change, and then in the « Writing by modbus/PLC » box, choose « allow » and validate. Go to System/Flash
all parameters and press « FLASH it » red button to save parameters (Otherwise changes are lost when
UNIGEN is switched off).
• Variables Ex2xxx can be written using MODBUS without restriction.

Reading example: Slave N°1, addresses from 001h to 003h included (3 registers)
Request:
Fields Value (hex)
Slave address 01
Function 04
MSB start address 00
LSB start address 01
MSB number of registers 00
LSB number of registers 03
CRC16 --

Response:
Fields Value (hex)
Slave address 01
Function 04
Number of bytes 06 (3 registers * 2 bytes per register)
1st byte (MSB of 1st reg.) xx
2nd byte (LSB of 1st reg.) xx
3rd byte (MSB of 2nd reg.) xx
4th byte (LSB of 2nd reg.) xx
5th byte (MSB of 3rd reg.) xx
6th byte (LSB of 3rd reg.) xx
CRC16 --

13/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

• Change RTU address / Modbus E01215 and RTU communication speed / Modbus E01216:

• Connect using a computer (see A51Z1 9 0015A).

• Type the password 1
• Go to Configuration / Modification by variable Number
• Chose 01215 or 01216, then select desired value, press SAVE.

• Go to System / save all variables

• Click on "Flash it!”.
• Disconnect UNIGEN, switch power off and then swith it on for new settings to take effect.

14/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 3. Settings
UNIGEN includes the following adjustments for calibration and settings:

Settings Picture Default value Description

6h Single turn potentiometers: Integral adjustment of

synchronization. Single turn potentiometers:
SYNCHRO Proportional gain adjustment of synchronization.
Integral Synchronization adjustment:
SYNCHRO • Turn P and I fully Counter Clockwise
6h
Proportional • Turn P potentiometer till the generator is
unstable, Come back in CCW to stop the instability.
I potentiometer is adjusted with the same procedure.
Single turn potentiometer (0…180s).
RAMP TIME 0s This setting adjusts the time for LOAD and UNLOAD
ramps. Duration is for 0…100% kW ramps.
Multi turn potentiometer (0-100%).
ADJUST Output span adjustment kW (0-5V on terminals 11-
kW monitor None 12 or 0-20mA/4-20mA on terminals 12-13).
See also SW4 configuration.
OFFSET Multi turn potentiometer (-10 to +10VDC).
Speed Adjustment of the Offset of the speed output. Used
control None to adjust the nominal frequency of the generator (ex:
output 50.00Hz).
GAIN 6h Single turn potentiometer (Span from 0 to 10VDC).
Speed Span adjustment of the speed control output. Used
control to adjust the maximum deviation asked by UNIGEN
output =+/-3 Hz
OFFSET Multi turn potentiometer (-10 to +10 VDC).
Voltage Offset adjustment of the voltage control output. Used
control None to adjust the nominal voltage of the alternator (i.e.
output 400VAC)
GAIN 6h Single-turn potentiometer (Span from 0 to 10VDC).
Voltage
control
Span voltage control output. Used to adjust the
output maximum deviation: = +/- 8% of the nominal voltage.

NOMINAL Have to be set during the commissioning. See

kW None chapter 6.2.
Configuration of switches, 2 positions:
SW1’terminal resistor of CAN bus’: OFF position resistor not
connected; ON position resistor of 120Ω connected.
SW2‘speed output option’: OFF position reverse speed
regulation for GAC speed regulator; ON position direct speed
regulation for others regulations.
SW3‘load sharing mode’: OFF for paralleling lines load sharing;
Adjustment of On position for CAN bus load sharing.
sw1 /sw2 /sw3 Not used on UNIGEN Industrial.
/sw4/sw5/sw6 SW4‘kW monitor output’: OFF for 0-5VDC and 0-20mA; ON for
/sw8 depend of 4-20mA output.
settings SW5‘synchronization’: OFF position the relay ‘SYNC OK’
Switch (terminals 34/35) closes only when conditions are ok and ‘SYNC
IN’ (terminal 3) is connected to the 0VDC; ON position the relay
Default:
‘SYNC OK’ (terminals 34/35) closes when conditions are ok.
SW2 ON,
SW6‘deadbus’: OFF position the relay ‘SYNC OK’ (terminals
Other 34/35) doesn’t close on deadbus condition; ON position the relay
switches OFF. ‘SYNC OK’ (terminals 34/35) closes on deadbus condition.
SW7 Speed pot. OFF position, external speed potentiometer is
always considered. ON position, external speed potentiometer is
considered when generator breaker is open.If not potentiometer
value is set to 0.
SW8‘terminal resistor of Modbus’: OFF position resistor not
connected; ON position resistor of 120Ω connected.
Not used switch for Industrial Unigen.

15/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

4. Display
UNIGEN includes LED to have information feedback.

Led Description

POWER Green LED.

SUPPLY This LED is ON when DC power supply (12 or 24VDC) is connected.

This LED is ON when synchronization is required (input ‘SYNC IN’

SYNC IN
closed to the 0VDC) - (SW5 and SW6 configuration).
This LED is ON when a droop is required (input ‘DROOP’ closed to
DROOP
the 0VDC).
Green LED.
BREAKER IN This LED is ON when the genset breaker is closed (input ‘BREAKER
IN’ closed to the 0VDC).
Green LED.
TRIP OUT.
This LED is ON when the relay ‘TRIP OUT’ is closed.
Red LED.
REV kW
This LED is ON when the relay ‘REV kW’ is closed.
START ON Green LED.
LOAD This LED is ON when the relay ‘START ON LOAD REQUEST’ is
REQUEST closed.
Green LED.
SYNC OK This LED is ON when the relay ‘SYNC OK’ is closed.
(SW5 and SW6 configuration).
Green LED.
MAINS
This LED is ON when the mains breaker is closed (input ‘MAINS
PARALLELED
PARALLELED’ closed to the 0VDC - UNIGEN PLUS only).
Green LED.
COMMAND
This LED is ON when a command mode is required (input
MODE
‘COMMAND MODE’ closed to the 0VDC - UNIGEN PLUS only).
Green LED.
This LED blinks when load sharing is done through CAN bus.
CANBUS
This LED blinks according to the number of UNIGEN modules
detected in the CAN bus (Modules with SW3 set to OFF).

16/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION

 5. Terminals
5.1. Terminals description
Câbles
N° des
Description recommandés Commentaires
borniers
(mm² / AWG)
DC Voltage from 9 to 40 VDC, 10 Watts.
1 POWER SUPPLY + 2.5 / 13 Twist protection.
Note: Terminal 2 must be connected to the 0V terminal of the
2 POWER SUPPLY - 2.5 / 13 speed governor with a 4 mm² wire.
Fuse: 5A / 40VDC.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
3 SYNC IN 1 / 17 This input activates automatic synchronization of the genset
(See SW5 and SW6 configuration).

Not isolated digital input, dry contact to 0V (10kΩ pull-up).

4 DROOP 1 / 17
This input forces kW and kVAR load sharing in DROOP mode.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
This input gives the position of generator breaker to the
5 BREAKER IN 1 / 17
UNIGEN.
Use a direct Aux contact of the breaker.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
6 UNLOAD 1 / 17
This input generate an unload ramp generator.
7 1 / 17 Dry contact: normally open. 250VAC, 5A.
TRIP OUT
This output controls the opening of generator breaker at the
8 TRIP OUT 1 / 17 end of the unload ramp.
9 REV kW 1 / 17 Dry contact: normally open. 250VAC, 5A.
10 REV kW 1 / 17 The relay is closed when generator is in reverse power.

11 kW monitor (0 – 5V) + 1.5 / 16 DC analogue output. 0 – 5V (Terminals 11 and 12),

12 kW monitor (0V) 0.25 / 23 0 – 20mA or 4-20mA (Terminals 12 and 13) (SW4 configuration).
This output (voltage and/or current) sends the actual value of
kW monitor (0 - 20mA) + kW generator.
13 0.25 / 23
or (4 - 20mA) +
14 SPEED SET CW +5V 0.25 / 23 * Analogue input 5kΩ potentiometer or -5/+5VDC between
terminal 2(-) and 15(+). Use a shielded wire.
15 SPEED SET cursor 0.25 / 23 *
This input allows a manual remote control of generator speed.
16 SPEED SET CCW -5V 0.25 / 23 * See SW7 configuration.
Generator OUT speed Analogue output +/-10 VDC. Use a shielded wire.
17 0.25 / 23 * This output controls the speed of generator. Offset and gain
control output
potentiometers, this output is compatible with all speed
Generator REF from governors of the market.
18 speed governor speed 0.25 / 23 * (See SW2 configuration)
control output A51M141 modules: Output PWM 500Hz 5V. See chapter 2.5
19 Shield 0.25 / 23 * Terminal to connect the shield of the analogue signals.

20 AVR OUT (+) 0.25 / 23 * Isolated analogue output +/-10VDC.

This output controls alternator voltage. Offset and gain
potentiometers, this output is compatible with all AVRs of the
21 AVR OUT (-) 0.5 / 20 *
market.
22 Generator I1+ 2.5 / 13
23 Generator I1- 2.5 / 13 AC current inputs from generator.
24 Generator I2 + 2.5 / 13 Current: from 0 to 5A. Max current: 15 A during 10s.
25 Generator I2 - 2.5 / 13 Load: 1 VA.
The nominal current of the secondary of the current
26 Generator I3 + 2.5 / 13 transformers must be as close as possible to 5A.
27 Generator I3 - 2.5 / 13
28 Générateur L1 1.5 / 16 AC voltage input measurement generator.
29 Générateur L2 1.5 / 16 Line to line voltage from 100 to 500VAC.
30 Générateur L3 1.5 / 16 Frequency: 50 or 60 Hz.

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 Câbles
N° des
Description recommandés Commentaires
borniers
(mm² / AWG)
Fuses: 100 mA / 600 VAC.
31 Générateur Neutre 1.5 / 16 Note: If the neutral input is not connected, UNIGEN will
generate an internal virtual neutral point.
32 1 / 17 Dry contact: Normally open, 250 VAC, 5A.
‘START ON LOAD REQUEST’ relay is closed when the load
request exceeds 80% of the nominal power -> slave generator
START ON LOAD
is to start.
33 REQUEST 1.5 / 16 ‘START ON LOAD REQUEST’ relay is opened when the load
request is above 20% of the nominal -> Slave generator is to
stop.
34 1.5 / 16 Dry contact: normally open, 250 VAC, 5A.
‘SYNC OK’ relay is closed when the coupling of the generators
is safe (See also SW5 and SW6 configuration):
- Voltage difference within limits.
SYNC OK
35 1.5 / 16 - Phase difference within limits.
- Frequency difference within limits.
- Phase sequence
- or Deadbus
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
36 SET UNAVAILABLE 1 / 17
Connect the signal "fault" from the generator.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
37 SLAVE INPUT 1 / 17
Set this UNIGEN as slave for automatic load/unload feature.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
MAINS PARALLELED
1 / 17 This input gives the position of mains breaker to the UNIGEN.
38 (UNIGEN PLUS)
Use a direct Aux contact of the breaker.
Not isolated digital input, dry contact to 0V (10kΩ pull-up).
Mode COMMAND
39 1 / 17 This input forces kW and kVAR load sharing in COMMAND
(UNIGEN PLUS)
MODE.
40 kW SET CW +5V
0.25 / 23 *
(Unigen+)
Analog input 5kΩ potentiometer or 0-5VDC between 42 (-) and
41 kW SET curseur
0.25 / 23 * 41 (+). Use a shielded wire.
(UNIGEN PLUS)
42 kW SET CCW 0V (UNIGEN
0.25 / 23 *
PLUS)
43 Non connecté
44 Parallel lines High(+)(for 0 to 3V. Isolated input.
2.5 / 13*
Unigen Plus) Load sharing and power set level (kW only) when SW3 is set to
OFF.
Parallel lines low(-)(for Compatibility with other UNIGEN and with analogue load
45 2.5 / 13* sharing line isolated or not isolated (ex: GCR). Compatibility
Unigen Plus)
with Wheatstone bridge.
46 CANBUS+ 2.5 / 13* Isolated input. Load sharing through CAN bus communication
47 CANBUS- 2.5 / 13* (SW3 set to ON for UNIGEN PLUS) - See also SW1 configuration.
48 SHIELD 0.25 / 23 * Terminal to connect the shield of the CAN signals.
49 MODBUS A
2.5 / 13 * 19200 bps. Used to communicate with SCADA.
(UNIGEN PLUS)
MODBUS RTU slave. Read (04 and 03) functions. (‘sw8’
MODBUS B
50 2.5 / 13 * configuration).
(UNIGEN PLUS)
51 Bus bar L1 1.5 / 16 AC voltage input measurement bus bar.
Line to line voltage from 100 to 500VAC.
52 Bus bar L2 1.5 / 16 Frequency: 50 or 60 Hz.
53 Bus bar L3 1.5 / 16 Fuses: 100 mA / 600VAC.
Note: If the neutral input is not connected, UNIGEN will
54 Bus bar Neutre 1.5 / 16 generate an internal virtual neutral point.
Note: * Shielded cable is recommended for these connections. Use 2 or 3 Conductor Foil Shield with drain Wire.
Note: Cable sizes are for guidance only. Cable size should be increased for long cable runs, to overcome possible
voltage drop and to increase noise immunity. Only for UNIGEN PLUS.

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 5.2. Wiring diagram
Terminals of the industrial UNIGEN are all present on UNIGEN PLUS.

Only for Unigen Plus.

5.3. Connection specifications

• Power supply: 9 to 40VDC, <1A with 12 VDC and <500mA with 24VDC.
• AC voltage inputs: 100 to 500VAC, 100mA max. The neutral wire can be connected or not.
• AC currents inputs: 0 to 5A, 1VA. Each input is isolated from the other ones.
• Possible over-current: 15A during 10s.
• Frequency measurement: 45 to 70 Hz – 15 VAC minimum between neutral and line.
• Digital inputs: Normally Open, to be connected to 0V (internal pull up of 10kΩ).
• Relay outputs: 5A, 230VAC max.
• Remote speed control input: 5kΩ potentiometer or +/-5VDC.
• Remote kW control input for COMMAND mode: potentiometer (5kΩ) or 0…+5VDC.
• kW monitor output (0-5VDC or 0-20mA/4-20mA): the maximum load impedance for the 0-20mA. Or 4-
20mA. is 300 Ohms and the minimum load impedance for the 0…+5VDC is 1kΩ.
• Speed bias output: The frequency control is made by the adjustable 0-10VDC output. The adjustments
are, Offset and Gain potentiometers.
• Voltage bias output: The voltage control is done via the AVR. The output is a +/-10V, output with Gain
and Offset adjustments.
2
Terminals: with screws, 2.5 mm .

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6. Risk
6.1. Caution
6.1.1. Grounding:
The grounding of the chassis of UNIGEN must be done with the M5 screw. Use a 4mm² wire to connect to earth, this
cable should be as short as possible.

6.1.2 Wiring rules:

The cables with high voltage (400VAC) and/or high current (5A) must be separated from the command cables. All the
command and digital inputs / outputs can be in the same cable path.
If you have to cross the command/DC cables with the 400V/5A cables, it is recommended to cross with a right angle.
The grounding must be done in a proper way to avoid personal injuries and for a reduction of EMC.

6.1.3 Vibrations:
In case of heavy vibrations, UNIGEN should be mounted using AV Mounts.

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 6.2. Power plant start-up/Commissioning
Caution: before starting the generating sets, please read the following part.
This is a standard commissioning for a simple power plant. If you use only this procedure, it can't engage our
responsibility.

Before commissioning (before going on site)

Check of schematics
How?
• Be sure you have the latest power plant schematics.
Why?
• To be sure the wires will be present on site (Can bus connector, shielded wires...).
What?
• 0 Volt wiring.
• Shields.
• Speed governor / UNIGEN Interface.
• Automatic Voltage Regulator / UNIGEN Interface (droop current transformer must be removed).
• CAN bus.
• Paralleled lines.

During commissioning
Start in safe condition
How?
• Generator breaker output locked in open position.
• Disconnect the wires between UNIGEN (terminals 17/18) and the speed governor.
• Disconnect the wires between UNIGEN (terminals 20/21) and the AVR.
• Ask the technician who had wired the power plant to lock the generator breaker open.
• Battery negative of each UNIGEN power supply (terminal 2) must be connected to each other
UNIGEN and to the 0V of the speed governor.
• Disconnect the wires of the relay ‘SYNC OK’ (terminals 34/35) of the UNIGEN.

Why?
• To be sure not to drive a false paralleling during the beginning of commissioning.

Switches configuration
How?
• Put switches in OFF/ON position before start the engine, see chapter 3 ‘Settings’ for more details.
Why?
• To configure several important functions of the UNIGEN.

Interface UNIGEN / Speed governor

Interface UNIGEN / Auto Voltage Regulator
How?
• Start the engine.
• Adjust the nominal speed and voltage, for example 50.00Hz & 400VAC, on the speed/voltage
regulator. If a trim pot is present on the AVR, adjust it to get +/-8% (see AVR manufacturer doc).
• Stop the engine.
• Remove the cover of the UNIGEN if necessary.
• Connect only the ref wire (terminal 18) to the speed governor “speed ref output”.

Speed setting :
• Start the engine.
• Adjust Speed gain RV10 full CCW on the UNIGEN.
• Measure the voltage between Ref and remote voltage input on speed regulator side.
• Adjust UNIGEN output voltage (terminals 17/18) adjusting the offset RV9 to have the same voltage
than measurement of previous point.
• Connect the control wire (terminal 17).
• Close the ‘SYNC IN’ input (connect terminal 3 to 0V). UNIGEN is trying to synchronize on a dead bus
(00.00Hz).
• Adjust the speed gain RV10 to have 48.00Hz.
• Open the ‘SYNC IN’ input.
• Stop the generator.
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Voltage setting :
• Adjust AVR Offset RV11 & Gain RV112 full CCW on the UNIGEN.
• Connect AVR outputs (terminals 20/21) to AVR.
• Adjust voltage offset RV11 to have 400VAC.
• Close ‘SYNC IN’ input (Terminal 3 to 0 volts).
• Adjust AVR Gain RV12 to reach 370VAC

Check the control of the breaker on dead bus

• Be sure there is no critical load connected on bus bar.
• Close the breaker and verify that the breaker feedback (terminal 5) is closed (the ‘BREAKER IN’ LED
should light on).
• Open the breaker and verify that the breaker feedback (terminal 5) is opened (LED not lit).

Adjustment of the nominal power

For the Industrial UNIGEN:
• Set the kW monitor output in 0-5V: switch SW4 to OFF position.
• Put in full CW the multi turn potentiometer ADJUST RV7.
• Close the circuit breaker of the generator. The ‘BREAKER IN’ led must light (terminal 5).
• Apply 100% of load on the generating set (with bench load for example).
• Adjust ‘NOMINAL kW’ potentiometer RV13 to reach 7.45VDC between terminals 11(+) and 12(-) of the
UNIGEN.
• Open the circuit breaker of the generator.
• Set switch SW4 as desired depending on your application.

UNIGEN PLUS (Generating set below 200kW):

On GE with a nominal power below 200kW, adjustment of NOMINAL kW potentiometer RV13 may be hard to
find. To adjust this setting more easily it may be helpful to decrease UNIGEN PLUS internal CT ratios (Factory
set to 1000). This can be done by lowering value of variables E11002, E11003 and E11004 (e.g. set them to
200):
• Connect to UNIGEN PLUS internal Website using a computer (see document A51Z1 9 0015A).
• Type in password “1”.
• Go to Configuration/Modification by variable nb page.

• Enter the number of the variable to modify (at first “11002”) and validate.
• Enter the new desired value and press SAVE button.
• Repeat these steps for variables E11003 and E11004.
• Go to page System/save all variables.
• Click on "Flash it!”.
• Disconnect UNIGEN, switch power off and then switch it on again for new settings to take effect.
• Finally, adjust the nominal power potentiometer as described below for engines above 200kW.

UNIGEN PLUS (Generating set with nominal power between 200kW and 4000kW):
• Switch SW3 to OFF position.
• Paralleling lines are not connected on terminals 44 and 45.
• Close the circuit breaker of the generator. The ‘BREAKER IN’ led must light (terminal 5).
• Apply 100% of load on the generating set (with bench load for example).
• Adjust ‘NOMINAL kW’ potentiometer RV13 to obtain 3V on parallel lines (terminal 44 & 45).
Open the circuit breaker of the generator.

Check wiring of current

• Put load.
• Measure the voltage between terminals 11 and 12.
• Shunt the phase 1 current directly of the secondary of the current transformer (CT).
• Measure the voltage between terminals 11 and 12. Check that this voltage decrease of 1/3 that
before.
• Do the same test for phases 2 and 3 (don’t forget to remove the shunt of each phase after test).
22/24 A51 Z0 9 0004 J EN - TECHNICAL DOCUMENTATION
 • Switch SW3 as desired depending on your application.

Check synchronization
• Close the breaker to have voltage on the bus bar (mains or other generator).
• Lock the engine breaker in open position.
• Start the engine to check the synchronization.
• Close ‘SYNC IN’ input (terminal 3 to 0VDC).
• Adjust P (RV15) & I (RV1) potentiometers of synchronization to have a response time of 4 or 5
seconds to get the ‘SYNC OK’ signal (terminals 34/35) the relay closes.
• With a voltmeter check on both sides of the breaker if the voltage is <20VAC on each phases.
• With the voltmeter check also that there is 400VAC between phase 1 of the engine and phase 2 of the
bus bar (crossed monitoring).
• In this test we don’t close the breaker.
• If the test is OK, connect the wires of the relay ‘SYNC OK’ (terminals 34/35) of the UNIGEN.

Load sharing / kW regulation

• Regarding the application check the stability of kW and kVAR regulation.
• Open Breaker.
• Stop engines.

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Environment
• Operational temperature: 0 to + 70°C.
• Storage temperature: -30 to +70°C.
• Humidity: 5 to 95%. The PCB is tropicalized to be used in humid climate areas. Protection IP20.
• Size: 275x200x26mm.
• Mounting: Can be placed in all positions.
• Weight: 1.5Kg.
• CE directives:
o Generic emission standard: EN 50081-2, EN 50082-2.
o Generic immunity standard: EN 61000-6-2.
o Low voltage directive: 73/23EEC.

Dimensions

165mm

115mm 25mm

Mounting holes
10mm (*4)
D=5mm

255mm
275mm

25mm

200mm

5mm nut (used for grounding)

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