UNIGEN 2.

0 synchro
Slave Synchro Unit

USER MANUAL – TECHNICAL DOCUMENTATION

Part Number: A51V0 9 0020 A EN

Last Update: January 2017
 User manual – technical documentation A51 V0 9 0020 A EN

Technical documentation history

Date Version Comment
January, 2017 A Initial edition

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A51 V0 9 0020 A EN User manual – technical documentation

Preamble

SETTINGS
The tables whose header have an orange-coloured background describe settings.
Settings (and readings) that show only in CRE Config, but not on the LCD, feature a purple border in
the HMI chapter as follows:

Setting Label Description

xxxx xxx Can be set in any HMI
xxxx xxx Can be set only in CRE Config

The setting content is referred to as [xxxx].

In the illustrations:
 Digital inputs and outputs – whether direct or through CANopen – whose assignment is
preset in the CRE Config software application show as follows; the shown position has
no meaning.
 Internal toggles preset through software show as switches with two throws. The code
xxxx or the name of the setting shows above:

assignment assignment
Digital xxxx
Digital
input output

SYMBOLOGY

Denotes a threshold monitoring

Denotes a control loop tuning (three

coefficients G, P, I)

Denotes the need to adjust the

amplitude and offset (center)

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.
You can download the most up-to-date version of this documentation and different other
documentations relating to UNIGEN 2.0 on our web site http://www.cretechnology.com.

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Content
1 Presentation ......................................................................................................................... 7
1.1 Generator automatic control ...................................................................................................... 7
1.2 Breakers control .......................................................................................................................... 7
1.3 Human machine interface ........................................................................................................... 8
1.4 Setting and supervision utility ..................................................................................................... 9
2 Installation ......................................................................................................................... 10
2.1 On-desk-ethernet setup ............................................................................................................ 10
2.1.1 Setting the PC connection ............................................................................................. 10
2.1.2 Changing the UNIGEN 2.0 IP address ............................................................................ 11
2.1.3 Hostname ...................................................................................................................... 11
2.1.4 Copyright ....................................................................................................................... 11
2.2 In-panel installation................................................................................................................... 12
2.2.1 Unpacking ...................................................................................................................... 12
2.2.2 Installation ..................................................................................................................... 12
2.2.3 Wiring the unit............................................................................................................... 13
2.2.4 Connection diagrams..................................................................................................... 18
3 Applications ........................................................................................................................ 20
3.1 Synchronization ......................................................................................................................... 21
3.1.1 Configuration ................................................................................................................. 21
3.1.2 Tuning ............................................................................................................................ 22
3.1.3 Manual synchronization ................................................................................................ 22
4 Operation ........................................................................................................................... 23
4.1 Protections ................................................................................................................................ 23
4.1.1 General .......................................................................................................................... 23
4.1.2 Audio or visual annunciator .......................................................................................... 23
4.2 Potential Alarms/Faults catalog ................................................................................................ 24
4.2.1 Generator electrical fault .............................................................................................. 24
4.2.2 Engine and battery ........................................................................................................ 24
4.2.3 Analog inputs ................................................................................................................. 24
4.2.4 Communication ............................................................................................................. 24
4.2.5 Reset .............................................................................................................................. 24
4.3 Breaker management ................................................................................................................ 25
5 Commissioning ................................................................................................................... 26
5.1 Introduction............................................................................................................................... 26
5.2 Analog speed governor output ................................................................................................. 27
5.3 Analog AVR (Auto Voltage Regulator) control .......................................................................... 29
5.4 Speed/voltage controlled by contacts/pulses ........................................................................... 31
5.4.1 Setup.............................................................................................................................. 31
5.4.2 Speed calibration procedure ......................................................................................... 32

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5.4.3 Voltage calibration procedure ....................................................................................... 32

5.5 Tests .......................................................................................................................................... 32
5.5.1 Individual check ............................................................................................................. 32
6 Human-machine interface ................................................................................................... 34
6.1 Security and operations through the front panel ..................................................................... 34
6.1.1 Security level and password .......................................................................................... 34
6.1.2 HMI status ..................................................................................................................... 35
6.1.3 Navigation in LCD .......................................................................................................... 35
6.1.4 Edition............................................................................................................................ 36
6.2 Supervision ................................................................................................................................ 36
6.3 Web server ................................................................................................................................ 37
6.4 Display menu ............................................................................................................................. 38
6.5 CONFIGURATION menu ............................................................................................................. 41
6.6 SYSTEM menu ............................................................................................................................ 45
6.7 DEDICATED PAGES ..................................................................................................................... 48
6.7.1 Faults and alarms........................................................................................................... 48
6.7.2 Information.................................................................................................................... 48
7 Communication buses ......................................................................................................... 49
7.1 Modbus TCP .............................................................................................................................. 49
7.1.1 Capabilities .................................................................................................................... 49
7.1.2 Configuration ................................................................................................................. 49
7.1.3 Description .................................................................................................................... 49
7.2 CANopen extension modules .................................................................................................... 52
7.2.1 Hardware ....................................................................................................................... 52
7.2.2 Configuration ................................................................................................................. 53
7.2.3 Mapping......................................................................................................................... 53
7.3 J1939 Communication ............................................................................................................... 54
7.3.1 Overview........................................................................................................................ 54
7.3.2 Search engines list ......................................................................................................... 54
8 Resources for setup & maintenance .................................................................................... 56
8.1 File transfer ............................................................................................................................... 56
8.1.1 UNIGEN 2.0 -> PC file transfer ....................................................................................... 56
8.1.2 PC -> UNIGEN 2.0 file transfer ....................................................................................... 57
8.1.3 Firmware upgrade ......................................................................................................... 57
8.2 Text file descriptioN .................................................................................................................. 57
8.2.1 Variable naming............................................................................................................. 57
8.2.2 Text file description ....................................................................................................... 58
8.3 I/O lines ..................................................................................................................................... 60
8.3.1 Digital inputs.................................................................................................................. 60
8.3.2 Digital and relay outputs ............................................................................................... 62

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8.3.3 Analog inputs ................................................................................................................. 65

9 Maintenance ...................................................................................................................... 67
9.1 Upgrading the software............................................................................................................. 67
9.2 Adding a custom HMI language ................................................................................................ 67
9.3 Troubleshooting ........................................................................................................................ 67
10 APPENDIX ........................................................................................................................... 71
10.1 MTU J1939 communication....................................................................................................... 71
10.2 CAN bus good practices ............................................................................................................. 73
10.3 Control Loop Tuning .................................................................................................................. 75
10.4 Potentiels Alarms-faults Table .................................................................................................. 76

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1 PRESENTATION

UNIGEN 2.0 SYNCHRO is a panel mounting electronic unit meant for the control of a single, two or three-
phase low-voltage generator. It is designed to work as a slave of a PLC unit. UNIGEN 2.0 SYNCHRO can
be used to synchronize one generator with an other power source.

UNIGEN 2.0 capabilities include:

PMS ILS SYNCHRO

Acquisition of the engine speed and the generator AC voltages x x x

Acquisition of the generator AC currents x x

Generator electrical protections x x x

PID control in load sharing mode x x

Control of actuators ; it is compatible with most speed governors (ESG) x x x

and AVR regulators

Synchronization before coupling x x

Analog inputs for reading resistive sensors x x x

Extension by CANopen units (Wago, Beckhoff, VIPA, etc) : up to 32 extra x x x

digital inputs and 32 extra digital outputs

Link to a PLC or a SCADA via Modbus TCP x x x

The engine-generator may have an Electronic Control Unit with CAN J1939 interface. J1939 and
CANopen interfaces can coexist – on a second CAN media – provided they use the same bit-rate.
The engine speed is derived from the AC frequency.

1.1 GENERATOR AUTOMATIC CONTROL

Two separate cascade control systems are used:
Primary control (UNIGEN) Secondary control
Speed ESG control ECU or ESG
Voltage AVR control AVR

The generated voltages and currents are measured in true RMS and used to calculate the load demand
across the aggregate. The synchronization requests drive the primary control which, according to its
configuration:
 Produces an analog signal Speed out+, sends pulses “+/- f” to digital outputs or writes to J1939
bus.
 Produces an analog signal AVR out+ or sends pulses “+/- U” to digital outputs.

1.2 BREAKERS CONTROL

Compared to UNIGEN 2.0 PMS, UNIGEN 2.0 SYNCHRO does not allow to control the breaker. A digital
output called « Synch check relay » is activated when the breaker can be closed (Synchronization or
dead bus bar)

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1.3 HUMAN MACHINE INTERFACE

LCD screen characteristics:

 Size: 40 x 70mm - 1.50 x 2.75in
 Pixels: 64 x 128
 Back light: 50 cd/m2 typical, configurable
 Contrast: configurable
 Type: STN

Back-lit auto-off LCD

The led blinks after a fault arises.

Acknowledged by pressing the lower button
The led blinks after an alarm arises.
Acknowledged by pressing the lower button

Press to access:
.the Fault page if new fault occurred (Fault
blinks)
.the Alarm page if new alarm occurred (Al.
blinks)
.pages with 2 statuses (Power and Engine) and
10 readings of special interest.
Press again to return.

Led Gen. ready Navigation/Edition Bus status led

(see below) (lit when live)
GeneratorBreaker status led
(lit when closed)

Keyboard:
Keys Navigation mode Edition mode
Cyclic navigation through menu & settings list Used to change the value of a setting. Hold down to change
faster

 Cyclic navigation through pages when an item –

is selected in a menu and validated
Shift Used with  to in/decrease LCD luminosity When in manual mode and breaker is open, used with  to
Used with   to adjust LCD contrast increase/decrease:
 speed command on Speed control page
 voltage command on Voltage control page

Used with to reset alarms and faults

Esc Return to parent menu (3 times to home) or Setting change rejection and return to the Navigation mode
preceding menu
Enter Page opening / switch to Edition mode Validation of the new setting and return to Navigation mode

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1.4 SETTING AND SUPERVISION UTILITY

A Windows™ PC with the software application CRE Config 2.70 or later must be connected on the
rear Ethernet socket, generally via a switch in a star network:

This allows you to preset all the UNIGEN 2.0 units when they are on desk: a text file that reflects the
first UNIGEN 2.0 unit’s configuration can serve as a template to deploy the setup to the other
UNIGEN 2.0 units in the cluster. The CRE Config multi-tabbed interface makes it easy.
Once all UNIGEN 2.0 units are mounted, CRE Config can be used to set them up and monitor the
generators. The CRE Config features a Scada section that can be used in particular as an event console to
UNIGEN 2.0:

UNIGEN 2.0 CRE Config/Scada

console

Time Label Variable State

Event

0h00 Breaker fault xxxx 1

Information
Information

Label Variable Value

Power
display

Engine Prod request xxxx 1

Prod request 1 Mode xxxx AUTO
Mode AUTO
 2,000
logger
Event

2
1 

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2 INSTALLATION

2.1 ON-DESK-ETHERNET SETUP

2.1.1 Setting the PC connection

Connect UNIGEN 2.0 to a PC with a 100 Ethernet Direct connection to PC: use a crossover cord.
cord Connection through a switch: use a direct cord; a
crossover cord such as 3-m long A53W1 is OK if the
switch manages it.
Power up UNIGEN 2.0 using a stabilized power Power supply range: 8…35VDC
supply
Open Windows control panel
Click:

 Local network (Windows XP)

 Network and Sharing Center / View status
(Windows Vista)
 Open Network and Sharing Center/Change
adapter settings/(Connection to) LAN/
Properties (Windows 7 & 8)

Click Parameters (Windows XP) or Properties

(Windows Vista or 7 or 8)

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Select TCP/IP or TCP/IP v4, and click Properties

Enter a PC address that differs from the one of the Last number: 0 … 255; avoid 0 and 255 as they are
UNIGEN 2.0 only by the last number, & click OK often taken for other purposes

2.1.2 Changing the UNIGEN 2.0 IP address

To change UNIGEN 2.0 IP address, in CRE Config (or on LCD), navigate to “System/Network
configuration (resp. About)”.
UNIGEN 2.0 supports the DHCP function: in this case, UNIGEN 2.0 must be connected on a network
with a DHCP server. During the power-on sequence, UNIGEN 2.0 is assigned an IP address by the
DHCP server. If DHCP process fails, the fixed IP address is used (factory setting: 192.168.11.1).
Note: Contact your network administrator to configure your router and module(s) to your needs.
2.1.3 Hostname
You can assign an alias to UNIGEN 2.0, in addition to the IP address; enter it in CRE Config to get
connected.
To change this alias, in CRE Config navigate to System/Network configuration.
Maximum length: 16 characters. With Windows, the last character defines the type of service (0 is
the usual value).
Allowed characters: reduced ANSI set; "-" and "." are allowed except at the start and end.
2.1.4 Copyright
UNIGEN 2.0 Ethernet communication uses the open source lwIP TCP-IP stack. Read
copyright/disclaimer below. More details on lwIP Web site:
http://savannah.nongnu.org/projects/lwip/
Copyright © 2001-2004 Swedish Institute of Computer Science. All rights reserved.
Redistribution and use in source and binary forms, with or without modification, are permitted provided that
the following conditions are met:
1. Redistributions of source code must retain the above copyright notice, this list of conditions and the following
disclaimer.
2. Redistributions in binary form must reproduce the above copyright notice, this list of conditions and the
following disclaimer in the documentation and/or other materials provided with the distribution.
3. The name of the author may not be used to endorse or promote products derived from this software without
specific prior written permission.
THIS SOFTWARE IS PROVIDED BY THE AUTHOR ``AS IS'' AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING,
BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE AUTHOR BE LIABLE FOR ANY DIRECT, INDIRECT,
INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR PROFITS; OR BUSINESS
INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY, WHETHER IN CONTRACT, STRICT
LIABILITY, OR TORT (INCLUDING NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS
SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.

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2.2 IN-PANEL INSTALLATION

The unit is designed for panel mounting, which provides user with access only to the front panel.

WARNING
THE UNIT IS NOT GROUNDED
Take all measures against Electronic Static Discharges.
Do not try to open the unit.
Failure to follow these instructions may damage the unit

Environmental requirements:
 Operating temperature: -30°C (-22°F) … 70°C (158°F); LCD display slows down a bit under -5°C
(23°F). Avoid direct exposure to the sun
 Storage temperature: -40°C (-40°F) … 80°C (176°F)
 Altitude: up to 2,000 m (6,561 ft); on higher altitudes, recommended max. AC voltage : 100VAC
2.2.1 Unpacking

Make sure the packaging contains:

 the unit
 four caps + screws packaged apart
 a delivery bill
Unpack and keep the packaging in event of return.
Make sure the unit does not show scratches or visible defaults. Otherwise describe them on the RMA
sheet (downloadable from CRE technology Web site).

2.2.2 Installation

Preparation
1. Cut out the panel to 220x160 mm minimum (8.7 in x 6.3 in)
2. Make sure the cut-out is smooth and clean
Mounting

0 Tool: cross-head screwdriver size 1

1 Pass the unit through the panel

In the rear, cover each of the four spacers

2
with a cap

3 Screw a cap against the panel

4 Repeat on the diagonally opposite spacer

Repeat on the other diagonal and tighten

5
equally (do not overtighten)

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2.2.3 Wiring the unit

Tool: insulated screwdriver Ø2.5 mm (0.1 in), tightening torque: 0.8 Nm (7 lb-in) max.
Accessories: 4, 5, 6, 8, 15 & 18-terminal cable connectors, protective gloves, carpet if the floor is wet.

WARNING
THE UNIT IS NOT PROTECTED
Use external fuses:
 Bus bar and Generator phases: 100mA/600VAC
 Battery positive: 5A/40VDC
Install the fuses as near as possible the unit, in a place easily accessible to the user.
The disconnection device must NOT be fitted in a flexible cord.
Failure to follow these instructions may damage the unit

!l DANGER
l
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
 The unit must only be installed and serviced by qualified electrical personnel
 Apply appropriate personal protective equipment (PPE) & follow safe electrical work practices
 Turn off power before installing or removing fuses, and before installing the unit
 Use a properly rated voltage sensing device to confirm the power is off
 Do not use renewable link fuses in fused switch
Failure to follow these instructions will result in death or serious injury

General procedure
1. Make sure the cable connectors are NOT plugged
2. Take on protective gloves
3. Connect the wires on each cable connector in accordance with the National Wiring Regulations
4. Plug each cable connector onto the related connector
1. 5. Plug a direct Ethernet cord (RJ45, male-male, 100 m max., 100; a crossover cable
such as 3-m long A53W1 is OK if the switch manages it or if the link to PC is direct) and lock
the rear door.
Recommandations
Wires section: 2.5 mm² (AWG13).
To avoid ElectroMagnetic Interferences, shield cables appropriately; for CAN bus, see the Appendix
CAN bus Good practices.
Segregation: keep power cables separate from the CAN bus cables. The latter can be installed in the
same duct as the low level DC I/O wires (under 10V).
If power & communication cables have to cross each other, do it at right angles to avoid crosstalk:

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Overview

Relay Mains & Gen AC voltages Analog

outputs inputs

8-35VDC / Digital outputs / Digital inputs CAN2 Speed / AVR CAN1

output

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Upper blocks
!l DANGER
EXPOSED TERMINALS l
Do not touch terminals L1, L2, L3 nor use non-insulated tools near them. These terminals are
unprotected and will expose the user to dangerous voltages
Failure to follow this instruction will result in death, serious injury or equipment damage

Block and mark Description Note

Breaker commands Normally open. Breaking capacity: 5A, 240VAC
Relay 1 Relay 1 +
Relay 1 -
Relay 2 Relay 2 +
Relay 2 -
AC voltages 100-480VAC, measure range: 35 … 75HZ, 100mA max; accuracy: 1%
N Bus/Mains N fsd
Option
L3 Bus/Mains L3
These lines must be protected externally with 100mA/600VAC
L2 Bus/MainsL2
fuses. Use two PTs of 2VA (Phase-to-phase)
L1 Bus/Mains L1
N Generator N Option
L3 Generator L3
These lines must be protected externally with 100mA/600VAC
L2 Generator L2
fuses. 1VA (Phase-to-neutral)
L1 Generator L1
Analog inputs 0-500
Common Connect it to Battery –
Input 3 Free input
Input 2 Free input
Input 1 Free input
Shield GND Ground plane

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Lower blocks

WARNING
RISK OF EQUIPMENT DAMAGE
As a protection against polarity reversal, install a 6A fuse between Battery positive lug & terminal 8-35VDC +.
Connect battery negative to GENSYS terminal 8-35VDC– with 2.5 mm² (AWG13) cable.
Failure to follow this instruction can damage the controller

Block and Mark Description Note

8-35VDC NOT protected against polarity reversal
- Power supply - 2.5mm² (AWG13)
+ Power supply + 8…35VDC, consumed current: 130 mA at 24V (standby & operation)
Shield GND Generator chassis
Digital outputs
1 Synch check relay
2
Free solid state output. State 1 at the supply voltage (max: 1.8A).
3 Protected against short circuits. A reactive load is supported. Not
Other free isolated from power.
4
outputs
5
6
Digital inputs
1 GE breaker
feedback
2 UNIGEN Activation
3
Free digital input with 10kΩ pull-up.
4 Accepts NO or NC contact to 0V.
5 Not isolated from power.
6 Other free inputs
7
8
9
CAN2: J1939-Extensions Isolated CAN bus J1939/CANopen. Twisted pair. See CAN appendix
CAN L Blue wire
CAN H White wire
Resistor – Strap to CAN H when inner resistor must be inserted (bus ends)
Shield 0V Connect the cable shield herein
Speed Compatible with most speed governors. Isolated from power
Out Speed output ±10V analog output to speed governor

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Block and Mark Description Note

common Speed reference Twisted pair; length < 5m (16ft) if unshielded, < 50m max if shielded
AVR Compatible with most regulators. Isolated from power
Out AVR output + Analog output ±10V
common AVR output – Twisted pair; length < 5m (16ft) if unshielded, < 50m max if shielded
CAN1: Inter UNIGEN Isolated CAN© bus, use twisted pair. Refer to the CAN appendix
CAN L White wire with a blue strip (when using a CRE cable)
CAN H Blue wire with a white strip (when using a CRE cable)
Resistor – Strap to CAN H when inner resistor must be inserted (bus ends)
Shield 0V Connect the cable shield herein

WARNING
RISK OF EQUIPMENT DAMAGE
Switch off the unit before plugging or unplugging the CAN bus connector or disconnecting wires
Failure to follow this instruction can damage the CAN transmitter/receiver

Note: Crank dropout: the unit survives for 70 ms at 24V, and 20ms at 12V.

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Other systems of voltage

If Biphase 180° is selected in CRE Config, connect voltages and currents to terminals L1-L3 (and N),
resp. I1-I3 (and common).
If Monophase is selected, connect voltages and currents to the terminals L1-N, resp. I1 and common.

2.2.4 Connection diagrams

These diagrams show that the Potential Transformers can be connected in various ways:
 Star (wye) on generator side (1 insulated high-voltage terminal per PT) ; the ratio is for example
√
√
 Vee on bus side (2 insulated high-voltage terminals per PT) ; the ratio is for example

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3 APPLICATIONS

Starting from the default settings, just enter the installation specification:
Setting Label Value
2000 Count of gen. 1 ≤ N ≤ 32
2001 GE Number 1 to 32 (differs for each UNIGEN 2.0 on the CAN bus)

Only in island operation

Setting Label Value
2002 Dead Bus manag. No[0], Yes [1]

Digital inputs Relays

Mandatory Mandatory
 Generator breaker feedback  Synch check relay
 UNIGEN Activation

After the engines have started, the UNIGEN 2.0 with an active « UNIGEN activation » signal :

- Set the digital output « Synch check relay » if the bus bar is unpowered (with an election in
island operation)
- Synchronize the generator if the bus bar is powered. The digital output « Synch check relay »
is set once the breaker can be closed.

Notes:
After the closure of the breaker, speed output and voltage output are equal to 0 percent..
In island operation, each generator is controlled by a UNIGEN 2.0 SYNCHRO. Communication by CAN
Bus allows to close the breaker on a dead bus bar by avoiding simultaneous closures.
If the generators are not yet started, when they lose the CAN bus, a downgraded mode is enforced;
the generator couplings are phased in: the generator #n cannot close its breaker before
[2306]/10 + 7 x n (seconds)

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3.1 SYNCHRONIZATION
3.1.1 Configuration

Various settings and readings are offered to control and monitor the synchronization:

Setting Label Description Default

2800 Voltage match Max. difference (in % of nominal value) between generator & bus 5%
bar voltage for coupling
2801 Freq. match Max. frequency difference between generator and bus bar for 0.1Hz
coupling
2802 Phase match Max. phase angle difference between generator and bus bar for 10°
coupling
2803 TM Fail sync Allocated time to synchronize 200s
(1)
2809 C2S dwell time Synchronization dwell time before authorizing to close the breaker 0.2s
Reading Label Description
0306 Phase sequence Phase sequence is correct and does not prevent closing the breaker
0307 Voltage Voltage gap is low enough for closing the breaker
0308 Frequency Frequency gap is low enough for closing the breaker
0309 Phase Phase gap is low enough for closing the breaker
0310 C2S check OK Synchroscope result (global validation)
(1) This parameter can be modified using TXT file or modification by variable number menu.

UNIGEN 2.0 launches the synchronization only if the bus bar/mains provides at least 80% of nominal
voltage. The bus bar/mains frequency and voltage are the set points of loop controls. When the
generator and bus bar match, UNIGEN 2.0 orders the breaker closing.

Time chart:

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3.1.2 Tuning
Prerequisite: Speed & AVR outputs are scaled to match the generator. See 5.2 and 5.3.
Associated parameters may be set in menu “Configuration/ Synchronization”.

Setting Label Description Default

Voltage
2951 P Proportional 50
2952 I Integral 20
Frequency
2901 P Proportional 5
2902 I Integral 20
Phase - Angle
2905 P Proportional 70

Tuning process :
1. Bus bar is live (Fed by Mains/Other generator).
2. Start this generator and go to “Display/Synchronization”
3. The generator synchronizes within 5s; otherwise, isolate the root cause (Voltage, frequency or
phase) and adjust:
 In a first time, the proportional in order to be closer of the set point
 In a second time (if need), the integral in order to faster reach the set point

3.1.3 Manual synchronization

UNIGEN 2.0 allows to realize a manual synchronization using the digital inputs
- Increase speed
- Decrease speed
- Increase voltage
- Decrease voltage

These digital inputs can be used only in « waiting » state (breaker open and digital input “UNIGEN
Activation” deactivates.

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4 OPERATION

4.1 PROTECTIONS
4.1.1 General

Protections are triggered by internal and external events (alarms, faults, digital inputs, CAN bus loss
…). To protect the process, the engine or the alternator, you must associate one of the predefined
actions to each such event. These actions or effects are of various kinds:
 they can just raise an alarm; notice shows on the front panel (ANSI30); a summary can be reported
 they can secure the equipment: the breaker trips safe … and can activate a free protective digital
output

The action is an attribute of the protection: CT settings, or of inter-module CAN bus loss. The Droop
effect is reserved to CAN bus fault.

Value Action Description

0 Disable (no action) –
1 Generator electrical fault The protection opens generator breaker
3 Alarm Notice as alarm on front panel

The actions are configured in CRE Config. Numerical values show only in text file. See 8.2.

4.1.2 Audio or visual annunciator

To trigger an external annunciator whenever a protection trips, connect it to an output preset to the Horn
function; the signal duration is modified by 2478; alternately, an input can be used for remote reset:

Protection
RS
S
2478

OUT Horn
t
R
Stop horn

Setting Label Description

2478 Horn delay Duration of ring. Default value: 10s. 0 means the horn will buzz until being manually stopped

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4.2 POTENTIAL ALARMS/FAULTS CATALOG

The potential alarms/faults are listed below.
 Potential Alarm/Fault: Alarm/Fault label; this text shows in the Alarm/fault pages
 Action on alarm/on fault: this variable allows you to define the associated protection type (2
potential values)
This list can be downloaded from CRE Config/System/PC transmit-receive/Action on alarm/fault”.

4.2.1 Generator electrical fault

(All protections trip after a definite time, except Short circuit which trips after an IDMT; see
Appendice)
Potential Alarms/Faults ANSI Description On alarm On fault
Overfrequency 81H Generator is in over frequency 2402 2438
Underfrequency 81L Generator is in under frequency 2405 2441
Overvoltage 59 Generator is in over voltage 2408 2444
Undervoltage 27 Generator is in under voltage 2411 2447
– Generator voltage measurement is
Phase measure inconsistent with configuration [2003] 2805 –

Fail to synch 25 The unit cannot synchronize to Bus 2804

4.2.2 Engine and battery

Potential Alarms/Faults Description On level 1/Min On level 2/Max
Min battery voltage Battery voltage under the minimum 2358 2376
Max battery voltage Battery voltage over the minimum 2361 2379

4.2.3 Analog inputs

Potential Alarms/Faults Description On level 1/Min On level 2/Max

Activated if measurement of analog input 1 is

AN1 min/max 2602 2605
under/over the threshold

Activated if measurement of analog input 2 is

AN2 min/max 2610 2613
under/over the threshold

Activated if measurement of analog input 3 is

AN3 min/max 2618 2621
under/over the threshold

4.2.4 Communication
Potential Alarms/Faults Description On level 1/Min On level 2/Max
Communication problem on the inter-unit CAN (only –
CAN1 bus fault 3052
power plant applications)
CAN2 bus fault A J1939/CANopen bus error is detected on CAN2. 3053 –
An alarm is activated to indicate a CANopen
CANopen
communication fault.

4.2.5 Reset
Clearing of faults/alarms:
- Locally: Shift +

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- Remotely: use the “Fault reset” input function

4.3 BREAKER MANAGEMENT

UNIGEN 2.0 ILS does not allow to control directly the breaker. This needs to be done using an
external product. The digital output « Synch check relay » set when the generator is synchronized.

As long as the breaker is closed, the digital output « Synch check relay » is activated. It will
deactivate if a protection configured as « Generator electrical fault » occurs.

The digital output « Generator electrical faults summary » can be also used to open the breaker
when a protection configured as « Generator electrical fault » occurs.

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5 COMMISSIONING

5.1 INTRODUCTION
Each function produces a speed or voltage deviation based on its own GPI coefficients.
UNIGEN 2.0 feeds the sum of deviations to the output stage either as analog signals (Speed out and
AVR out+) or as pulses train or J1939 frames (speed):

[4405] is the sum of all applicable speed deviations due to:

 Frequency and phase synchronization
 Manual command

[4411] is the sum of all applicable voltage deviations due to:

 Volt synchronization
 Manual command


CAUTION
Follow strictly, throughout the aggregate, the scaling procedures (amplitude -offset) to have the best
synchronization, load sharing and droop

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5.2 ANALOG SPEED GOVERNOR OUTPUT

The Speed output signal provides the set point for ESG, used in speed control and frequency
synchronization. It is the sum of the components listed in the section 5.1. The voltage range -10V
…+10V must be fitted in amplitude and offset to allow UNIGEN 2.0 to vary the ESG set point on a
correct range; the aim is that UNIGEN 2.0 can control the frequency in the +/-3Hz band around the
nominal frequency:
F

3Hz
+V Sum

Nom

Amplitude offset

3Hz
-V

Deviation ESG amplitude

ESG offset + Speed out

Speed common
1. Connect the speed common wire only

2. In “Configuration/Engine”, preset the amplitude and offset as described in the table further
(if not listed, contact CRE Technology)
ESG amplitude …V
ESG offset …V
F 50Hz Lecture
Engine Speed 1500 Lecture
Speed Sum 0000

3. Start the generator

4. Trim the governor potentiometer to read 50Hz (or 60Hz)
5. Connect the Speed out signal; adjust the offset so that the frequency is 50Hz (or 60Hz)
6. Adjust Speed sum to +100% :
o Page “Configuration/Engine”
o With the Shift +  keys , adjust the amplitude so that the frequency is 53Hz (or
63Hz)
7. Return to 0%; adjust the offset if needed to get back 50Hz (or 60Hz)

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8. Select the Speed Sum and adjust it to –100% with the Shift +  keys in order to check the
variation range till 47Hz (or 57Hz)
9. Adjust the speed sum to 0%.

The next table gives both settings for various ESGs. For other models, preset amplitude and
offset according the manufacturer documentation and/or contact our Customer service.
Manufacturer Model ESG ampl. ESG ESG input ESG ref Note
offset
with analog input 0.5V 0V ILS input 4V
BARBER 0.5V 0V ILS signal ILS+2.5V
COLMAN Digital The tuning depends
DPG 2201 ILS signal
supply(+5V) on the connections
ILS signal BAT-
ECM for QSK23 / 11 (Barber
QSK40 / QSK45 / 2.5V 0V Colman Freq. 06 (5V)
QSX15 / QSK 60 bias input)
EFC 1.5V 0V 8 9 See schematic
ECM (QST30) 18 15 (7,75V)
+/- 1.5 Hz not to reach
EMR 2V 2.5V 24 25
EMR overspeed
ESD5330 –5V M G
All other ESD –5V N G
GHANA
PWC 2000 J G
CONTROL
E6 B3
KG6 / System E6 2.5V 2.5V E3 A3
PANDAROS DC6 2V 2.5V B3 A3
2V 2.5V L C Two different wirings
JDEC
G2 5V(ref speed) 999 for the same governor

MDEC 4V 0V 8 36 & 7 (5V)

2 and 12 connected
ECM 1300 2V 2.5V 30 5V
for external setting

EDC IV
1.5V 3V Pot. signal
EDC III
- 2301A/D ILS+speed 0V 3V 10 11 Shunt 14-16
- (Without U&I) 25 26 Shunt 26 (com) on 0V
2301D
2301A Speed only 4.5V 2.5V 15 16 16 connected to 0V
EPG System
Remove the shunt
P/N 8290-189 2.5V 0V 11 (0.6V) nc
P/N 8290-184 between 11 and 12

Because of the very high sensitivity of Cummins EFC module input, use the schematic below to
connect UNIGEN 2.0 to the EFC. The resistors must be as close as possible to the speed governor
terminal. This way, UNIGEN 2.0 analog speed output can be set higher (2205) according to the
resistors used.

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5.3 ANALOG AVR (AUTO VOLTAGE REGULATOR) CONTROL

The AVR out signal provides the set point for AVR, used in voltage control and voltage
synchronization (U=U). The components of AVR output are listed in the section 5.1. The voltage
range -10V …+10V must be fitted in amplitude and offset to allow UNIGEN 2.0 to vary the AVR set
point on a correct range; the aim is that UNIGEN 2.0 can control the voltage in the +/-30V band
around the nominal voltage:
U

+V Sum 30V

Nom
Amplitude

offset
30V

-V

Deviation AVR amplitude

AVR offset + AVR out +

AVR common

1. Connect the AVR common wire only

2. In “Configuration/Generator”, preset the amplitude and offset as described in the table
further

AVR amplitude …V
AVR offset …V
V1 230V Lecture
U31 400V Lecture
Voltage Sum 0000

3. Start the engine

4. Trim the AVR potentiometer to read 400V
5. Connect the AVR out signal; adjust the offset so that the voltage is 400V
6. Adjust Voltage sum to +100% :
a. Page “Configuration/Generator”
b. With the Shift +  keys , adjust the amplitude so that the voltage is 430V
7. Return to 0%; adjust the offset if needed to get back 400V

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8. Adjust Voltage Sum to -100% with the Shift +  keys in order to check the variation range till
370V
9. Adjust voltage Sum to 0%.

Table below gives both settings for various AVRs. For other models, contact our Customer service.

Manufacturer Model AVR ampl. AVR offset AVR out AVR common Comment
Mid point of a
R16 0V 8 resistive bridge
betw. 7 & 9/10
Cosimat N 4.5V 4.5V Mn n
MA329 A2(+) A1(-)
AEC63-7 Remove shunt between
6 7
AVC63-4(A) terminal 6 & 7 of the AVR
AVC63-12 1.0V 0V 2 3
DECS32-15-xxx
DECS63-15-xxx
Use VAR control included in the DECS
DECS125-15-xxx
DECS300
DVR KVAR/PF 7 45
VR6 1.0V 0V 3 2
CDVR 4.5V 0V P12.3 P12.6

K65-12B
1.0V 0V 2 3
K125-10B

See drawings: AVRout feeds either analog input.

D510 10V 0V 0…10V bias input provides a higher range of voltage bias
control. AVR com is set to 5V
R230/438/448/
1.0V 0V Pot input + Pot input – Remove the shunt
449
R610 3F 4.5V 0V 22 23
DVR2010
1.5V (10%)
DVR2000E 0V A B
3V (30%)
M40FA640A 0.35V 0V 8 6
M40FA644A 3.0V 1.5V
UVR6 2.0V –4.5V Pot + Pot –
Trim potentiometer V of
FB EXTPOT+ EXTPOT– AVR fully counterclockwise.
Remove shunt
MX321 A1 A2
MX341 A1 A2 Trim potentiometer of AVR
fully clockwise
SX440 A1 A2

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5.4 SPEED/VOLTAGE CONTROLLED BY CONTACTS/PULSES

When digital outputs are connected to speed governor and/or AVR, the UNIGEN 2.0 PID controllers
send speed/voltage increments/decrements by changing the state of these outputs:

UNIGEN 2.0
K1 K2 K3 K4

De crease Volt
De crease Hz

Increase Volt
Increase Hz
K1 K2 K3 K4

Calibration device: various devices can be used depending on the governor/AVR.

Adjustable resistance Manual potentiometer Tapper (push-buttons)
Raise
RES

Governor/AVR Governor/AVR Lower Governor/AVR

A digital potentiometer, that converts the pulses into analog values, has its own settings: U0 (fsd) & Time.
A motorized potentiometer: a stepper motor with a brake moves the tap

5.4.1 Setup
In “Configuration/Outputs/Digital outputs”, assign to outputs a function Increase/Decrease
speed/voltage by pulse.

When digital outputs are used to control speed/voltage by pulse, dedicated parameters are shown in
the speed/voltage regulation control menu. Those parameters are listed in the table below.

Speed governor Voltage regulator Description

3650 3651 Dead band
3652 3653 Pulse width
2908 2954 Centering gain by pulse
Sum of all speed/voltage deviations (positive or negative) as
4405 4411 detailed in section 5.1, p26

A pulse is generated when the absolute value of the regulation output is bigger than the dead band
setting. The higher the regulation output is, the closer pulses will be from each other. Period
between two pulses can be calculated as follows:

Note that calculated value of the regulation output depends on the settings applied to the dedicated
PIDs.

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5.4.2 Speed calibration procedure

Preliminary step:
1. Adjust the resistance at mid value or set the potentiometer tap in the mid position or the
tapper in the mid position (unless UNIGEN 2.0 is directly connected to the governor)
2. Check the sum of all deviations [4405]
The components of total deviation are split in two, as they are compensated in different ways. Finally,
the compensations will be added.

 Set 3650 to 1.00% which is 1 percent of deviation (i.e. 0.03Hz of dead band)
 Set 3652 to 0.2s which corresponds to a 200ms pulse width
 Remove the I component of the synchronization control: set 2906 and 2902 to 0
Note: To get the best results during synchronization, it's often useful to set the P values 2901 and
2905 high when tuning the synchronization (typical values from 80 to 200).

Setting for synchronization

If the generator makes too much or not enough correction during synchronization, it means that the
pulse width is not properly adjusted:
 Decrease 3652 to reduce the pulse control on the governor
 Increase 3652 to have more correction on the governor

If the generator oscillates around the set point during an active phase or if it’s hard to reach the set
point, it means that the dead band 3650 is not properly adjusted:
 Decrease dead band 3650 to improve the accuracy around the set point
 Increase dead band 3650 if the generator oscillates in frequency or in load

If there is a digital potentiometer between UNIGEN 2.0 and the speed governor, set U0 (fsd) and
Time; if you don’t get the desired compensation, check the following points:
 Is the potentiometer still running when UNIGEN 2.0 sends an output signal?
 Check that the speed/voltage range controlled by the potentiometer is wide enough
Note: If pulses always generate an over-compensation, then it may be because the potentiometer is
still running even after the UNIGEN 2.0 pulse is finished. In this case a shunt resistor on the
potentiometer input may correct the problem by ensuring a proper low level at the input when UNIGEN
2.0 issues no pulse

5.4.3 Voltage calibration procedure

To calibrate the voltage control, execute the same procedure as the speed calibration procedure:
3651: Dead band (in %),
3653: Pulse width

5.5 TESTS
Make sure that you have the latest power plant schematics and that all the cables (CAN bus, shielded
cables, speed governor / UNIGEN 2.0 interface...) are ready. The HMI can be either LCD or CRE
Config/Scada.
5.5.1 Individual check
Check up
1. Disconnect the breaker control cables for safety purpose
2. Check the speed governor and AVR control settings and connection

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3. Check UNIGEN 2.0 settings according to the desired setup

4. Ask the technician who has wired the power plant to lock the generator breaker open
5. Check the battery voltage.
Check the protections
Make sure that at least these protections are properly set:
 Overspeed
 Overvoltage

Start the generator

1. Start the generator
2. Check the generator readiness led is on
3. Check that the engine speed and the generator voltage are stable and adequate (e.g. 1500rpm,
50Hz, 400VAC); the data is available in « Display/Generator »
4. On the screen « Configuration/Engine » & « Configuration/Generator », make sure the
speed/voltage deviations is optimum (+/-3Hz and +/-30V) when using Shift +  & Shift + 
(See 5.2 and 5.3)
5. Stop the generator

Check the control of the generator breaker on dead bus bar

1. Start the generator
2. Set the digital input « UNIGEN Activation »
3. Make sure the digital output « Synch check relay » is set
4. Deactivate the digital input « UNIGEN Activation »
5. Make sure the digital output « Synch check relay » goes off
6. Stop the generator

Check the synchronization

Synchronization is done on a bus fed by one or more generator :
1. Check the bus bar voltage and the bus bar led
2. Start the generator
3. Set the digital input « UNIGEN Activation »
4. Using the Information screen [I] button, check that UNIGEN 2.0 tries to synchronize
5. When there is no phase difference anymore (synchroscope at noon in “Display
menu/Synchr.”), check the phase sequence and check that all the voltages match upstream
and downstream from the breaker. If a check is negative, check the wiring of the generator
voltage and bus voltage
6. Make sure the digital output « Synch check relay » is set
7. When you are sure there is no wiring problem, stop the generator
Note: If the synchronization point cannot be reached easily, see 3.1.

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6 HUMAN-MACHINE INTERFACE

UNIGEN 2.0 offers several interfaces for setup and monitoring:

 the built-in LCD screen
 CRE Config software application interface
 a PC web browser
The CRE Config software is outlined in a specific manual; specific pages are described further. The
splash page text is customized in CRE Config/System/Display properties.

6.1 SECURITY AND OPERATIONS THROUGH THE FRONT PANEL

6.1.1 Security level and password

UNIGEN 2.0 features password-protected access levels to define which menu and items can be
accessed:

Level Default password Authorization Accessible pages and items

By default, this level is not password
0 No password. Press ENTER DISPLAY menu pages only
protected, but you can implement one
1 1 (digit “ONE”) User level, settings and commissioning All three menus

2 1234 Used to change advanced settings All items (CRE Config only);

The password can be changed in CRE Config/System.

INDEX
Display
Configuration
System

To access the Display menu, press ENTER.

To access the Configuration and System menus, the padlock must be released:
1. Press  to select Configuration
2. Press ENTER to switch to password input mode (as for other settings); the first character is
represented by a black rectangle
3. Scroll the character set by pressing  till you get the desired first character and press ENTER
to validate it
4. Shift to the next character pressing ; select the value pressing  and press ENTER to
validate it (* substitutes for each character entered)
5. Repeat for other characters
6. To validate the password, press ENTER
To log out, wait for the time TM password set in the System menu (default value: 5 min); then the
home shows and configuration is subjected to the input of a password.

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6.1.2 HMI status

To inhibit some keys or buttons, go to CRE Config/System/Button inhibition.

This can also be done through 16-bit word:

Setting Label Description

E3557 Button inhibit Each bit inhibit one button/key when set to 1

Bits numbers:
Inhib.bit 8 7 6 5 4 3 2 1

Key/Button ESC ENTER     SHIFT

6.1.3 Navigation in LCD

Press ESC ENTER and type in the level 1 password as described above to access the top level menu:
INDEX
Display
Configuration
System

A black pointer spots the currently selected item/setting; a white one features other items/settings.
Three main menus are available on the LCD screen and the web client monitor:
 Display gives information on generator & busbar, & displays real-time information & status
 Configuration is used to hone the settings done in CRE Config/Configuration
 System is used to change on the fly the settings done in CRE Config/System (Date/Hour,
Screen features, ...)
To cycle through the menus and menu items, press  or .  

To cycle through the pages of lists of settings/readings, press  or :  

MENU PAGES PARAMETRES

Previous
X-1/n

Next

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6.1.4 Edition
To change a setting:
1. Navigate to the setting
2. Press ENTER to switch to Edition mode; the current value blinks
3. Press  or  to get the new value
  

4. Press ENTER to validate the new value, ESC to reject it. UNIGEN 2.0 returns to Navigation
mode.
It is also possible via the bus Modbus TCP. See 7.1.

6.2 SUPERVISION

If you keep the PC connected, you can monitor the generator from CRE Config/Scada through
UNIGEN 2.0.

An alarm/faults handler is built-in.

Note: In the handler, the buttons are greyed out until the PC is connected to UNIGEN 2.0.

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6.3 WEB SERVER

The UNIGEN 2.0 web server provides a very easy and efficient way of:
 loading/downloading configuration file.
 Downloading alarm/fault/log events
 Update firmware
 Visualize alarm/fault

To do so:
1. Connect UNIGEN 2.0 to your PC using an Ethernet direct cable
2. Start a Web browser such as Firefox or Internet Explorer
3. Type in the IP address (factory setting: http://192.168.11.1), or UNIGEN 2.0 hostname
4. When the UNIGEN 2.0 password page appears, enter your password

In the browser, the only soft key is ESC, used to return to the parent menu.

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6.4 DISPLAY MENU

The LCD menu gives access to the following information:

 Generator electrical meter
 Bus electrical meter
 Synchronization
 Engine meters
 Inputs/Outputs state
 About (Only level 0)

A Generator electrical meter

These pages display in real time all generator electrical measurements in true RMS.
A- 1Global view
 Phase-to-neutral voltage of phase 1
 Phase-to-phase voltage of phase pair 3-1
A- 2Frequency (Hz)
A- 3 Phase to neutral (V)
 V1, V2, V3
A- 4 Phase to phase (U)
 U31, U23, U12
Notes: The frequency is available if the phase-to-neutral voltage exceeds 15VAC. These pages fit the
preset voltage system (see further).

B Bus/Mains
These pages display in real time all bus/mains electrical measurements.
B- 1 Global view
 Phase-to-neutral voltage of phase 1
 Phase-to-phase voltage of phase pair 3-1
B- 2 Frequency
B- 3 Phase to neutral (V)
 V1, V2, V3
B- 4 Phase to phase (U)
 U31, U23, U12
Note: These pages fit the voltage system selected (see further)

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C Synchronization
This page displays:
 Synchroscope (phase difference)
 Differential frequency and voltage (bar graphs)

D Engine meters
D- 1
 Engine speed (RPM)
 Battery voltage
D- 2
 Running hours

E Inputs/outputs state
E- 1 Digital inputs 1-5
The name of each input is displayed with its status: active =full dot, inactive = hollow dot.
 1 (Raw) is the status of the physical input,
 2 (Processed) is the status after conditioning (delay, …).
E- 2 Digital inputs 6-9
Idem.
E- 3 Digital outputs
The name of each output is displayed with its state: active =full dot, inactive = hollow dot.
E- 4 Relay outputs
This menu shows the state of the two relay outputs (Generator breaker).
The name of each output is displayed with its state: active =full dot, inactive = hollow dot.
E- 5 Analog inputs 1-3
The name of each input is displayed with its
 Value if really analog
 Status if digital: active =full dot, inactive = hollow dot.

F About
These pages show only if you have entered as observer (no password). Otherwise, find it in
“System/About“.
1. S/N: serial number, Type (A51V0), Version, Boot version
Host name, IP, NM (network mask), GW (gateway). See 2.1.

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CRE Config/Scada gives access to readings in addition to the preceding ones.

CLOCKS
Reading Label Description Timeout

4450 Loss of speed sensor Time since the speed sensor signal is not available 2203
4465 Speed & voltage stabilization Time generator is waiting to let engine speed & volt stabilize 3469
before taking the load (not applicable to static paralleling)
4466 Voltage stabilization Voltage stabilization counter for static paralleling 2056

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6.5 CONFIGURATION MENU

To access this menu, a password is required; the LCD menu gives access to the following information:
 Power plant
 Generator
 Bus
 Engine
 Protections (Only CRE Config software)
 Timers (Only CRE Config software)
 Synchronization
 Modification by variable n°
The settings with a purple left border are for CRE Config only.
A Power plant

Power plant applications

Setting Label Value Description
2001 Number of module 1 … 32 Number given to this particular UNIGEN 2.0 on the
CAN bus
2000 Total count of modules 1 … 32 Total count of UNIGEN 2.0 units installed on the CAN
bus

2002 Deadbus No [0] An external logic controls dead bus management

management
Yes [1] Dead bus management via inter UNIGEN 2.0 digital
CAN bus
2003 Voltage schema Monophase [0] Voltage system selection
Biphase 180° [1]
Triphase 120° [2]

B Generator
B- 1 Generator
Setting Label Description
2102 Nominal voltage Generator nominal voltage
2253 Nominal voltage (2) Second nominal voltage of the generator, activated with logical input

B- 2 Generator
Setting Label Description

2100 PT ratio Ratio of the voltage transformers (Ex: 20 kV to 100 V: type in 200). Default value: 1

B- 3 Generator
AVR CONTROL
Setting Label Description
2251 AVR amplitude
Use in case of analog voltage control. See 5.3.
2252 AVR offset
3651 Dead band
Use in case of voltage control by pulse. See 5.4.
3653 Pulse width

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C Bus/Mains
C- 1 Bus/Mains
Setting Label Comment
2150 PT ratio Ratio of the potential transformers

2152 Nominal voltage Bus nominal voltage

D Engine

Setting Label Possible value Comment

2205 ESG amplitude 0…10.0V Use in case of analog speed control. See 5.2.

2206 ESG offset –10.0V…+10.0V

3650 Dead band 0.00% to 100.00% Use in case of speed control by pulse. See
5.4.
3652 Pulse width 0.1s to 10.0s

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E Protections
All protections work with :
 A threshold: triggering level of protection
 A timer: time before triggering the protection
 An action to do when the fault is present

Generator
Protection 1 (level 1) 2 (level 2)
Threshold Delay Action Threshold Delay Action
Over frequency 2400 2401 2402 2436 2437 2438
Under frequency 2403 2404 2405 2439 2440 2441
Over voltage 2406 2407 2408 2442 2443 2444
Under voltage 2409 2410 2411 2445 2446 2447

F Timeouts and delays

Setting Label Description
3469 Stabilisation Time to wait for speed and voltage to get steady

2478 Horn delay Drop-off delay. See 4.1.2.

G Synchronization
This page allows setting the synchronization settings used to allow the synch check relay to operate.
Setting Label Description
2810 Voltage match Maximum difference (in %) between generator and bus bar voltage for
coupling
2811 Freq. match Maximum frequency difference between generator and bus bar for
coupling
2802 Phase match Maximum phase angle difference between generator and bus bar for
coupling
2803 Fail to synch. Allocated time to synchronize

(1)
2809 C2S dwell time Synchronization dwell time before authorizing to close the breaker (default
value 200ms)
2804 Control on fail Selects the action in case of synchronization fails
synch
(1) This setting can be modified using TXT file or modification by variable number menu

Used to tune the frequency and phase synchronization PID to decrease the synchronization time. The
built-in synchroscope shows and lets you monitor in real time any change made on these settings.
Setting Label Description

Voltage
2951 P Proportional gain of the voltage synchro
2952 I Integral of the voltage synchro
Frequency
2901 P Proportional gain of the frequency synchro

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Setting Label Description

2902 I Integral of the frequency synchro

Phase - Angle
2905 P Proportional gain of the phase synchro
2906 I Integral of the phase synchro

H Modification by variable number

This page is very useful when you are familiar with key variable numbers, for example the ones you
often modify. Simply enter the variable number, and then enter its value.
Note: You can only change settings 2xxx…3xxx. Some are not accessible in regular menus.

CRE Config EXTRA SETTINGS

These settings can still be modified through the LCD (Modification by variable number).

DIGITAL INPUTS AND OUTPUTS, AND CANopen

See chapters 8.3 et 7.2.
LOGGER
UNIGEN 2.0 can save up to 1350 pieces of data. In addition to Power state, up to 10
readings/statuses can be selected. This includes archived alarms and faults. They are archived on
change of value.
Format:
jj/mm/aa hh:mn:ss.100ms label XXXX=YYYY . XXXX = parameter number, YYYY = value.

In CRE Config/Configuration/Logger:
 Tick the box Log on/off to enable the data logger
 Enter the codes in the text area (using the spin is NOT recommended as you have to scroll a lot).

The records can be downloaded from CRE Config or the web site.

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6.6 SYSTEM MENU

It gives access to the following pages where with readings, or settings to modify:
 Date/Time
 Screen setup
 Ethernet
 About (read only)

A Date / Time
“Date / Time” allows you to modify the date and the time:
Label Description
Date Year/Month/Day/Day of week
Time (hh:mm) Time adjustment (H M)

B Screen setup (Display properties and password)

Setting Label Default Description

3554 Contrast 50% Adjustment of LCD contrast from 0 to 100%
3555 Backlight 100% Adjustment of LCD backlight from 0 to 100% of the max backlight intensity
3552 Backlight saver 5 min Time without navigation (in minutes) after which the backlight turns off.
timeout 0 means infinity.
3553 Password 5 min Time without navigation (in minutes) after which password is inactive.
timeout 0 means infinity.
3551 Screen saver 5 min Time without navigation (in minutes) after which the display exit menus
timeout and show screen saver. 0 means infinity.
– Line 1 to Line 2 CRE Tech The two lines of text displayed in the Splash screen saver can be
its URL modified on the fly. Each line can include up to 21 characters in length

C Ethernet
This page allows to configure the Ethernet connexion with the following parameters:
 DHCP
 IP address
 Network Mask
 GateWay IP address
 HTTP port
 Modbus port

D About
This page displays some information on module and on Ethernet connection.
 Serial number (S/N)
 Module reference (type)
 Software version
 Boot software version
 Hostname
 IP address
 Network Mask
 GateWay IP address

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SCREEN SAVER
The page displayed when the user does not interact with UNIGEN 2.0 (keys not used) is called
“SCREEN SAVER”. Information displayed on this page depends on the UNIGEN 2.0 status, as
described in the following table. Some settings can also be used to customize this behaviour.

Screensaver Description Mode

Synchronization Frequency difference (bar graph) In synchronization state

column Voltage difference (bar graph)
Phase difference (column)
Frequency match (OK/NOK)
Voltage match (OK/NOK)
Phase match (OK/NOK)

Generator Frequency (in large font) When the generator

overview Voltage (in large font) breaker is opened and
engine ready

Customized 2 custom lines In waiting state

screen Current date and time

PASSWORD
This page allows you to change passwords, from level 0 to the currently connected level. Passwords
are limited to 8 characters maximum. Refer to chapter 6.1.1.

LANGUAGES
Setting Label Possible value Description
English
Francais Language of the menus displayed on the LCD and on
3556 Language
Espanol embedded web site
Italian

Note: It is possible to add a custom language. Refer to chapter Maintenance.

COMMUNICATION PORTS CONFIG

INTER-UNIGEN CAN
This isolated communication port is dedicated to inter-unit data communication using a proprietary
protocol. This bus is designed for dead bus management. Action to be performed upon CAN bus fault
[3052] occurrence can be set (select menu Options/Advanced).
The bus speed is fixed at 125kbit/s.
CANopen-J1939
This isolated bus is used for communication with CANopen remote I/O modules (Beckhoff, Wago,
Vipa...) and/or electronic engines communication (J1939).
ETHERNET
This page allows you to configure the Ethernet connection to communicate with a PC. Please contact
your network administrator to configure router and module(s) according to your need.
Setting Label Default Description
3012 DHCP select Disable [Disable]: fixed IP address
[Enable]: DHCP protocol (dynamic IP address) enabled
(1)
3000…3003 IP Address 192.168.11.1 Fixed IP address of the unit (DHCP disabled or in fault)

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Setting Label Default Description

(1)
3008…3011 IP GW address 0.0.0.0 Gateway IP address (DHCP disabled)
(1)
3004…3007 IP NM 255.255.255.0 Network mask (DHCP disabled)
3013 Port HTTP 80 TCP communication port
3014 Port Mod TCP 502 Modbus TCP communication port
(1) Only available if DHCP protocol is disabled.

Notes: On CRE Config, these modifications are taken into account during power on sequence. Restart
UNIGEN 2.0.
On LCD, modification of port numbers is taken into account during power on sequence. Restart
UNIGEN 2.0.

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6.7 DEDICATED PAGES

The dedicated pages include:
 The faults page
 The alarms page
 The information page.
At any time, you can display the faults/alarms/information on LCD screen by pushing button.

If an active fault exist and has not been acknowledged yet, the active fault page will be displayed.
Otherwise if an active alarm exist and has not been acknowledged yet, the active alarm page will be
displayed.
Otherwise the information page will be displayed.

You can navigate through these dedicated pages with the high, low, left, right arrows buttons.
To return on previous page, press ESC or button.

6.7.1 Faults and alarms

The latest 15 active faults and alarms show in addition of the latest 30 archive faults and alarms.
They are time-stamped as follows:
dd/mm/yy hh:mn:ss protec. label On (or Off).

To reset the tripped protections, press “SHIFT+I.

Note: Fix the condition triggering the protection before clearing the alarm; failure to do this will
trigger the protection again.
To erase the Faults/Alarms archive, in CRE Config/Display/Faults or Alarms, press Erase button.
Note: Erase button will erase all archives including Faults, Alarms and loggers.

6.7.2 Information

These pages allow displaying the power current state with the associate elapsed time in this state.
In addition, 2 variables per page can be consulted.

Power [4001] displays the unit current state regarding power management.
Custom variables: To display any reading, enter its 5-digit code.

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7 COMMUNICATION BUSES

7.1 MODBUS TCP

7.1.1 Capabilities

The complete list of variables is in the file A51V0 90030_.xls.

Through an Ethernet communication where UNIGEN 2.0 acts as a Modbus TCP server, you can
 Upload many readings and UNIGEN 2.0 internal variables
 Download values for many UNIGEN 2.0 internal variables:
Nature Range Access right by nature
Readings (measurements, statuses) 0000 … 1999 Read only
Settings 2000 … 3999 Read/Write
Modes, statuses, settings 4000 … 9999 Read
Readings associated with digital inputs 4500 … 4649 Write (subject to activation)

In addition, in order to decrease load on Ethernet, the following functions are supported:
 Reading Bit Fields, listed in a dedicated tab of the file and organized in 16-bit words
 Reading contiguous configurable data block

7.1.2 Configuration

To communicate through Modbus TCP, define the following settings:

 UNIGEN 2.0 IP address set in “System/Ethernet”
 Modbus TCP port [3014], generally 502, set in “System/Ethernet”
 Modbus rights: see further

UNIGEN 2.0 handles up to 4 Modbus TCP connections. This can be used for multiple HMIs for
example.
For more details on the Ethernet configuration, see the chapter 2.1.

7.1.3 Description

WARNING
RISK OF UNINTENDED EQUIPMENT OPERATION
It’s recommended to stop the engine before changing some settings
Failure to follow this instruction can damage equipment
Functions
UNIGEN 2.0 supports the following Modbus functions:
Function Description
01, 02 Read logical values (coil status, discrete input status)
03, 04 Read holding/input registers (16 bits)
05 Write logical value (single coil)
06 Write single register (16-bit variable)
15 (0x0F) Write multiple logical values (multiple coils)
16 (0x10) Write multiple registers
All UNIGEN 2.0 variables are 16-bit registers. Yet it might be useful to consider them as logical values
(if they are only set to 0 or 1) to simplify Modbus communication with some external PLC. If function
01 or 02 is used to read an internal register that is different from 0, then returned value will be 1.

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UNIGEN 2.0 registers start from address 0. Depending on your Modbus TCP client equipment-
software, you may need to use an offset of 1 when reading/writing registers as addresses may start
from address 1. In this case, request address/register number 1 to access variable 0000 inside
UNIGEN 2.0.

The 32-bit variables can be written to only with function 0x10.

If a digital input modifies a piece of data also to be written by Modbus, the latest request takes over
the other.

Data 10000…10299 can be read by block. See further.

Access rights
The access rights depend on the parameter nature and on massive permissions. To grant massive
access rights, set to 1 the corresponding bits in the word 3015:

function registers

Writing to Engine
Writing to input
Reading using
Writing using
Modbus TCP

Modbus TCP

Date/Time
Not used

Not used

Writing to
Not used

Not used

Not used

counters
Bit # 9 8 7 6 5 4 3 2 1 0
Default value 1 1 0 0 0 0 1 0 0 0

In CRE Config/System/Network configuration/Modbus access rights, just tick a checkbox:

Bit # Label Use
0 Writing to Date/Time Synchronization of UNIGEN 2.0 clock. See chapter A
1 Writing to Engine meters Manual adjustment of counters (see next table). See chapter A
2 Writing to digital input
function register
8 Reading using Modbus TCP Opens the possibility to grant reading individual permissions
9 Writing using Modbus TCP Opens the possibility to grant writing individual permissions

The counters, encoded on 32 bits, include:

Counters (MSB|LSB) Label

0080|0079 Generator kWh
0082|0081 Generator kVARh
0084|0083 Engine running hours

Bit Fields
Bit fields are meant for decreasing communication bus load. They pack up to 16 logic variables inside
a single register. This way a single Modbus request can be used to read a chunk of information. Each
variable contains the current value of 16 logic variables such as breaker positions, faults, alarms…
They are listed out in the Bit fields tab of the document A51V0 90030_.xls.
The bit fields 0956 … 0969 have latched values: a reset is required for them to return to 0.
Note: Available data are related only to faults that occurred after the latest power up sequence.
Events that occurred before UNIGEN 2.0 has been power cycled are listed in the FAULT pages but NOT
among the variables.

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Custom blocks
To create your own blocks, use the variables 10000 … 10299 in CRE Config/Configuration/Modbus.
There are two ways to configure these blocks:
A. Configuration in CRE Config/Modbus: enter the codes of the variables to read; the readings
on the registers 10000 … 10299 will be the pointed values
B. Configuration by an external device; this device must request the following:
1. Write 1 to 3016 to enter into the configuration mode
2. Write the codes to the desired registers (10000 … 10299)
3. Write 0 to 3016 to enter into the read mode

Then to read your own block, you just need to read by Modbus the register 10000 to 10299.
Time stamping is done by the master.

Example:
If the configuration is as follows E10000 = 14; E10001=15; E10002=16, the reading by Modbus of the
3 registers will give to you the hours/minutes/seconds of the UNIGEN 2.0.

Later, CRE Config can upload the new configuration if needed.

Modbus communication example

The table below exemplifies a Modbus TCP client sending a reading request (function 04) of 6
registers starting from variable 0079.

Client request UNIGEN 2.0 server response

Field Value Field Value
Function code 04 Function code 04
Starting register (MSB) 00 Data bytes (=2 x count of requested registers) 6
Starting register (LSB) 79 Value of register 0079 (MSB) D0
Count of registers (MSB) 00 Value of register 0079 (LSB) D1
Count of registers (LSB) 06 Value of register 0080 (MSB) D2
Value of register 0080 (LSB) D3
Value of register 0081 (MSB) D4
Value of register 0081 (LSB) D5

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7.2 CANOPEN EXTENSION MODULES

CANopen extension modules can be used to increase the number of digital inputs and outputs of
UNIGEN 2.0. Overall max. count of added inputs: 32 I and 32 O. They are read/written to every
100ms.

7.2.1 Hardware

Each bus coupler is a slave node that supports up to 64 I/O modules that offer different kinds of I/O.
Outputs can be by transistors or relays. I/Os can be distributed across up to 4 daisy-chained couplers.

Manufacturer WAGO BECKHOFF VIPA

Bus coupler

750-3xx

BK5150 LC5100 (low cost, no VIPA053-1CA00

isolation)
ID by DIP switch ID by rotary switch ID by DIP switch ID by DIP switch
I/O modules 75x-4xx (inputs) KLxxxx All the digital I/O VIPA 021-1BF50 (inputs)
75x-5xx (outputs) terminals are sup- VIPA022-1BF00 (outputs)
ported except the
KL15xx, KL25x2, KL2692
and KL27x1 terminals

The modules are stackable and mounted on a DIN-rail. Refer to the extension module’s user manual
for correct wiring on the CANopen module side. Check whether the inputs/outputs are protected
against short-circuits. If needed, connect the drain to the DIN rail.
Make sure there is a resistor of 120 between CAN H and CAN L on both ends of the cable. For
details, refer to the Appendix CAN bus good practices.

Available bit-rates: 125/250/500 kbps, 1 Mbps.

Note : CANopen can be used in parallel with J1939 at 250 kbit/s.

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7.2.2 Configuration
Setting Label Value Description
3151 CANopen config 1 8 inputs + 8 outputs of coupler ID# 1
2 16 inputs + 16 outputs of coupler ID# 1
3 32 inputs + 32 outputs of coupler ID# 1
4 Custom configuration, defined by more settings
3153 CANopen ID# 1 0 … 255 Identifier of the first coupler
3154 CANopen IN 1 0 … 32 Count of inputs on the first coupler
3155 CANopen OUT 1 0 … 32 Count of outputs on the first coupler
3156 CANopen ID# 2 0 … 255 Identifier of the second coupler
3157 CANopen IN 2 0 … 32 Count of inputs on the second coupler
3158 CANopen OUT 2 0 … 32 Count of outputs on the second coupler
3159 CANopen ID# 3 0 … 255 Identifier of the third coupler
3160 CANopen IN 3 0 … 32 Count of inputs on the third coupler
3161 CANopen OUT 3 0 … 32 Count of outputs on the third coupler
3162 CANopen ID# 4 0 … 255 Identifier of the fourth coupler
3163 CANopen IN 4 0 … 32 Count of inputs on the fourth coupler
3164 CANopen OUT 4 0 … 32 Count of outputs on the fourth coupler
The assignment of I/Os is done in the order of couplers and the lower variable number is associated
to the lower message number configured.
The CANopen inputs and outputs have the same attributes as regular inputs and outputs except the
Delay on drop-off of inputs (See chapter 8.3):

Setting Attribute
Digital inputs 1 … 32
3200 … 3231 Function
3232 … 3263 Delay on pick-up
3264 … 3295 Validity
3296 … 3327 Direction
Digital outputs 1 … 32
3350 … 3381 Function
3382 … 3413 Mode (direction):
0: normally de-energized
1: normally energized

On power-up, the configuration is automatically launched. The status 3150 turns to 1.

The error time-out (3152) is 10.0s by default.

7.2.3 Mapping

CANopen inputs and outputs are accessed by their code:

 Inputs: 0800 … 0831
 Outputs: 4751 … 4782

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7.3 J1939 COMMUNICATION

7.3.1 Overview

J1939 is a CAN protocol used by “electronic” motors, which include an ECU (or ECM, EMS). In the
case of UNIGEN 2.0, it allows you to send commands of speed control.

Bit rate: 250kbit/s.

To use the J1939 communication:
1. Enter the “Configuration/Engine/J1939“ page
2. In the list, select the manufacturer [3100]
3. Select the ECU type [3101]
4. Connect the engine ECU and the UNIGEN 2.0 J1939 port

The pair manufacturer-ECU determines the following settings:

 UNIGEN 2.0 address on the CAN bus
 ECU address on the CAN bus
 Speed control: through J1939 or by analog output/pulses

UNIGEN 2.0 can communicate with a large number of J1939 engines. As the engine list accrues,
please contact CRE Technology or your local distributor if your engine is not mentioned in this
document.
In any case, if your ECU does not belong to the following list, try:
1. To select the generic ECU from your manufacturer
2. To select the GENERIC manufacturer, then modify the UNIGEN 2.0 [3103] and ECU [3102]
address according to the ECU documentation (Modification by variable number)

7.3.2 Search engines list

Manufacturer [3100] ECU [3101]

[1] GENERIC [0]
S6 (DC16-45A) [1]
GENERIC [0]
EMS2 [1]
EDC4 [2]
94xGE [3]
124xGE [4]
[2] 1640-2GE [5]
1643GE [6]
D6 [7]
D7 [8]
D13GE-Tier3 [9]
[3] GENERIC [0]
1100 (A4E)
GENERIC [0]
NEF (EDC) [1]
[4] CURSOR [2]
CURSOR9 (EDC) [3]
CURSOR11 [4]
(1)
GENERIC [0]
[6] QSX15-G8 (CMS570) [1]
CM850 [2]

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Manufacturer [3100] ECU [3101]

QSB5 (PGI 1.1) [3]
QSB7 (PGI 1.1) [4]
QSL9 (PGI 1.1) [5]
QSM11 (PGI 1.1) [6]
QSX15 (CMS570) [7]
QSK19 (PGI 1.1) [8]
QSK38 (PGI 1.1) [9]
QSK50 (PGI 1.1) [10]
QSK60 (PGI 1.1) [11]
[7] GENERIC [0]
JDEC [1]
[8] GENERIC [0]
ADEM A4E2 (C4.4 & C6.6) [1]
GENERIC [0]
[9] EMR [1]
EMR2 [2]
EMR3 [3]

[10]
ECU8 + Smart Connect [3]
Voir Appendice MTU

(1) Cummins 109G ECU may not support speed control through J1939. ECU with Cummins G Drive firmware should support J1939 speed control

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8 RESOURCES FOR SETUP & MAINTENANCE

UNIGEN 2.0 handles several files used for setup or maintenance.

The Configuration file allows you to:
 Set the value of every setting
 Change the units of analog inputs (example: V, mbar, psi, …)
 Change the accuracy when displaying analog values (example: 24V or 24.0V)
 Change the labels of inputs and the screensaver
The log file contains the history of time-stamped data (alarm/faults, FIFO data as selected in CRE
Config/Configuration/Logger). It is used for maintenance.
The action file contains the list of effects of alarm/faults. It is a sub-file of the text file. They are listed
out in 4.1.1.
The firmware upgrade is a zip file.

8.1 FILE TRANSFER

These files can be transferred to or from UNIGEN 2.0.

Use CRE Config/System/PC transmit-receive OR the web server.
GENSYS
Transfer
settings
Reset to
factory

Erase

PC
Erase and Reset to factory settings are available in CRE Config (for the latter, select
Options/Advanced and connect on level 2).

8.1.1 UNIGEN 2.0 -> PC file transfer

This page allows you to download a file from UNIGEN 2.0 to the PC:
 Configuration file
 Log file
 List of actions on alarms/faults
Note: The file transfer is only possible when the engine is waiting (No synchronization, No load
sharing).
Configuration file
To display the current configuration file in an internet browser, select “Configuration file”.
In the web browser, to save this file, right-click in the page with the text file, and select Save as.

CAUTION
To edit a new configuration from the configuration file, it is strongly recommended to
use a configuration file compatible with the installed firmware version:
1. Upload the file from UNIGEN 2.0
2. Modify it
3. Download this new configuration file to UNIGEN 2.0

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Log file
Upload the file. In the web browser, to save the file, right-click in the page with the file, and select
Save as.
List of actions on alarm/fault
By selecting “Action on alarm/fault”, a file containing all potential alarms/faults and their use is
displayed.
To save this file, right-click in the page with the text file, and select Save as.
Example:
S/N:4316A0003
Type:A51V0
Version:v0.03
Bootversion:v1.20
Date:06/01/17
Hour:10h30m59s

***** Effet alarme/defaut *****

0 : Disable
1 : Gen electrical fault
3 : Alarm

(1) -> level 1

(2) -> level 2

Potentiel Alarm./Def. Parametre actuel ANSI C37-2

V00600 Etat CAN1 (1) <-- V03052 = 8
V00602 CAN2 etat (1) <-- V03053 = 0
……

8.1.2 PC -> UNIGEN 2.0 file transfer

This page allows you to send parameters file, or language file.
1. Click the “Browse...” button
2. Select the file to download
3. Click the “Save” button.
When the operation is completed, a screen shows on the PC.
Note: Before edition it is recommended to save the current configuration with the “UNIGEN 2.0 -> PC”
page. The file transfer is only possible when the engine is waiting (No synchronization, no load
sharing).

8.1.3 Firmware upgrade

This page allows you to upgrade to the latest firmware that can be found on CRE technology Web
site. See chapter Maintenance.

8.2 TEXT FILE DESCRIPTION

8.2.1 Variable naming

The file named A51 V0 9 0030x.xls describes each variable.

The variable format is VXYYYY.
X relates to the type of variable:
 0 and 1: a reading or a real-time value (Voltage phase 1, CAN bus fault …)
 2, 3 and 4: a setting to store in non-volatile memory (Generator number, Nominal power …)

YYYY is the code of the variable.

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The parameters are stored in a non-volatile FLASH memory in the unit. It is possible to download or
upload them with a PC, which allows the user to save, modify and reuse them later.
All these values are stored in the text file. This chapter describes the layout of the file.
8.2.2 Text file description
The complete unit setup can be contained in a simple text file. This file can be downloaded from
UNIGEN 2.0 to be kept on a PC. It can also be manually edited on a PC and sent to UNIGEN 2.0 to fully
setup it in a single step.
This text file is made up of different blocks:
 Parameter values
 Label definitions
 Text definitions
 Unit and accuracy definitions
Parameter definition block
The block start is the {PARAMETERS} statement. Each setting (2000 … 4000) can be found as an input
in this block. The structure of the input is as follows:
 The variable parameter number preceded by the letter V (Ex: V02000)
 The parameter value (Ex: 2)
 The label (optional: only for user information) (Ex: Nb of gen.)
 The minimal value (optional: only for user information) (Ex: +00001)
 The maximal value (optional: only for user information) (Ex: +00032)
 Unit
Example:
{PARAMETERS}
V02000 2 Nb of gen. +00001 +00032
V02001 1 GE number +00001 +00032

It is possible to modify the values directly in the text file before uploading it into UNIGEN 2.0. The
user must be sure that the modified value is within the minimum / maximum range of the
parameter. Failure to do so leads to an error message during uploading (see chapter 9.3).
It is also possible to write to an incomplete parameter block (not all parameters are displayed in the
list). When uploaded, such a file modifies only the parameters which have been entered, the others
remain unchanged. This procedure can be used to upload an old text file into a newer module or to
activate special features independently.
Label definition block
The block start is the {LABELS} statement. This block is used to define custom labels for CRE Config
and the LCD (digital I/Os, analog Is, CANopen I/Os, relay outputs, cycles before maintenance).
Each line of this block contains 2 elements:
 The variable number of the text, preceded by the letter L for label
 The text itself between quotes
{LABELS}
L01130 Sample label

Labels are 14 characters long.

Supported characters include [a...z], [A...Z], [0...9] and the following characters:
<space> ?! # $ ( ) * + / : ; = [ ] ^ _ . -
All other characters are NOT recommended, and will be replaced by ? characters.
Note: All custom labels apply to all languages.
Text definition block
The block start is the {TEXTS} statement. Each line of this block contains 2 elements:
 The variable number of the text, preceded by the letter T

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 The text itself between quotes

This block includes two items for the logo page and one for hostname:
Text
T0001 CRE Technology
T0002 www.cretechnology.com
T0003 Hostname

Texts are 21 characters long at most.

Units and accuracy definition block

The block start is the {UNITS} statement.
This block defines what kind of units and accuracy is associated with each analog value.
You need to define only the unit of the analog input itself. All associated parameters (thresholds for
instance) are automatically modified accordingly.
The table below lists the different units supported by UNIGEN 2.0.
Only the three programmable analog inputs have an entry in this block (to get the variable number,
refer to the file A51 V2 9 0030x.xls).
The structure of a unit/accuracy definition consists of the variable number preceded by a letter (U for
Unit, A for Accuracy definition) and followed by a code as shown in the examples below. The use of
unit and accuracy is described in 8.3.3.

{UNITS}
U00150 14
U00151 18
U00152 00
…
A00150 1
A00151 1
A00152 0
…

The table below shows the list of codes which correspond to the supported accuracies and units. In
the examples above, analog input #1 (150 variable) is displayed in mBar (Unit code = 14) and with
one decimal digits (Accuracy code = 1).

Code Accuracy Code Unit Code Unit Code Unit Code Unit Code Unit
00 ““ Power-energy Pressure Temperature Time
0 1 Electrical 07 kW 13 Bar 18 °C 24 s
1 0.1 01 V 08 kWh 14 mBar 19 °F 25 h
2 0.01 02 kV 09 kVAR 15 kPa Volume 26 days
3 0.001 03 mA 10 kVARh 16 PSI 20 L Time related
3
04 A Rotating speed Angle 21 m 27 Hz/s
3 3
05 kA 11 rpm 17 ° 22 mm 28 m /h
Frequency Percent Mass 23 Gal 29 L/h
06 Hz 12 % 31 kg 30 Gal/h

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8.3 I/O LINES

8.3.1 Digital inputs

Each input is tagged with a label defined in CRE Config/Configuration, and features several attributes
set in the Configuration menu:
 Validity
 Direction
 Delay
 Function
Configurable input label
This is the name you give to the input. The name shows in the info, alarm, and fault
screens if programmed accordingly.
Direction
For each input, two options are available:

Num Label Function

0 Norm open Used unless the input is used for protection
1 Norm close Normally closed; must be selected if the input is normally
connected to 0V and is opened when active

Delays
For each input, two delays can be defined in 100ms steps between 0 and 6553s.

Raw input
Delay on Delay on
pick-up drop-off
Delayed input

Raw input
Delay on Delay on
pick-up drop-off

Delayed input

Summary

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Note: If a digital input changes a piece of data also to be written by Modbus, the latest request takes
over the other. If 2 digital inputs are assigned to one function, the latest change is taken into account.
Input functions
ESSENTIAL INPUTS
Function Use/Description Ref. chapter
Must be selected if the input is not connected (default value
Not used
generally)
Generator breaker
Generator breaker position feedback 4.3
feedback

UNIGEN CONTROL
Function Use/Description Ref. chapter
UNIGEN activation This digital input allows you to start or stop the synchronization. 3

FRONT PANEL BUTTONS

Function Use/Description Ref. chapter
External reset. Alternative to local fault reset in Fault and Alarm 4.2.5
Fault reset
pages
Test leds Activates all LEDs of the module in order to check that the LEDs work

SPEED VOLTAGE COMMANDS

Function Use/Description Ref. chapter
Increase speed Increase of the frequency in state « waiting »
Decrease speed Decrease of the frequency in state « waiting »
Increase voltage Increase of the voltage in state « waiting »
Decrease voltage Decrease of the voltage in state « waiting »

EXTERNAL ALARMS/FAULTS
Function Use/Description Ref. chapter
Generator fault request External protection set a generator fault. 4.1.1
Remote alarm External protection set an alarm on the product ibidem
Selective external reset; in addition, an output must be preset to
Stop horn 4.1.2
Horn

ALTERNATIVE SELECTIONS
Function Use/Description Ref. chapter
Nominal speed 2 Alternative nominal speed selected
Nominal voltage 2 Alternative nominal voltage selected

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8.3.2 Digital and relay outputs

Each output is tagged with a label defined in CRE Config/Configuration, and features several
attributes set in the Configuration menu:
 Direction
 Pulse length: 0 means no pulse
 Function
Directions
Each output can be:
 NE: normally energized; the output is de-energized when its function is activated
 ND: normally de-energized; the output is energized when its function is activated

Pulse length
Each digital output can be configured to act as a pulse. The pulses lengths are defined with the
parameters E2761 to E2766.

Set to 0 in order to have a continuous output (No pulse).

Output functions
SYNCHRO COMMANDS
Function Description Ref. chapter
Synch check relay Command to close generator breaker 4.3

LEDS STATUS
Function Description Ref. chapter
Faults LED Reflects the led status
Alarm LED idem
Generator LED Reflects the led status

GENERATOR STATUS
Function Description Ref. chapter
Generator ready Activated when generator voltages and frequency are stable
Generator voltage
Activated if the generator is started and a voltage is detected
presence
Generator stop Activated if generator is at rest

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SPEED/VOLTAGE COMMANDS
Function Description Ref. chapter
Increase speed by pulse Speed regulator requiring +/- contacts 5.4
Decrease speed by
Speed regulator requiring +/- contacts. ibidem
pulse
Increase voltage by
Idem speed ibidem
pulse
Decrease voltage by
Idem speed ibidem
pulse

SYNCHRONIZATION
Function Description Ref. chapter
Dead bus bar 4.1
Phase sequence match Phase sequences are the same for synchronization 3.1
Voltage match Voltages are close enough for synchronization ibidem
Frequency match Frequencies are close enough for synchronization ibidem
Phase match Phases are close enough for synchronization ibidem
Authorization to close
Synchronization request accepted ibidem
breaker
Fail to synchronize Synchronization request denied (PID setting, fail to close breaker) ibidem

ALARMS/FAULTS SUMMARY
Function Description Ref. chapter
Generator electrical faults 4.1
External panel. Trigger: at least one generator-detected “fault”
summary
Alarms summary External panel. Trigger: at least one generator-detected “alarm” ibidem
External horn or flashing light. Activated whenever a protection
Horn triggers. The output is activated when one or more of summary 4.1.2
outputs is activated, and reset on acknowledgment

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In addition, most protection activations described in chapter 4.2 can be reported on a digital output.
On CRE Config, they are listed by categories as shown below. These outputs are available only if the
associate alarm/fault is configured.
ENGINE PROTECTION
GENERATOR PROTECTION
COMMUNICATION FAULTS

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8.3.3 Analog inputs

In addition to the speed and electrical currents and voltages, three analog inputs are available. They
measure a resistance 0…500. However, they can serve as digital inputs or 20 mA transducer input.

Input
Each input is tagged with a name and preset to a function. It features several attributes preset in CRE
Config/Configuration/Inputs/Analog inputs:
 Accuracy (number of digits after decimal point) among 1 / 0.1 / 0.01 / 0.001
 Unit, among No unit, V, kV, mA, A, kA, Hz, kW, kWh, kVAR, kVARh, rpm, %, Bar, mbar, kPa,
psi, °, °C, °F, L, Gal, s, h, days, Hz/s, m3/h, L/h, Gal/h
 Calibration, measure value according to resistor value in 

Calibration
Calibration is used to estimate a reading from a resistance value by interpolation between 2
wrapping resistance values. Negative values are supported for readings. Enter a table in CRE Config
/Configuration/Inputs/Analog inputs/Analog Measure Calibration or in text file.
Select the Accuracy, desired grade of details for tweaking and manual entering: 0.001, 0.01, 0.1 or 1.
Enter the limits of reading according to the sensor calibration; generally the lower limit is 0 and the
slope is Range/Rating. Calculate and enter the intermediary readings to get a linear distribution.

Protections
The input threshold features several attributes preset in CRE Config/Configuration/Protections/
Analog inputs protection:
 Level (LV): limit value in units; it can be a low or high threshold
 Delay (TM): time after which the trespassing is confirmed
 Validation (CT): protection type to which the signal contributes (3 potential values; see chapter 6.1)
 Direction (SS): is it a low (0) or high (1) threshold

SS C2
C3
IN
H,2
LV OUT: past threshold
L,3

TM TON
CT C1 8
1 OUT: protection type
Reset

Summary
The attributes show in the text file:
Threshold
Level Delay Validation Direction Function
AI 1 level 1 2600 2601 2602
2606 2607
AI 1 level 2 2603 2604 2605
AI 2 level 1 2608 2609 2610
2614 2615
AI 2 level 2 2611 2612 2613
AI 3 level 1 2616 2617 2618
2622 2623
AI 3 level 2 2619 2620 2621

Use of an analog input as a digital input

To mimic a digital input, connect the input to Power– through a switch, and select the function to
implement in the list CRE Config/Configuration/Analog inputs/Function. Refer to 8.3.1.
Then set the delay, validity and polarity.

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Use of an analog input as a transceiver input

To mimic a 20mA input, connect the input with a 39Ω resistor between the analog input and the
analog common, and select the function 20mA transceiver in the list CRE
Config/Configuration/Analog inputs/Function. The non-linearity of the sensor can be corrected
through a curve. Select the tweaking grade – the resolution in actual value – in accordance with the
sensor accuracy.

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9 MAINTENANCE

9.1 UPGRADING THE SOFTWARE

Prerequisite:
1. Upgrading software is done via the Ethernet connection. It’s mandatory to have a PC and to
connect on UNIGEN 2.0
2. Stop the generator
3. Save the current configuration as a text file; refer to chapter 8.1.1 Otherwise the default
settings will be enforced (except for the Ethernet settings)
4. Disconnect all the terminals, except the power supply and Ethernet connections.

Start upgrade:
1. Connect to CRE Config/System/PC transmit-receive or to UNIGEN 2.0 web site
2. Select Update firmware and browse the archive (UNIGEN 2.0 version .zip, ex: v1.00.zip)
3. Click on Update button
Alarm/Fault leds blink and state is display on LCD screen
4. Wait until Update firmware successful shows
5. If need, restore the settings from the text file previously save.

Note: During upgrading (about 2 minutes), UNIGEN 2.0 re-start. Wait until you receive the end of
upgrade before using UNIGEN 2.0.

9.2 ADDING A CUSTOM HMI LANGUAGE

By default, 4 languages are available: English, French, Spanish, Italian.

In addition, two custom languages can be embedded in UNIGEN 2.0.
To add your own language, 2 steps are necessary:
1. Translation
 Ask for the Excel file to CRE Technology or your own dealer
 Fill in the columns for the new language: labels meant for your UNIGEN 2.0 model.
 Return the Excel file to CRE Technology or your own dealer that will send you back a .bin file

2. Downloading
When you receive the related .bin file, in CRE Config/System/PC transmit-receive, download
.bin file via Upload file command.
Wait until Download successful shows.

Note: Unless the contrary is expressly stipulated, CRE Technology reserves the right to use your
translation for other uses.

9.3 TROUBLESHOOTING

To get a history of alarms-faults, stop the generator, connect to CRE Config/System/PC transmit-
receive/Download log file from UNIGEN 2.0, and click Download.
To restore factory settings into CRE Config, navigate to CRE Config/System/PC transmit-receive/Reset
factory settings, and click Reset.

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Message "CAN bus" fault

Check the related connections, including the one of internal resistor (jumper). Refer to the Appendix.
For inter-UNIGEN bus, check the related settings: count of generators, number of each generator.

No J1939 communication
Check that the ECU is powered.
Check that the configuration correspond to the engine/ECU.
Check that the wiring is correct. Refer to the Appendix.
Power cycle UNIGEN 2.0 and ECU.
Check that the ECU and its settings are consistent with the J1939 standard.
Note: Some ECUs do not provide information if the engine is on stop.

The engine starts but runs above/below nominal speed.

Check the wiring.
Check the speed output. Refer to 5.2.

No connection with the PC: consider deactivating the firewall.

List of potential error messages when transferring a file to UNIGEN 2.0
Note: … indiquate a variable number, a label number or a text number according the error message.
It will help you to locate your error in your configuration file.
ERROR 001: Only when genset is STOP
File transfer between computer and the unit should be done only when all conditions below are met i.e.
when engine is stopped.

ERROR 002: Unknown file type

The file type send is unknown. Check the selected file.

ERROR 004: Write data or checksum error

ERROR 008: Update failed. Please restart update.
Write error in flash during update of the software. Restart the update of the software.

ERROR 010: Variable …. doesn't exist.

The parameter doesn’t exist. Check compatibility of the version/type of the module and the
configuration file.

ERROR 011: No write right on variable ….

Access to this variable is not allowed. Only parameter can be modified.

ERROR 012: No write right on label ….

Access to this label is not allowed. Check your configuration file.
ERROR 013: Text …. doesn't exist.
Access to this text is not possible because it doesn’t exist. Check compatibility of the version/type of the
module and the configuration file.

ERROR 014: No write right on …. unit

Access to this unit is not allowed. Check your configuration file.

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ERROR 015: Need password 2 to write on …. variable

Actual password is not sufficient to access such configuration/control level.

ERROR 017: Configuration not allowing …. variable value

The actual setting of the module doesn’t allow modifying this parameter with this value. Check your
configuration file and the value of the parameter before sending again your configuration file.

ERROR 018: Variable …. out of range

The value of the parameter is out of range. Check your configuration file before sending again.

ERROR 019: Wrong value for …. variable

An unexpected value has been detected on this parameter. Check the value of the parameter before
sending again.
Ex: a text character has been detected instead of a number.

ERROR 020: Language file not for UNIGEN 2.0

The language file send doesn’t correspond to a language file for UNIGEN 2.0. Check the selected
language file.

ERROR 021: Too much languages already download

The maximum number of language supported by UNIGEN 2.0 has been reached.

ERROR 022: Wrong language file version

The language file version is above to the UNIGEN 2.0 version. Upgrade your UNIGEN 2.0 with the latest
version available or catch the language file compatible with your UNIGEN 2.0 version.

ERROR 023: Label …. doesn't exist.

Modifying this label is not allowed. Check the label number before sending again the configuration file.

ERROR 024: Unit …. doesn't exist.

Modifying this unit is not allowed. Check the unit number before sending again the configuration file.

ERROR 025: Wrong accuracy value on …. (0,1,2 or 3)

The value of the accuracy is out of range. The value must be between 0 and 3.

ERROR 026: Wrong unit value on …. (from 0 to xxx)

The value of the unit is out of range. The value must be between 0 and xxx.

ERROR 027: No header in language file

No header or wrong header of the language file. Check the selected language file before send it again.

ERROR 028: No filename found or too long

No filename or filename is too long. The maximum size of a filename is 40 characters. Rename file and
send it again.

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ERROR 029: Wrong accuracy on parameter ….

The value of the modify parameter has not the right accuracy. Check the value of your parameter
before sending again you configuration file.
Ex: Below, it’s missing the digit a the tenth 5.00
V02205 5.0_ ESG amplitude +000.00 +010.00V

Warnings do not prevent the module to work but inform the user of a potential problem in his
configuration file.

WARNING 001: Wrong size of label ….

WARNING 002: Wrong character entered in label ….
WARNING 003: Wrong size of text ….
WARNING 004: Wrong character entered in text ….
These advices indicate that entered labels/texts are too long or a character is not supported by module.
Invalid characters will be replaced by “?”. The valid characters are the followings:
0123456789.-
ABCDEFGHIJKLMNOPQRSTUVWXYZ
!#$()*+/:;=[]^_?
abcdefghijklmnopqrstuvwxyz
The maximum size of a label is 14 characters and of a text is 28 characters.
Modify labels/texts according to the rules above.

WARNING 005: Too many errors...

All errors/warnings messages could not be displayed. There are probably other problems in your
configuration file. Solve displayed problems and send your configuration file again in order to display the
additional error/warning messages.

WARNING 006: No unit specify on unit ….

WARNING 007: No value specify on parameter ….
WARNING 008: No text specify on text ….
WARNING 009: No label specify on label ….
These warnings indicate that no value has been indicated inside the configuration file for an
unit/parameter/text or label. The values will stay unchanged.

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10 APPENDIX

10.1 MTU J1939 COMMUNICATION

ECU 8
Smart Connect is used to:
 select the speed set point source through a 3-bit code,
 set the frequency and speed droop

UNIGEN 2.0

Through the K1 connection box, the bus connects ECU8, Smart Connect and UNIGEN 2.0: one bus
between ECU8 and Smart Connect, one bus between Smart Connect and UNIGEN 2.0. X4 is the Smart
Connect J1939 CAN port.

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10.2 CAN BUS GOOD PRACTICES

This chapter describes rules to be used to ensure reliable CAN communication. These rules must be
applied to all CAN communications, including inter-UNIGEN CAN bus and ECU/remote I/O CAN bus.
In an EMI environment, use a shielded cable to connect CAN bus. The table below lists the standard
CAN wiring :

Terminal Standard CAN Mandatory

1 Reserved
2 CAN-L X
3 CAN GND X
4 Reserved
5 CAN SHLD (optional)
6 GND (optional)
7 CAN-H X
8 Reserved
9 CAN V+ (optional)
SHIELD X
CABLES

WARNING
RISK OF EQUIPMENT DAMAGE
Switch off the unit before plugging or unplugging the CAN bus connector or disconnecting the wires
Failure to follow this instruction can damage the CAN transmitter/receiver

Cables used must be selected to respond to CAN bus specificities. Always use shielded twisted wire
pairs. Deploy the CAN bus in a bus (no mesh, ring or star topology) as shown below:

Bus Mesh Ring Star

Both ends of the CAN bus must be terminated with a 120Ω resistor.
The next figure gives the example of three units connected through a CAN bus. Do NOT install any
resistor in the middle unit and connect the incoming wire and the outgoing wire on the same
terminal (max 1.5 mm² or AWG16; use preferably the same section for both).

terminal terminal terminal

L L L
120Ω

120Ω

H H H
RES RES RES
GND GND GND

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CRE Technology provides a complete range of products aimed at installing your CAN bus
(cords, wires, connectors…). Please read the document Harness information or contact
your local CRE Technology distributor to help you choose equipment that fits your needs.

MAXIMAL LENGTH & BIT RATE

The maximal length of a CAN bus depends mostly on the communication speed, but also on the
quality of wires and connectors used.
The following table shows the maximal length of a CAN bus depending on the bit rate.
Bit rate (kbits/s) 10 20 50 125 250 500 800
Maximal length (m) 5000 2500 1000 500 250 100 50
The next table lists the standard bit rate of each CAN protocol that can be used by a CRE Tech. unit:
Bus Protocol Bit rate (kbits/s) Note
CAN1 CRE Technology protocol 125 Fixed
CAN2 CANopen 125 (default) Can be selected between 125/250/500/1000 kbit/s (By
CRE Config software or modification by variable
number)
J1939 + CANopen 250 Fixed

CAN1: CRE TECHNOLOGY INTER-UNITS CAN BUS

This CAN bus is used as a communication means between units from a single power plant. Features
are:
 Dead bus management
 Other data exchange
Standard CAN bus rules apply here. Refer to previous section to connect units properly on CAN bus.

CAN BUS FAULT

CAN communication between CRE technology units is continuously checked by each unit on the CAN
bus. The count of units connected to CAN bus must be the same as the count of units declared inside
each unit (count of UNIGEN 2.0 units). Otherwise a CAN bus fault is triggered. This may also occur if:
 Two or more units share the same unit number
 120Ω termination resistors are not used correctly (see previous section)
 CAN bus cable is not properly connected.
This CAN bus fault can only be reset when the correct count of unit is seen on the CAN bus. As with
every protection, the way to handle a CAN bus fault can be selected.

Note: If you disconnect a UNIGEN 2.0 from the inter UNIGEN 2.0 CAN bus, change the count of
generators on ALL other UNIGEN 2.0 units of the power plant.

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10.3 CONTROL LOOP TUNING

Each control is carried out by two actions: Proportional and Integral.

+
Set point + G Command

–
I
Measurement
G: global gain
P: proportional gain
I: integral gain

P adjusts the rise time (time needed for the system to reach its set point for the first time). Using
only the P factor always leaves a static error between the set point and the actual value.

I reduces the deviation between the set point and the actual value.
By increasing P or I, the rise time decreases. However, the overshoot increases and may also make
the system unstable (P: fast hunting, I: slow hunting).
G is a sensitivity adjustment for the other settings.

Empirical tuning:
A. First set G to 50%
B. Set the parameters P, and I to 0
C. Increase the value of P until the system becomes unstable. From this position, decrease the
value of P to 60% of the previous value
D. If the system is unstable, decrease G; if it is too slow, increase G.

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10.4 POTENTIELS ALARMS-FAULTS TABLE

Download the list from CRE Config/System/PC transmit-receive/Actions on alarm-fault, and tick the boxes to show how the alarms/faults contribute to severity indication and,
if any, summary outputs (grey shade prompts usual choice):

HH

LL

LL
H

H
HH

HH
L

LL
H
L
Generator Underfrequency (81L)
Generator Overfrequency (81H)

Generator Undervoltage (27)

Generator Overvoltage (59)

Max battery voltage

Min battery voltage
Fail to synch (25)
Phase measure
1
3

1: Generator electrical Fault

3: Alarm

Notes :
1) CAN bus inter-UNIGEN faults are not shown.
2) H = level 1, HH = level2

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Head office: FRANCE

Distributors
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Check our entire distributors list around the world on our Web site http://www.cretechnology.com.

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